Subaru Legacy 4th GEN

FW-2
Foreword
FOREWORD
1. Foreword
A: FOREWORD
These manuals are used when performing mainte-
nance, repair or diagnosis of Subaru LEGACY.
Applicable model:
2008MY BL*****, BP*****
The manuals contain the latest information at the
time of publication. Changes in the specifications,
methods, etc. may be made without notice.
HU-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 com-
ponent. The specification, maintenance and other
information for the components are included, and
the diagnostic information has also been added
where necessary.
2. CONTENTS
The first page has an index with tabs.
HU-3
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:
HU-00017
(14)
(9)
(8)
(7)
(6)
(10)
(4) (10)
(22)
(11)
(19)
(17)
(15)
(13)
(12)
(18)
(16)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(11)
(10)
(9)
(12)
(13)
(19)
(18)
(20)
(17)
(16)
(24)
(10)
(25)
(5)
(4)
(4)
(4)
(3)
(3)
(3)
(2)
(1)
(21)
(15)
(23)
T7
T2
T2
T2
T2
T2
T2
T4
T5
T5
T8
T6
T6
T6
T11
T10
T1
T1
T3
T3
T3
T1
T9
T4
T5
T5
T3
T4
T3
T2
T4
T2
T1
T3
(20)
(21)
(23) (22)
(10)
(24)
(25)
(26)
(35)
(34)
(27)
(14)
(28)
(29)
(31)
(32)
(37)
(30)
(33)
(36)
T3
T2 T1 .... ,
: Selective part
: Replacement part
: Sealing point
: Should be lubricated with oil.
: Should be lubricated with grease.
: Tightening torque
HU-4
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:
(A) Component (D) Cautions (G) Tightening torque
(B) Process (E) Tool number of special tool (H) Illustration
(C) Reference (F) Name of special tool
HU-00020
1) Remove the manual transmission assembly
from vehicie. <Ref. to MT-33, REMOVAL, Manual
Transmission Assembly.>
15.Main Shaft Assembly for Sin-
gle-Range
A: REMOVAL
11) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
NOTE:
Secure the lock nuts in two places after tightening.
ST1 498937000 TRANSMISSION HOLDER
(A)
(B)
(C)
(D)
(G)
(E) (F)
(H)
Tightening torque:
118 N m (12.0 kgf-m, 86.8 ft-lb)
ST1 ST2
ST2 499987003 SOCKET WRENCH (35)
HU-5
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)
The figure used in these manuals are described in the SI units and conventional units are described in ( ).
Item SI units Conventional unit Remarks
Force N (Newton) kgf 1 kgf = 9.80655 N
Mass (Weight) kg, g kg, g
Capacity 2, m2 or cm
3
2or cc 1 cc = 1 cm
3
= 1 m2
Torque Nm kgf-m, kgf-cm 1 kgf-m = 9.80655 Nm
Rotating speed rpm rpm
Pressure kPa (kilopascal) kgf/cm
2
1 kgf/cm
2
= 98.0655 kPa
mmHg 1 mmHg = 0.133322 kPa
Power W PS 1 PS = 0.735499 kW
Calorie Wh cal 1 kcal = 1.16279 Wh
Fuel consumption rate g/kwh g/PSh 1 g/PSh = 1.3596 g/kWh
HU-6
9. EXPLANATION OF TERMINOLOGY
List
AAI : Air Assist Injection MD : Mini Disc
A/B : Airbag MID : Multi-information Display
ABS : Anti-lock Brake System MFI : Multi Point Injection
A/C : Air Conditioner MP-T : Multi-Plate Transfer
A/F : Air Fuel Ratio MT : Manual Transmission
ALT : Generator NA : Natural Aspiration
ASSY : Assembly NC : Normal Close (Relay)
AT : Automatic Transmission NO : Normal Open (Relay)
ATF : Automatic Transmission Fluid OP : Option Parts
AWD : All Wheel Drive P/S : Power Steering
BATT : Battery P/W : Power Window
CD-R/RW : CD Recordable/Rewritable PCD : Pitch Circle Diameter
CPU : Central Processing Unit PCV : Positive Crankcase Ventilation
DOHC : Double Overhead Camshaft RH : RH (Right Hand)
DVD : Digital Versatile Disc Rr : Rear
ECM : Engine Control Module SI-DRIVE : SUBARU Intelligent Drive
EGR : Exhaust Gas Recirculation SOHC : Single Overhead Camshaft
ELR : Emergency Locking Retractor SRS : Supplemental Restraint System
EX : Exhaust SSM : Subaru Select Monitor
F/B : Fuse & Joint Box ST : Special Tool
FL : Fusible Link SW : Switch
Ft : Full-time (AWD) TCS : Traction Control System
FWD : Front Wheel Drive TGV : Tumble Generator Valve
GPS : Global Positioning System T/M : Transmission
H/U : Hydraulic Unit TPMS : Tire Pressure Monitoring System
IG : Ignition ViS-C : Viscous Coupling
INT : Intermittent VSV : Vacuum Switching Valve
ISC : Idle Speed Control VTD : Variable Torque Distribution
LH : LH (Left Hand) W/H : Wiring Harness
LSD : Limited Slip Differential Pr : Primary
M/B : Main Fuse & Relay Box 2ndr : Secondary
SPC-2
LEGACY
SPECIFICATIONS
1. LEGACY
A: DIMENSION
1. SEDAN MODEL
*1
: With sunroof
*2
: 2.5 GT spec. B model
2. WAGON MODEL
*1
: With sunroof
B: ENGINE
Model 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC
Overall length mm (in) 4,700 (185.0)
Overall width mm (in) 1,730 (68.1)
Overall height (at C.W.) mm (in) 1,425 (56.1) 1,425 (56.1), 1,435 (56.5)
*2
1,435 (56.5)
Compartment
Length mm (in) 1,900 (74.8)
Width mm (in) 1,445 (56.9)
Height mm (in) 1,165 (45.9), 1,100 (43.3)
*1
Wheelbase mm (in) 2,670 (105.1)
Tread
Front mm (in) 1,495 (58.9)
Rear mm (in) 1,485 (58.5)
Minimum road
clearance
mm (in) 150 (5.9) 150 (5.9), 160 (6.3)
*2
160 (6.3)
Model 2.5 L SOHC 2.5 L DOHC turbo
Overall height (at C.W.) mm (in) 1,475 (58.1)
Compartment
Length mm (in) 1,840 (72.4)
Width mm (in) 1,445 (56.9)
Height mm (in) 1,190 (46.9), 1,145 (45.1)
*1
Tread
Front mm (in) 1,495 (58.9)
Rear mm (in) 1,485 (58.5)
Minimum road clearance mm (in) 150 (5.9) 155 (6.1)
Engine type
Horizontally opposed, liquid cooled, 4-cylinder,
4-stroke gasoline engine
Horizontally opposed,
liquid cooled, 6-cylinder,
Valve arrangement Overhead camshaft
Bore stroke mm (in) 99.5 79.0 (3.917 3.110)
89.2 80.0
(3.512 3.150)
Displacement cm
3
(cu in) 2,457 (149.9) 3,000 (183.06)
Compression ratio 10.0 8.4 10.7
Ignition order 1 3 2 4 1 6 3 2 5 4
Idle speed at Park or
Neutral position
rpm
650 (MT)
700 (AT)
750 650
Maximum output kW (HP)/rpm 125 (170)/6,000 184 (243)/6,000 185 (245)/6,600
Maximum torque Nm (kgf-m, ft-lb)/rpm 230 (23.5, 170)/4,400 327 (33.3, 241)/3,600 291 (29.7, 215)/4,200
SPC-3
LEGACY
SPECIFICATIONS
C: ELECTRICAL
D: TRANSMISSION
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
*1
F: SUSPENSION
Ignition timing (at idling) BTDC 13
MT: 12
AT: 17
15
Spark plug Type and manufacturer NGK: FR5AP-11 NGK: SILFR6A NGK: ILFR6B
Generator 12V 110A
Battery
Type and
capacity (5HR)
MT 12V 48AH (55D23L)
AT 12V 52AH (75D23L)
Transmission type 5MT 4AT 5MT 5AT 6MT 5AT
Clutch type DSPD TCC DSPD TCC DSPD TCC
Gear ratio
1st 3.454 2.785 3.166 3.540 3.636 3.540
2nd 2.062 1.545 1.882 2.264 2.235 2.264
3rd 1.448 1.000 1.296 1.471 1.521 1.471
4th 1.088 0.694 0.972 1.000 1.137 1.000
5th 0.780 0.738 0.834 0.891 0.834
6th 0.707
Rev. 3.333 2.272 3.333 2.370 3.545 2.370
Reduction gear
(Front)
1st
reduction
Type of gear Helical Helical Helical
Gear ratio 1.000 1.000 1.000
Final
reduction
Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid
Gear ratio 3.900 4.111 3.900 3.083 3.900 3.272
Reduction gear
(Rear)
Transfer
reduction
Gear ratio 1.000 1.000 1.100
Final
reduction
Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid
Gear ratio 3.900 4.111 3.900 3.083 3.545 3.272
Type Rack & pinion
Turns, lock to lock 3.2 2.8, 2.6
*1
2.6
Minimum
turning diameter
m (ft)
Curb to
curb
10.8 (35.4), 11.6 (38.0)
*1
11.6 (38.0)
Wall to
wall
11.6 (38.1), 12.4 (40.7)
*1
12.4 (40.7)
Front Macpherson strut type suspension
Rear Multi-link type suspension
SPC-4
LEGACY
SPECIFICATIONS
G: BRAKE
H: TIRE
*1
*2
: Model for Canada
I: CAPACITY
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brake Ventilated disc brake
Parking brake Mechanical on rear brakes
Wheel size 16 6
1
/
2
JJ
*2
, 17 7JJ 17 7JJ, 18 7JJ
*1
18 7JJ
Tire size
P205/55 R16 89H
*2
,
P205/50 R17 88V
215/45 R17 91W,
215/45 R18 89Y
*1
P215/45 R18 89W
Type Tubeless, Steel belted radial
Model
2.5 L SOHC 2.5 L DOHC turbo
3.0 L
DOHC
5MT 4AT 5MT 5AT 6MT 5AT
Fuel tank 2 (US gal, Imp gal) 64 (16.9, 14.1)
Engine oil
Total capacity
(Overhaul)
2 (US qt, Imp qt) 5.0 (5.3, 4.4)
7.0
(7.4, 6.2)
Filling amount of
engine oil
2 (US qt, Imp qt)
When replacing
engine oil and oil filter
4.2 (4.4, 3.7) 4.3 (4.5, 3.8)
5.7
(6.0, 5.0)
When replacing
engine oil only
4.0 (4.2, 3.5)
5.5
(5.8, 4.8)
Transmission gear oil 2 (US qt, Imp qt)
3.5
(3.7, 3.1)

3.5
(3.7, 3.1)

4.1
(4.3, 3.6)

ATF 2 (US qt, Imp qt)
9.3
(9.8, 8.2)

9.8
(10.4, 8.6)

9.8
(10.4, 8.6)
Front differential gear oil 2 (US qt, Imp qt)
1.2
(1.3, 1.1)

1.4
(1.5, 1.2)

1.4
(1.5, 1.2)
Rear differential gear oil 2 (US qt, Imp qt) 0.8 (0.8, 0.7)
1.0
(1.1, 0.9)
0.8
(0.8, 0.7)
Power steering fluid 2 (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine coolant 2 (US qt, Imp qt)
6.4
(6.8, 5.6)
6.3
(6.7, 5.5)
7.3
(7.7, 6.4)
7.2
(7.6, 6.3)
7.3
(7.7, 6.4)
7.2
(7.6, 6.3)
SPC-5
LEGACY
SPECIFICATIONS
J: WEIGHT
1. US MODEL
Model
Sedan
2.5 L SOHC
2.5 i 2.5 i Limited
5MT 4AT 4AT
Curb weight
(C.W.)
Front kg (lb)
819
(1,805)
826
(1,820)
839
(1,850)
846
(1,865)
841
(1,855)
850
(1,875)
853
(1,880)
Rear kg (lb)
665
(1,465)
674
(1,485)
669
(1,475)
678
(1,495)
669
(1,475)
676
(1,490)
676
(1,490)
Total kg (lb)
1,483
(3,270)
1,499
(3,305)
1,508
(3,325)
1,524
(3,360)
1,510
(3,330)
1,526
(3,365)
1529
(3,370)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
Gross vehicle weight (G.V.W.) kg (lb)
1,960
(4,325)
1,960
(4,325)
1,960
(4,325)
1,960
(4,325)
1,960
(4,325)
1,960
(4,325)
1,960
(4,325)
Option
Vehicle dynamics
control

Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
SPC-6
LEGACY
SPECIFICATIONS
Model
Sedan
2.5 L DOHC turbo
3.0 L
DOHC
2.5 GT Limited
2.5 GT
spec. B
3.0 R
Limited
5MT 5AT 6MT 5AT
Curb weight
(C.W.)
Front kg (lb)
871
(1,920)
898
(1,980)
900
(1,985)
903
(1,990)
912
(2,010)
928
(2,045)
Rear kg (lb)
678
(1,495)
683
(1,505)
683
(1,505)
683
(1,505)
689
(1,520)
680
(1,500)
Total kg (lb)
1,549
(3,415)
1,581
(3,485)
1,583
(3,490)
1,585
(3,495)
1,601
(3,530)
1,608
(3,545)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
2,010
(4,435)
2,010
(4,435)
2,010
(4,535)
2,010
(4,435)
2,010
(4,435)
2,010
(4,535)
Option
Vehicle dynamics
control

Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
SPC-7
LEGACY
SPECIFICATIONS
2. CANADA MODEL
Model
Sedan
2.5 L SOHC
2.5 i 2.5 i Limited
5MT 4AT 4AT
Curb weight
(C.W.)
Front kg (lb)
819
(1,805)
826
(1,820)
839
(1,850)
846
(1,865)
850
(1,875)
853
(1,880)
Rear kg (lb)
665
(1,465)
674
(1,485)
669
(1,475)
678
(1,495)
676
(1,490)
676
(1,490)
Total kg (lb)
1,483
(3,270)
1,499
(3,305)
1,508
(3,325)
1,524
(3,360)
1,526
(3,365)
1,529
(3,370)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,960
(4,325)
1,960
(4,325)
1,960
(4,325)
1,960
(4,325)
1,960
(4,325)
1,960
(4,325)
Option
Vehicle dynamics
control

Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
SPC-8
LEGACY
SPECIFICATIONS
Model
Sedan Wagon
2.5 L DOHC turbo 2.5 L SOHC
2.5 GT Limited
2.5 GT
spec. B
2.5 i
5MT 5AT 6MT 5MT 4AT
Curb weight
(C.W.)
Front kg (lb)
871
(1,920)
898
(1,980)
900
(1,985)
912
(2,010)
814
(1,795)
821
(1,810)
835
(1,840)
841
(1,855)
Rear kg (lb)
678
(1,495)
683
(1,505)
683
(1,505)
689
(1,520)
685
(1,510)
694
(1,530)
685
(1,510)
694
(1,530)
Total kg (lb)
1,549
(3,415)
1,581
(3,485)
1,583
(3,490)
1,601
(3,530)
1,499
(3,305)
1,515
(3,340)
1,520
(3,350)
1,535
(3,385)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
1,960
(4,325)
1,960
(4,325)
1,960
(4,325)
1,960
(4,325)
Option
Vehicle dynamics
control

Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
Model
Wagon
2.5 L DOHC turbo
2.5 GT Limited
5MT 5AT
Curb weight
(C.W.)
Front kg (lb)
869
(1,915)
898
(1,980)
Rear kg (lb)
703
(1,550)
703
(1,550)
Total kg (lb)
1,572
(3,465)
1,601
(3,530)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
2,060
(4,545)
2,060
(4,545)
Option
Vehicle dynamics
control

Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
SPC-9
LEGACY
SPECIFICATIONS
3. OPTION
Option Front kg (lb) Rear kg (lb) Total kg (lb)
Vehicle Dynamics Control 5.6 (12.4) 0.2 (0.4) 5.8 (12.7)
Audio 1.8 (4.0) 0.7 (1.5) 2.5 (5.5)
Power package 1.8 (4.0) 3.1 (6.8) 4.9 (10.8)
Side airbag 1.9 (4.2) 1.9 (4.2) 3.8 (8.4)
Curtain airbag (Sedan model) 0.4 (0.9) 5.3 (11.7) 5.7 (12.6)
Curtain airbag (Wagon model) 0.5 (1.1) 5.0 (11.0) 5.5 (12.1)
Sunroof (Sedan model) 8.1 (17.9) 8.9 (19.6) 17.0 (37.5)
Sunroof (Wagon model) 8.3 (18.3) 18.7 (41.3) 27.0 (59.6)
Navigation (DVD) 2.2 (4.9) 0.8 (1.8) 3.0 (6.6)
SPC-10
OUTBACK
SPECIFICATIONS
2. OUTBACK
A: DIMENSION
1. WAGON MODEL
*1
: With sunroof
B: ENGINE
C: ELECTRICAL
Overall height (at C.W.) mm (in) 1,605 (63.2)
Compartment
Length mm (in) 1,840 (72.4)
Width mm (in) 1,445 (56.9)
Height mm (in) 1,190 (46.9), 1,145 (45.1)
*1
Tread
Front mm (in) 1,495 (58.9)
Rear mm (in) 1,490 (58.7)
Minimum road clearance mm (in) 215 (8.5) 220 (8.7) 215 (8.5)
Engine type
Horizontally opposed, liquid cooled,
4-cylinder, 4-stroke gasoline engine
Horizontally opposed,
liquid cooled, 6-cylinder,
Valve arrangement Overhead camshaft
Bore stroke
mm (in)
99.5 79.0 (3.917 3.110)
89.2 80.0
(3.512 3.150)
Displacement cm
3
(cu in) 2,457 (149.9) 3,000 (183.06)
Compression ratio 10.0 8.4 10.7
Ignition order 1 3 2 4 1 6 3 2 5 4
Idle speed at Park
or Neutral position
rpm
650 (MT)
700 (AT)
750 650
Maximum output kW (HP)/rpm 125 (170)/6,000 184 (243)/6,000 185 (245)/6,600
Maximum torque Nm (kgf-m, ft-lb)/rpm 230 (23.5, 170)/4,400 327 (33.3, 241)/3,600 291 (29.7, 215)/4,200
Ignition timing (at idling) BTDC
MT: 10
AT: 15
MT: 12
AT: 17
15
Spark plug Type and manufacturer NGK: FR5AP-11 NGK: SILFR6A NGK: ILFR6B
Generator 12V 110A
Battery
Type and capacity
(5HR)
MT 12V 48AH (55D23L)
AT 12V 52AH (75D23L)
SPC-11
OUTBACK
SPECIFICATIONS
D: TRANSMISSION
5MT: 5-forward speeds with synchromesh and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
E: STEERING
F: SUSPENSION
Transmission type 5MT 4AT 5MT 5AT 5AT
Clutch type DSPD TCC DSPD TCC TCC
Gear ratio
1st 3.454 2.785 3.166 3.540 3.540
2nd 2.062 1.545 1.882 2.264 2.264
3rd 1.448 1.000 1.296 1.471 1.471
4th 1.088 0.694 0.972 1.000 1.000
5th 0.825 0.738 0.834 0.834
Rev. 3.333 2.272 3.333 2.370 2.370
Reduction gear
(Front)
1st
reduction
Gear ratio 1.000 1.000 1.000
Final reduction
Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid
Gear ratio 4.111 4.444 4.444 3.272 3.272
Reduction gear
(Rear)
Transfer reduction
Type of gear Helical Helical
Gear ratio 1.000 1.000
Final reduction
Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid
Gear ratio 4.111 4.444 4.444 3.272 3.272
Type Rack & pinion
Turns, lock to lock 3.2
Minimum turning diameter m (ft)
Curb to curb 10.8 (35.4)
Wall to wall 11.6 (38.1)
Front Macpherson strut type suspension
Rear Multi-link type suspension
SPC-12
OUTBACK
SPECIFICATIONS
G: BRAKE
H: TIRE
*1
: 2.5 L SOHC model for Canada
I: CAPACITY
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brake
Parking brake Mechanical on rear brakes
Model 2.5L SOHC BASE 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC
Wheel size 16 6
1
/
2
JJ 16 6
1
/
2
JJ
*1
, 17 7JJ 17 7JJ 17 7JJ
Tire size P225/60 R16 97H P225/60 R16 97H
*1
, P225/55 R17 95V
Type Tubeless, Steel belted radial
Model
2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC
5MT 4AT 5MT 5AT 5AT
Fuel tank 2 (US gal, Imp gal) 64 (16.9, 14.1)
Engine oil
Total capacity
(Overhaul)
2 (US qt, Imp qt) 5.0 (5.3, 4.4) 7.0 (7.4, 6.2)
Filling amount of
engine oil
2 (US qt, Imp qt)
When replacing
engine oil and oil
filter
4.2 (4.4, 3.7) 4.3 (4.5, 3.8) 5.7 (6.0, 5.0)
When replacing
engine oil only
4.0 (4.2, 3.5) 5.5 (5.8, 4.8)
Transmission gear 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)
9.8
(10.4, 8.6)
9.8
(10.4, 8.6)
Front differential gear oil 2 (US qt, Imp qt) 1.2 (1.3, 1.1) 1.4 (1.5, 1.2) 1.4 (1.5, 1.2)
Rear differential gear oil 2 (US qt, Imp qt) 0.8 (0.8, 0.7)
Power steering fluid 2 (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine coolant 2 (US qt, Imp qt) 6.4 (6.8, 5.6) 6.3 (6.7, 5.5) 7.3 (7.7, 6.4) 7.2 (7.6, 6.3) 7.2 (7.6, 6.3)
SPC-13
OUTBACK
SPECIFICATIONS
J: WEIGHT
1. US MODEL
Model
Wagon
2.5 L SOHC
2.5 i
5MT 4AT
Curb weight
(C.W.)
Front kg (lb)
823
(1,815)
830
(1,830)
844
(1,860)
846
(1,865)
846
(1,865)
Rear kg (lb)
696
(1,535)
705
(1,555)
696
(1,535)
696
(1,535)
696
(1,535)
Total kg (lb)
1,520
(3,350)
1,535
(3,385)
1,540
(3,395)
1,542
(3,400)
1,542
(3,400)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
Option
Vehicle dynamics
control

Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
Model
Wagon
2.5 L SOHC
2.5 i Limited
5MT 4AT
Curb weight
(C.W.)
Front kg (lb)
837
(1,845)
857
(1,890)
860
(1,895)
860
(1,895)
862
(1,900)
Rear kg (lb)
712
(1,570)
712
(1,570)
712
(1,570)
712
(1,570)
712
(1,570)
Total kg (lb)
1,549
(3,415)
1,569
(3,460)
1,572
(3,465)
1,572
(3,465)
1,574
(3,470)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
Option
Vehicle dynamics
control

Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
SPC-14
OUTBACK
SPECIFICATIONS
Model
Wagon
2.5 L DOHC turbo
2.5 XT Limited
5MT 5AT
Curb weight
(C.W.)
Front kg (lb)
880
(1,940)
882
(1,945)
912
(2,010)
914
(2,015)
Rear kg (lb)
723
(1,595)
723
(1,595)
723
(1,595)
723
(1,595)
Total kg (lb)
1,603
(3,535)
1,606
(3,540)
1,635
(3,605)
1,637
(3,610)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
2,060
(4,545)
2,060
(4,545)
2,060
(4,545)
2,060
(4,545)
Option
Vehicle dynamics
control
Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
Model
Wagon
3.0 L DOHC
3.0 R
LL Bean
5AT
Curb weight
(C.W.)
Front kg (lb)
923
(2,035)
925
(2,040)
Rear kg (lb)
719
(1,585)
719
(1,585)
Total kg (lb)
1,642
(3,620)
1,644
(3,625)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
2,100
(4,635)
2,100
(4,635)
Option
Vehicle dynamics
control
Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
SPC-15
OUTBACK
SPECIFICATIONS
2. CANADA MODEL
Model
Wagon
2.5 L SOHC
2.5 i 2.5 i Limited
5MT 4AT 4AT
Curb weight
(C.W.)
Front kg (lb)
823
(1,815)
830
(1,830)
844
(1,860)
850
(1,875)
857
(1,890)
860
(1,895)
Rear kg (lb)
696
(1,535)
705
(1,555)
696
(1,535)
705
(1,555)
712
(1,570)
712
(1,570)
Total kg (lb)
1,520
(3,350)
1,535
(3,385)
1,540
(3,395)
1,556
(3,430)
1,569
(3,460)
1,572
(3,465)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
2,010
(4,435)
Option
Vehicle dynamics
control

Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
SPC-16
OUTBACK
SPECIFICATIONS
Model
Wagon
2.5 L DOHC turbo
2.5 XT Limited
5MT 5AT
Curb weight
(C.W.)
Front kg (lb)
880
(1,940)
882
(1,945)
912
(2,010)
914
(2,015)
Rear kg (lb)
723
(1,595)
723
(1,595)
723
(1,595)
723
(1,595)
Total kg (lb)
1,603
(3,535)
1,606
(3,540)
1,635
(3,605)
1,637
(3,610)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
2,060
(4,545)
2,060
(4,545)
2,060
(4,545)
2,060
(4,545)
Option
Vehicle dynamics
control

Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
Model
Wagon
3.0 L DOHC
3.0 R 3.0 R Limited
5AT
Curb weight
(C.W.)
Front kg (lb)
914
(2,015)
916
(2,020)
923
(2,035)
925
(2,040)
Rear kg (lb)
703
(1,550)
703
(1,550)
719
(1,585)
719
(1,585)
Total kg (lb)
1,617
(3,565)
1,619
(3,570)
1,642
(3,620)
1,644
(3,625)
Gross axle
weight ratio
(G.A.W.R.)
Front kg (lb)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
1,040
(2,295)
Rear kg (lb)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
1,060
(2,340)
2,100
(4,635)
2,100
(4,635)
2,100
(4,635)
2,100
(4,635)
Option
Vehicle dynamics
control

Power package
Side airbag
Curtain airbag
Sunroof
Navigation (DVD)
SPC-17
OUTBACK
SPECIFICATIONS
3. OPTION
Option Front kg (lb) Rear kg (lb) Total kg (lb)
Vehicle Dynamics Control 5.6 (12.4) 0.2 (0.4) 5.8 (12.7)
Audio 1.8 (4.0) 0.7 (1.5) 2.5 (5.5)
Power package 1.8 (4.0) 3.1 (6.8) 4.9 (10.8)
Side airbag 1.9 (4.2) 1.9 (4.2) 3.8 (8.4)
Curtain airbag (Sedan model) 0.4 (0.9) 5.3 (11.7) 5.7 (12.6)
Curtain airbag (Wagon model) 0.5 (1.1) 5.0 (11.0) 5.5 (12.1)
Sunroof (Sedan model) 8.1 (17.9) 8.9 (19.6) 17.0 (37.5)
Sunroof (Wagon model) 8.3 (18.3) 18.7 (41.3) 27.0 (59.6)
Navigation (DVD) 2.2 (4.9) 0.8 (1.8) 3.0 (6.6)
SPC-18
OUTBACK
SPECIFICATIONS
PC-2
Precaution
PRECAUTION
1. Precaution
A: CAUTION
Please clearly understand and adhere to the follow-
ing general precautions. They must be strictly fol-
lowed to avoid minor or serious injury to the person
doing the work or people in the area.
1. ABS
Handle the ABS as a total system. Do not disas-
semble or attempt to repair parts which are not in-
structed in this manual. Follow the directions in this
manual when performing maintenance on the AB-
SCM&H/U. When parts other than those specified
are disassembled, it is possible that the ABS sys-
tem will not operate when needed or cause it to op-
erate incorrectly and result in injury.
2. VEHICLE DYNAMICS CONTROL (VDC)
Handle the VDC as a total system. Do not disas-
semble or attempt to repair individual parts. Follow
the directions in this manual when performing
maintenance on the VDCCM&H/U. When parts
other than those specified are disassembled, it is
possible that the VDC system will not operate when
needed or cause it to operate incorrectly and result
in injury.
3. BRAKE FLUID
If brake fluid gets in your eyes or on your skin, do
the following:
Wash eyes and seek immediate medical atten-
tion.
Wash your skin with soap and then rinse thor-
oughly 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 traf-
fic rules and regulations to avoid bodily injury and
interrupting traffic.
6. AIRBAG
To prevent bodily injury from unexpected deploy-
ment of airbags and unnecessary maintenance, fol-
low the instructions in this manual when performing
maintenance on or near the airbag components,
around front of the vehicle (radiator panel, front
wheel apron, front side frame, front bumper, front
hood, front fender), around side of the vehicle (front
door, rear door, center pillar, rear fender, side sill,
rear wheel apron), around rear of the vehicle (rear
seat cushion, rear floor, rear crossmember), and on
or near the airbag wiring harnesses.
To prevent unexpected deployment, turn the igni-
tion switch to OFF and disconnect the ground cable
from battery, then wait at least 20 seconds before
starting work.
7. AIRBAG AND SEAT BELT
PRETENSIONER DISPOSAL
To prevent bodily injury from unexpected airbag
deployment, do not dispose the airbag modules
and seat belt pretensioner in the same way as oth-
er waste. Follow all government regulations con-
cerning disposal of refuse.
8. AIRBAG MODULE
Adhere to the following when handing and storing
the airbag module to prevent bodily injury from un-
expected 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.
9. AIRBAG SPECIAL TOOL
To prevent unexpected deployment, only use spe-
cial tools.
10.WINDOW
Always wear safety glasses when working around
any glass to prevent glass fragments from damag-
ing your eyes.
11.WINDOW ADHESIVE
Always use the recommended or equivalent adhe-
sive when attaching glass to prevent it from coming
falling, resulting in accidents and injury.
PC-3
Precaution
PRECAUTION
12.OIL
When handling oil, carefully observe the following
to prevent unexpected accidents.
Prepare container and waste cloths when per-
forming work which oil could possibly spill. If oil
spills, wipe it off immediately to prevent from pene-
trating into floor or flowing outside, for environmen-
tal protection.
Follow all government regulations concerning
disposal of refuse when disposing.
13.FUEL
When handling and storing fuel, carefully observe
the following to prevent unexpected accidents.
Be careful of fires.
Prepare a container and cloth to prevent scatter-
ing of fuels when performing work where fuels can
be spilled. If the fuel spills, wipe it off immediately to
prevent it from penetrating the floor or flowing out,
to protect the environment.
Follow all government and local regulations con-
cerning disposal of refuse when disposing.
14.ENGINE COOLANT
When handling engine coolant, adhere to the fol-
lowing to prevent from unexpected accident.
Never remove the radiator cap because of the
danger of engine coolant blowing out when the en-
gine coolant is hot.
Prepare a container and cloth to prevent spray-
ing of engine coolant when performing work in
which engine coolant can be spilled. If the fuel
spills, wipe it off immediately to prevent from pene-
trating into floor or flowing out for environmental
protection.
cerning disposal of refuse when disposing.
15.AIR CONDITIONER REFRIGERANT
In order to prevent from global warming, avoid re-
leasing air conditioner refrigerant into the atmo-
sphere. Using a refrigerant recovery system,
discharge and reuse it.
PC-4
Precaution
PRECAUTION
NT-2
Note
NOTE
1. Note
A: NOTE
This is the information that can improve the effi-
ciency of maintenance and assure the sound work.
1. FASTENERS NOTICE
Fasteners are used to prevent the parts from dam-
age, dislocation and play due to looseness. Fasten-
ers must be tightened 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 possi-
bility of static electricity. Always use a static elec-
tricity prevention cord or touch grounded metal for
the elimination of static electricity before conduct-
ing work.
3. BATTERY
When removing the battery terminal, always be
sure to turn the ignition switch to OFF to prevent
electrical damage of the control module from over-
current. Be sure to remove the battery ground ca-
ble first.
4. SERVICE PARTS
Use genuine parts for maximum performance and
maintenance when conducting repairs. Subaru/FHI
will not be responsible for poor performance result-
ing from the use of parts except for genuine parts.
5. PROTECTING VEHICLE UNDER MAIN-
TENANCE
Make sure to attach the fender cover, seat covers,
etc. before work.
6. ENSURING SECURITY DURING WORK
When working in a group of two or more, perform
the work with calling each other to ensure mutual
safety.
7. LIFT AND JACK
When using a lift or shop jack raise a vehicle or us-
ing rigid rack to support a vehicle, always follow in-
structions 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.
NOTE:
When using a lift, follow its operation manual be-
fore work.
Do not work or leave unattended while the vehi-
cle is supported with jack, support it with rigid
racks.
Be sure to use the rigid racks with rubber at-
tached to cradle to support the vehicle.
When using a plate lift, use a rubber attachment.
Align the cushion rubber end of plate lift with the
end of rubber attachment. (Portion b) Also, align
the protrusion portion of the supporting locations
with the end of attachment. (Portion a)
(A) 80 mm (3.1 in) or more
(B) 100 150 mm (3.94 5.91 in)
(C) 120 190 mm (4.72 7.48 in)
NT-00070
(A)
(B)
(C)
NT-3
Note
NOTE
Do not use the plate lift whose attachment does not reach the supporting locations.
(1) Supporting locations (3) Swing arm lift (5) Plate lift
(2) Pantograph jack (4) Rigid rack (6) Attachment
NT-00086
a
a
b
(1)
(2)
(3)
(4)
(5)
(6)
(6)
(6)
(6)
NT-4
Note
NOTE
(A) Front (B) Rear

(1) Front crossmember (2) Rear differential
NT-00170
(1)
(2)
(A)
(B)
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 locations on the vehicle.
TIE-DOWN LOCATION
CAUTION:
Use the T-hook for rear tie-down. Do not use the hook other than T-hook, otherwise it can be removed
when transporting vehicles.
CHAIN DIRECTION AT TIE-DOWN CONDITION
NOTE:
Pull the chains LH and RH in the same direction,
but front and rear side in the counter direction. Pull
all the chains in a same moment.
(1) Hook for tie-down
(1)
(1) (1)
NT-00149
NT-00117
NT-6
Note
NOTE
CHAIN PULLING RANGE AT TIE-DOWN CON-
DITION
Vehicle sinking volume at tie-down condition
Measure the distance between the highest tire
point and highest arch point before and after tie-
down. Difference of measured values (sinking vol-
ume) should be within 50 mm (1.97 in) and make
sure to fix the vehicle securely.
(1) Chain pulling range at tie-down condition
(2) 20
(3) 45
(F) Front side
(1) Tightening direction of chain
(2) 45
NT-00122
(2)
(2)
(2)
(2)
(3) (3) (3) (3)
: (1)
(2)
(2)
NT-00151
(1)
(1)
(2)
(2)
F
NT-00076
L
L
NT-7
Note
NOTE
9. TOWING
Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD, AT or VTD, 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.
Front
Remove the fog light cover (except for OUTBACK model) and hook cover, and then install the hook.
Rear
(A) Fog light cover (except for OUT-
BACK model)
(B) Hook cover (C) Hook
(A)
(C)
(B)
(C)
(B)
NT-00171
NT-00078
NT-8
Note
NOTE
Notes
Marked : OK, Marked : Prohibited, Marked : Conditionally OK.
Towing Precautions MT AT
Lifting up four wheels (On a trailer) Towing the vehicle after lifting up all four wheels is a
basic rule for AWD model.
Rope Check if both front and rear wheels are rotated nor-
mally.
AT model driving conditions: Driving speed 50 km/h
(31 MPH) or less
Allow driving distance 30 km (19 miles) or less
Raising the front wheels Prohibited for full-time AWD model.
Lifting up the front wheels Prohibited, due to damage on bumper, front grille, etc.
Do not raise the vehicle with bumper.
NT-00023
NT-00024
NT-00025
NT-00026
NT-9
Note
NOTE
CAUTION:
Check ATF, gear oil and rear differential oil before driving.
Place the shift lever in N position during towing.
Do not lift up the rear wheels to avoid unsteady rotation.
Turn the ignition key to ACC, then check the steering wheel moves freely.
Release the parking brake to avoid tire dragging.
Since the power steering does not work, be careful for the heavy steering effort. (When engine
is stopped)
Since the servo brake does not work, be careful that the brake is not applied effectively. (When
engine is stopped)
In case of the malfunction of internal transmission or drive system, lift up four wheels (on a trail-
er) for towing.
10.FRONT HOOD STAY INSTALLATION
At the check and general maintenance
When wider hood opening is necessary
Set the stay into the hole of lower hood as shown in the figure below.
NT-00079
NT-00080
NT-10
Note
NOTE
11.GENERAL SCAN TOOL
Using general scan tools will greatly improve the ef-
ficiency of repairing engine electronic throttle con-
trols. Subaru Select Monitor can be used to
diagnose the engine, ABS, air conditioner and oth-
er parts.
12.AWD CIRCUIT MEASURES
1) Full-time AWD MT model
Since viscous coupling (limited slip differential) is
used in the center differential, cut-off of AWD circuit
cannot be carried out.
2) Full-time AWD 5AT model
Since VTD type is used in the center differential,
cut-off of AWD circuit cannot be carried out.
3) Full-time AWD 4AT model
Insert a spare fuse into FWD fuse holder in the fuse
box located in the left side of engine room to select
the FWD. Since electronically controlled MT-P hy-
draulic multi-plate clutch is adapted for center dif-
ferential, select FWD. When maintenance is
performed with jack-up or on the free roller, check
the illumination of AWD warning light in the combi-
nation meter.
13.SPEEDOMETER TEST
1) Rear wheel free roller system
(1) Set the free roller on the floor of rear wheel
side securely according to the wheel base and
rear tread of the vehicle.
(2) Let the vehicle ride on the tester and free
roller gently.
CAUTION:
Fix the vehicle using a pulling metal (chain or
wire) to the front and rear towing hooks or tie-
down hook to prevent the lateral runout of front
wheels and springing out of vehicle.
(3) Set the speedometer tester.
(4) Conduct the speedometer test work.
CAUTION:
Do not operate the clutch quickly and do not ac-
celerate or decelerate suddenly during work.
2) Rear wheel jack-up system
(1) Set the vehicle on speedometer tester.
CAUTION:
Fix the vehicle using a pulling metal (chain or
wire) to the front and rear towing hooks or tie-
down hook to prevent the lateral runout of front
wheels and springing out of vehicle.
(2) Jack up the rear wheels and set the rigid
racks to the specified locations of side sill.
(3) Conduct the speedometer test work.
CAUTION:
Do not operate the clutch quickly and do not ac-
celerate or decelerate suddenly during work.
(A) FWD fuse holder
(B) AWD warning light
NT-00081
(B)
(A)
(A) Free roller
(A) Rigid rack
NT-00033
(A)
NT-00034
(A)
NT-11
Note
NOTE
14.BRAKE TEST
1) Full-time AWD MT model
(1) Perform this test after driving the vehicle 2 to
3 km (1.24 to 1.86 miles) on road in order to sta-
bilize the viscous torque of viscous coupling.
(2) Keep the front or rear wheels on the ground
for this test.
NOTE:
Effect of the viscous torque on braking force will be
added approx. 25 kg compared with FWD model.
(3) When the brake dragging force is large.
Check the dragging of brake pad or brake
shoe.
Since it may be affected by the viscosity of
viscous coupling, jack up either of the front or
rear two wheels to check the each wheel rota-
tion condition with the viscous coupling affec-
tion removed.
2) Full-time AWD AT model
(1) Keep the front or rear wheels on the ground
during measurement.
(2) When the brake dragging force is large.
Check the dragging of brake pad or brake
shoe.
Specifications:
When measurement is difficult to carry out
because both of front wheels are locked, brake
force measurement in this condition conforms
to standard grand total.
(A) Brake tester
(B) Position for measuring front wheel
(C) Position for measuring rear wheel
NT-00029
(C)
(A)
(B)
(A) Brake tester
(B) Position for measuring front wheel
(C) Position for measuring rear wheel
Braking force
Rear wheel total More than 10% of load on front or rear
wheels
Difference between
right and left
wheels
Less than 8% of load on front or rear
wheels
Grand total More than 50% of vehicle weight at
the time of test
NT-00029
(C)
(A)
(B)
NT-12
Note
NOTE
15.ON THE CAR WHEEL BALANCING
CAUTION:
Carry out this procedures after measuring
the balance of each single tire.
Set the vehicle so that the front and rear
wheels are the same height.
Release the parking brake during measure-
ment.
Rotate each wheel by hands, and make sure it
rotates without dragging.
Do not operate the clutch quickly and do not
accelerate or decelerate suddenly during work.
When an error is indicated during engine
drive, do not use the motor drive together.
1) Set the rigid rack to the specified locations of
side sill, jack up the front or rear two wheels of non-
measuring side and set the pickup stands to two
wheels of measuring side.
2) For drive wheel, drive the tires with engine for
measurement.
3) For non-drive wheel, drive the tires from the on
the car wheel balancer for measurement.
(A) Balancer body
(B) Pickup stand
NT-00031
(A)
(B)
ID-2
Identification
IDENTIFICATION
1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER & LABEL LOCATIONS
The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle.
POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION
(1) Emission control label (3) Model number label (5) Emission control label FMVSS
label (U.S. model)
CMVSS label (Canada model)
(2) Vehicle identification number
(V.I.N.)
(4) Tire inflation pressure label
(Drivers side)
(2)
(2)
(4)
(1)
(5)
(3)
ID-00167
ID-3
Identification
IDENTIFICATION
ENGINE
AUTOMATIC TRANSMISSION
4AT
5AT
MANUAL TRANSMISSION
5MT (non-turbo model)
5MT (turbo model)
6MT
(1) Engine serial number (Punch mark)
(2) Engine type (Crankcase upper side)
(1) AT type label
(2) Transmission serial number label
(1) AT type label
(2) Transmission serial number label
ID-00059
(2)
(1)
ID-00135
(2)
(1)
ID-00067
(2)
(1)
(1) Transmission serial No.
(2) MT type label
(2) MT type label
(2) MT type label
(2)
(1)
ID-00203
ID-00136
(2)
(1)
ID-00137
(1)
(2)
ID-4
Identification
IDENTIFICATION
REAR DIFFERENTIAL
T-TYPE
VA1-TYPE
VA2-TYPE
MODEL NUMBER LABEL
(1) Type (white paint)
(1) Type (label)
ID-00056
(1)
DI-00396
(1)
(1) Type (label)
DI-00397
(1)
ID-00200
ID-5
Identification
IDENTIFICATION
2. MEANING OF V.I.N.
The meaning of the V.I.N. is as follows:
]4S3BL616X86200001[
The starting and ending brackets ( ] [ ) are stop marks.
Digits Code Meaning Details
1 3 4S3 Manufacturer body area 4S3: Except for OUTBACK model
4S4: OUTBACK model
4 B Car line LEGACY
5 L Body type L: Sedan
P: Wagon
6 6 Displacement 6: 2.5 L AWD
8: 3.0 L AWD
7 1 Grade 0: OBK 2.5 BASE
1: 2.5 i, OBK 2.5 i
2: 2.5-LTD, OBK 2.5 i-LTD
3: OBK 2.5 XT-LTD
4: OBK 3.0 R
5: OBK 3.0 R-LTD, 3.0 R-LTD
6: OBK 3.0 R-LB (L.L.Bean)
7: 2.5 GT-LTD
9: 2.5 GT-B
8 6 Restraint or GVWR
Class
6: Manual belts, Dual airbag, Side airbag (Except for OUT-
BACK model)
C: Class C (GVWR 4001 5000 lb) (OUTBACK model)
9 X Check digit 0 9 &X
10 8 Model year 8: 2008MY
11 6 Transmission type 3: Full-time AWD 6MT
4: Full-time AWD 5AT
6: Full-time AWD 5MT
7: Full-time AWD 4AT
12 17 200001 Serial number From 200001: Sedan
From 300001: Wagon
ID-6
Identification
IDENTIFICATION
3. MODEL NUMBER PLATE
The model number plate indicates the type, V.I.N. <Ref. to ID-5, MEANING OF V.I.N., IDENTIFICATION,
Identification.>, applied model, option code, trim code, engine type, transmission type and the exterior color
code. This information is helpful when placing orders for parts.
BL9DYHJ
The engine and transmission type are as follows.
ENGINE
EJ253BSEFB
1 B Series LEGACY
2 L Body type L: Sedan
P: Wagon
3 9 Engine displacement
Drive system
Suspension system
9: 2.5 L AWD
E: 3.0 L AWD
4 D Model year D: 2008MY
5 Y Destination Y: U.S., Canada
6 H Grade C: 2.5 GT Limited
D: OUTBACK 2.5 XT Limited
F: 2.5 GT spec. B
H: 2.5 i
K: 2.5 i Limited
P: OUTBACK 2.5 BASE
S: OUTBACK 2.5 i
T: OUTBACK 2.5 i Limited
U: OUTBACK 3.0 R
V: OUTBACK 3.0 R Limited
X: OUTBACK 3.0 R L.L.Bean
7 J Transmission, fuel feed
system
D: DOHC MFI Turbo 5MT
J: SOHC MFI 5MT
H: DOHC MFI Turbo 6MT
L: SOHC MFI 4AT TIP
U: DOHC MFI 5AT TIP
V: DOHC MFI Turbo 5AT TIP
1 and 2 EJ Engine type EJ: 4 cylinder
EZ: 6 cylinders
3 and 4 25 Displacement 25: 2.5 L
30: 3.0 L
5 3 Fuel feed system 3: MFI non-turbo (SOHC)
5: MFI turbo
D: MFI non-turbo (DOHC, H6)
6 B Emission control B: For USA
7 S Mounted transmission C: D-5AT
E: 5MT (Flexible type flywheel, Wide angle damper type disc
wheel)
G: 6MT
P: 4AT
S: 5MT (Flexible type flywheel)
8 10 EFB Detailed specifications Used when ordering parts. See the parts catalog for details.
ID-7
Identification
IDENTIFICATION
TRANSMISSION
TY758VCEAA
REAR DIFFERENTIAL
XJ
1 T Transmission T: Transmission
2 Y Transmission type G: Full-time AWD 5AT center differential
V: Full-time AWD AT center differential
Y: Full-time AWD MT center differential
Z: Full-time AWD AT MPT
3 and 4 75 Identification 1B: 4AT
5D: 5AT
75: 5MT
85: 6MT
5 8 Series 6: 6MT
7: 5AT
8: 5MT or 4AT
6 V Transmission specifica-
tions
C: Full-time AWD VTD 5AT
L: Full-time AWD MPT 4AT
M: Full-time AWD center differential 4AT
V: Full-time AWD 5MT single range with viscous coupling cen-
ter differential
W: Full-time AWD 6MT single range with viscous coupling cen-
ter differential
7 C Mounted vehicle C: 2.5 L SOHC
F: 2.5 L SOHC
V: 3.0 L DOHC
W: 2.5 L DOHC Turbo
8 10 EAA Detailed specifications Used when ordering parts. See the parts catalog for details.
Code Reduction gear ratio LSD
CD 4.444 Viscous
CF 4.444 Viscous
EW 3.900 Viscous
HY 3.545 Torsen
JE 4.111 Viscous
T1 3.900 None
T2 4.111 None
TP 4.444 None
XJ 4.111 None
XU 3.272 Viscous
XZ 3.083 Viscous
ID-8
Identification
IDENTIFICATION
OPTION
U5UC
1 2 U5 Destination C0: Canada
U4: U.S. For USA
U5: U.S. For states using California emission standards
U6: U.S. For states not using California emission standards
3 U Option equipment 3: Cruise control, Power pack
D: Vehicle dynamics control (VDC), Cruise control
E: Vehicle dynamics control (VDC), Cruise control, Power pack
U: Cruise control
4 C Option equipment C: A/C, Side airbag, Curtain airbag
K: A/C, Side airbag, Curtain airbag, Sunroof, Navigation system
W: A/C, Side airbag, Curtain airbag, Sunroof
RM-2
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
Always use gasoline of the same or higher octane value than specified in the owners manual. Ignoring the
specifications below will result in damage or poor performance of engine and fuel injection system. Use the
specified gasoline to correct performance.
Unleaded gasoline
In order to reduce air pollution, use unleaded gasoline for the vehicle equipped with catalytic converter. Using
leaded gasoline may damage the catalytic converter.
3. LUBRICANTS
Use either lubricants in the table below or equivalent. See the table below to choose the correct SAE viscos-
ity.
Lubricants Recommended materials
API standard ILSAC standard
Engine oil
Choose oil suitable for the standard
from the right.
SM Energy conserving GF-4
Manual Transmission Oil GL-5
AT front differential gear oil GL-5
Rear differential gear oil GL-5
SAE
5W-30
N
E
E
R
G
G
Y
CON
S
E
R
V
I
N
A
P
I
S
E
RVIC
E
S
M
RM-00049
A
M
E
R
I
C
A
N
P
E
T
R
OLE
U
M
I
N
S
T
I
T
U
T
E
FOR
GASOLINE
ENGINES
C
E
R
TI F
E
I
D
RM-00002
RM-3
SAE viscosity No. and applicable temperature
Engine oil
Manual transmission oil, rear differential gear oil and AT front differential gear oil
(F) 22 4 14 50 68 86 104
(C) 30 20 10 0 10 20 30 40
5W-30 Recommend
32
10W-30 or 10W-40
RM-00060
RM-00058
(C)
22 4 14 50 68 86 104 (F)
30 20 10 0 10 20 30 40
85W
75W-90
80W
90
32
RM-4
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
CAUTION:
Always use the recommended or equivalent ATF. Using material except recommended one or sub-
stitute would cause trouble.
5. COOLANT
Use genuine coolant to protect the engine.
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any compressor oil other than DENSO OIL 8.
Fluid Recommended materials Alternative Remarks
Automatic transmission fluid SUBARU ATF HP
IDEMITSU: ATF HP
Castrol: Transmax J

Power steering fluid DEXRON III
Brake fluid FMVSS No. 116, DOT3, or DOT4
Clutch fluid FMVSS No. 116, DOT3, or DOT4
Coolant Recommended materials Item number Alternative
Coolant SUBARU coolant 000016218 Phosphoric acid (non-amine) type
Water for dilution Distilled water Tap water (Soft water)
Cooling system protective agent Cooling system conditioner SOA345001 None
Air conditioner Recommended materials Item number Alternative
Refrigerant HFC134a None
Compressor oil DENSO OIL 8 None
RM-5
7. GREASE
Use grease and supplementary lubricants shown in the table below.
8. ADHESIVE
Use the adhesives shown in the table below, or equivalent.
Grease Application point Recommended materials Item number Alternative
Supplementary
lubricants
Oxygen sensor
Bolts etc.
Spray type lubricant
Grease
MT main shaft NICHIMOLY N-130
Clutch master cylinder push rod SILICONE GREASE G-40M 004404003
Gear shift lever
Clutch activating cylinder
Clutch pedal
Brake pedal
Clutch bearing
Clutch release lever
SUNLIGHT 2 003602010
Select lever Multemp AC-D
Multemp SH-W (Shift lock part)

Door latch
Door striker
SILICONE GREASE G-30M 004404002
Steering gearbox
VALIANT GREASE M2 003608001
ONE LUBER SG
or MO
Disc brake (lock pin, guide pin,
piston boot)
NIGLUBE RX-2 000041000
Between brake pad and shim Molykote AS-880N K0777YA010
Brake pad clip Molykote M7439 K0777YA000
Front axle PTJ NKG302 28395AG02A
Front axle EBJ NTG2218-M 28395AG01A
Rear axle EBJ
Rear axle BJ
NKG106 28395AG040A
Rear axle DOJ NKG205 28495AG00A
Adhesive Application point Recommended materials Item number Alternative
Adhesive
Windshield, rear window
glass, rear quarter
glass, rear gate and
body
Dow Automotives adhesive:
ESSEX U-400HV or the equivalent
Glass primer: U-401 and U-402
Painted surface primer: U-413

Rearview mirror base REPAIR KIT IN MR 65029FC000
Soft vinyl
CEMEDINE 540
3Ms EC-776, EC-847 or EC-1022
(Spray type)
Momentary sealant CEMEDINE 3000 ARMSTRONGs Eastman 910
RM-6
9. SEAL MATERIAL
Use the seal material shown in the table below, or equivalent.
Seal material Application point Recommended materials Item number Alternative
Seal material
MT transmission case
Converter case
THREE BOND 1215 004403007 DOW CORNING No. 7038
Cylinder block
DOHC camshaft cap
(Turbo model)
Cylinder head plug
(Turbo model)
Oil pump (Except for
3.0 L model)
SOHC camshaft cap
Cam cap (3.0 L
model)
Cylinder head plug
(Turbo model)
Rocker cover (3.0 L
model and turbo model)
Oil pan (Pan upper)
(3.0 L model)
Block (Pan upper) (3.0
L model)
Back cover (Front
cover, block head, pan
upper) (3.0 L model)
Engine oil pan (Except
for 3.0 L model)
Separator cover
(Except for 3.0 L model)
THREE BOND 1217G K0877Y0100
Transmission oil pan (AT
model)
THREE BOND 1217B K0877YA020
Seal material
Rear differential
Engine oil pressure
switch
Connector (Oil hose)
(Turbo model)
Connector (Heater
hose) (3.0 L model)
Cylinder head (Nipple)
(3.0 L model)
Camshaft bowl-shape
plug (3.0 L model)
THREE BOND 1324 004403042
Rear differential
Service hole plug
(Except for 3.0 L model)
PCV valve
THREE BOND 1105 004403010 DOW CORNING No. 7038
Steering adjusting screw THREE BOND 1141 004403006
Front sealing cover
Rear sealing cover
3M Butyl Rubber 8626
PI-2
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 ve-
hicle to its normal condition.
Check the vehicle before delivery is in normal condition.
Check the vehicle or parts for any damage occurred during transportation or storage.
Check the vehicle after repair is in normal condition.
Make sure to provide a complete vehicle to customer.
For above reasons, all SUBARU dealers (dealerships) must carry out the PDIs before delivery of vehicle.
Refer to this manual unless otherwise specified.
PI-3
B: PRE-DELIVERY INSPECTION (PDI) PROCEDURE
STATIC CHECKS JUST AFTER VEHICLE RECEIPT
Procedure Check point
1. Appearance check 1. If the vehicle is covered with protective coating, visually check the vehicle
body for damage and dents. If the protective coating has been removed,
visually check the body painted area for damage or stains in detail.
2. Visually check the glass and light lenses for any damage, cracks or exces-
sive 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 If the vehicle is about to be delivered to customer, attach a back-up fuse.
4. 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.
3. Operate the power door lock switch to check that the door (rear gate) is
locked and unlocked normally.
5. Operation check of child safety lock system Check the child safety lock system operates normally.
6. Open/close operation checks of trunk lid 1. Operate the trunk lock release lever to check that the trunk lid opens normally.
2. Check that main and sub keys can lock/unlock the release lever, and that
valet key can not lock/unlock the release lever.
3. Open and close the trunk lid to see that there are no abnormal conditions.
7. Operation check of trunk lid release lever Operate the trunk lid release lever to check that the trunk lock is unlocked
normally.
8. Check the rear gate for lock/unlock and open/
close operations.
1. Check if the rear gate can be unlocked normally through the emergency hole.
2. Open and close the rear gate to see that there are no abnormal condi-
tions.
9. Operation check of fuel lid opener lock release
lever
Operate the fuel lid opener to check that the fuel lid is unlocked normally.
10. Accessory check Check that the following accessories are provided.
Owners manual
Warranty booklet
Maintenance note
Spare key
Jack
Tool set
Spare tire
11. Operation check of front hood lock release
system
Operate the front hood lock release lever to check that the front hood is
unlocked normally.
12. Battery Check the battery terminals for any abnormal conditions such as rust and
trace of battery fluid leaks.
13. Brake fluid Check that the fluid level is normal.
14. Engine oil Check that the oil level is normal.
15. Transmission gear oil Check that the transmission gear oil level is normal.
16. AT front differential gear oil Check that the AT front differential oil level is normal.
17. Engine coolant Check that the engine coolant level is normal.
18. Clutch fluid Check that the clutch fluid level is normal.
19. Window washer fluid Check that the window washer fluid level is normal.
20. Front hood latch check Check that the hood is closed and latched securely.
21. Keyless entry system Check that the keyless entry system operates normally.
22. Alarm system Check that the alarm system operates normally.
23. Seat 1. Check the seat surfaces for stains or dirt.
2. Check the seat installation conditions and functionality.
3. Check that the occupant detection system for passengers seat operates
normally.
24. Seat belt 1. Check the seat belt installation conditions and functionality.
2. Check that the seat belt warning system operates normally.
PI-4
CHECKS WITH THE ENGINE RUNNING
DYNAMIC TEST WITH THE VEHICLE RUNNING
CHECKS AFTER DYNAMIC TEST
25. Test mode connector Test mode connector
26. Immobilizer system 1. Check that the engine starts with all keys that are equipped on vehicle.
2. 60 seconds after turning ignition switch from ON to ACC or OFF, or imme-
diately after removing the key, check that the security indicator light blinking.
27. Starting condition Start the engine and check that the engine starts smoothly.
28. Exhaust system Check that the exhaust noise is normal and no leaks are found.
29. Indicator and warning lights Check that all the indicator and warning lights are gone out.
30. Heater & ventilation Check that the heater & ventilation system operates normally.
31. Air conditioner Check that the air conditioner operates normally.
32. Clock Check that the clock operates normally.
33. Audio Check the radio, CD player for normal operation.
34. Navigation system 1. Check all display functions for normal operation.
2. Check the map disc (DVD) are provided on vehicle.
3. Check that the navigation system operates normally.
35. Front accessory power supply socket Check that the front accessory power socket operates normally.
36. Lighting system Check that the lighting system operates normally.
37. Wiper deicer Check that the wiper deicer operates normally.
38. Illumination control Check that the illumination control operates normally.
39. Window washer Check that the window washer system operates normally.
40. Wiper Check that the wiper system operates normally.
41. Power window operation check Check that the power window operations normally.
42. Sunroof Check that the sunroof operates normally.
43. Door mirror Check that the remote control mirror operates normally.
44. Brake test Check the foot brake for normal operations.
45. Parking brake Check the parking brake for normal operations.
46. AT shift control Check that the AT shift patterns are correct.
47. Cruise control Check that the cruise control system operates normally.
48. ATF level Check that the ATF level is correct.
49. Power steering fluid level Check that the power steering fluid level is normal.
50. Fluid leak check Check for fluid/oil leaks.
51. Water leak test Spray the vehicle with water and check for water leaks.
52. Appearance check 2 1. Remove the protective coating (if equipped).
2. Check the body paints for damage and stain.
3. Check the plated parts for damage and rust.
PI-5
1. APPEARANCE CHECK
If the vehicle is covered with protective coating,
visually check the vehicle body for damage and
dents.
When the protective coating is removed, visually
check the body paints for damage or stains in detail
and repair as necessary.
Visually check the windshield glass, door glass-
es and light lenses for any damage, cracks or ex-
cessive gaps to the body sheet metal and repair as
necessary.
Visually check the plated parts, such as the
grilles and door knobs, for damage or loss of gloss
and replace the parts as necessary.
2. TIRE CHECK
Check the tires for damage, defective, and dents
on wheels.
Check and adjust the tire size, spare tire and tire
air pressure described on the tire air pressure label
(drivers side).
3. FUSE INSTALLATION
Fuses for the back-up circuit have been removed to
prevent battery discharge. If the vehicle is about to
be delivered to the customer, attach a 20 A fuse (A)
as shown in the figure.
4. LOCK/UNLOCK AND OPEN/CLOSE
OPERATION CHECKS OF DOORS.
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.
2) Completely close the drivers door, and then
check the smooth movement with operating door
lock knob from lock to unlock several times. Set the
door lock knob (A) to lock position. Then pull the in-
ner 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 en-
sure that doors will not open.
3) Close all the doors, and then press the lock on
power door lock switch at drivers side. Check that
all doors including rear gate are locked.
PI-00158
(A)
(A) Unlock
(B) Lock
(A) Door lock knob
(B) Inner remote
PI-00246
(A)
(B)
(A)
(B)
PI-00192
PI-00392
PI-6
4) Press the drivers side power door lock switch to
unlock side. Check that all doors including rear
gate are unlocked.
5) Check that the power door lock switch on the
passengers side also locks and unlocks.
6) Insert the key to ignition switch, and open the
drivers side door. Press lock on power door lock.
Check that the door is not locked.
5. CHECK THE OPERATION OF CHILD
SAFETY LOCK SYSTEM
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 the doors will not open.
4) Pull the outer handles to ensure that doors will open.
6. OPEN/CLOSE OPERATION CHECKS OF
TRUNK LID
1) Operate the trunk lock release lever to check
that the trunk lid opens normally.
2) Open and close the trunk lid several times for
smooth movement.
3) Lock the trunk lock release lever using main key
or sub key.
4) Check that the trunk lock release lever does not
operate.
5) Check if the trunk lock release lever is not locked
and unlocked using valet key.
7. OPERATION CHECK OF TRUNK LID
RELEASE HANDLE
1) Use a flat tip screwdriver. Slide the screwdriver
blade from the slit aperture of the lock assembly ful-
ly to the end until you hear a click. This places the
latch in the locked position.
2) Move the release handle from outside the vehi-
cle in the direction of the arrow to check if the latch
is released.
(A) Lock
(B) Unlock
(A) Lock
(B) Unlock
PI-00393
PI-00247
(B)
(A)
PI-00164
(A)
(B)
PI-00258
PI-00248
PI-00249
PI-7
8. LOCK/UNLOCK AND OPEN/CLOSE
OPERATION CHECKS OF REAR GATE
1) Open and close the rear gate several times for
smooth movement.
2) Operate the rear gate lever to check that the rear
gate is locked and unlocked normally.
(1) Remove the cover inside the rear gate.
(2) Operate the lever to check that the rear gate
is locked and unlocked normally.
9. OPERATION CHECK OF FUEL LID
OPENER LOCK RELEASE LEVER
Operate the fuel lid opener to check that the fuel lid
is unlocked normally. Check that the filler cap is se-
curely closed.
10.ACCESSORY CHECK
Check that the following accessories are provided.
Owners manual
Warranty booklet
Maintenance note
Spare key
Jack
Tool set
Spare tire
PI-00165
PI-00166
(A) Jack
(B) Jack handle
PI-00168
(B) (A)
PI-00169
(B)
(A)
PI-8
11.OPERATION CHECK OF FRONT HOOD
LOCK RELEASE SYSTEM
Operate the front hood lock release lever (A) to
check that the front hood is unlocked normally.
Operate the lever (B) and check that the front hood
is opened normally. Support the front hood with
hood stay.
12.BATTERY
Check the battery terminals to make sure that there
are no rust or corrosions due to fluid leaks.
13.BRAKE FLUID
Check that the brake fluid level is normal. If the
amount is insufficient, carry out a brake line test to
identify brake fluid leaks and check the brake oper-
ation. After that, refill the brake fluid tank with the
specified type of fluid.
(A)
PI-00195
PI-00381
(B)
PI-00250
(A) MAX. level
(B) MIN. level
PI-00251
M
IN
M
A
X
(B)
(A)
PI-9
14.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.
Except for 3.0 L model
3.0 L model
15.TRANSMISSION GEAR OIL
Check that the transmission gear oil level is normal.
If the amount of fluid is insufficient, check that no
leaks are found. Then add the necessary amount of
the specified transmission gear oil.
5MT model (Non-turbo model)
5MT model (Turbo model)
6MT model
(A) Oil level gauge
(B) Engine oil filler cap
(C) Upper level
(D) Lower level
(E) Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)
(F) Notch mark
(A) Oil level gauge
(C) Upper level
(D) Lower level
(C)
(F)
(B)
(A)
(E)
(D)
PM-00362
L
F
(A)
(B)
(C)
(E)
(D)
PM-00363
(A) Oil level gauge
(B) Upper level
(C) Lower level
(A) Oil level gauge
(B) Upper level
(C) Lower level
(A) Oil level gauge
(B) Upper level
(C) Lower level
PM-00030
(B)
(C)
(A)
(B)
(C)
(A)
PI-00391
MT-00449
(A)
(A)
(B)
(C)
PI-10
16.AT FRONT DIFFERENTIAL GEAR OIL
Check that the AT front differential oil level is nor-
mal. If the amount of oil is insufficient, check that no
leaks are found. Then, add the necessary amount
of the specified AT front differential oil.
4AT model
5AT model
17.ENGINE COOLANT
Check that the engine coolant level on the reservoir
tank is normal. If the amount of engine coolant is in-
sufficient, check that no leaks are found. Then, add
the necessary amount of coolant with the specified
concentration.
18.CLUTCH FLUID
Check that the clutch fluid level is normal. If the
amount of fluid is insufficient, check that no leaks
are found. Then, add the necessary amount of
specified fluid.
19.WINDOW WASHER FLUID
Check that the window washer fluid level is normal.
If the amount is insufficient, check that no leaks are
found. Then, add the necessary amount of washer
fluid.
20.FRONT HOOD LATCH CHECK
Retract the front hood stay and close the front
hood. Check that the front hood is securely latched.
(A) Oil level gauge
(B) Upper level
(C) Lower level
(A) Oil level gauge
(B) Upper level
(C) Lower level
PI-00183
(B)
(C)
(A)
(A)
PI-00184
(A)
(C)
(B)
(A)
F
L
(A) Reservoir tank
(B) MIN. level
(C) MAX. level
PI-00253
X
A
M
N I
M
(C)
(B)
(A)
PI-11
21.KEYLESS ENTRY SYSTEM
NOTE:
The following inspections show the initial settings.
When the settings are different from the initial set-
tings, use Subaru Select Monitor to check the de-
tails of each setting for inspections. <Ref. to
LAN(diag)-26, OPERATION, Read Current Data.>
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 rear gate and trunk open button for at
least one second.
Check if the trunk is opened and the hazard light
blinks twice and the buzzer sounds twice. (Sedan
model)
Check if the rear gate is unlocked and the hazard
light blinks twice and the buzzer sounds twice.
(Wagon model)
4) Press the LOCK button on the keyless trans-
mitter with one of the doors (including the rear gate
and trunk) opened. Check if all the doors are
locked, hazard light blinks five times and the buzzer
sounds five times and warning shows one of the
doors (including the rear gate and trunk) open.
5) Close all the doors including rear gate and trunk.
Press the LOCK button momentarily on the key-
less transmitter. Check that all the doors (including
rear gate and trunk) are locked, hazard light blinks
once and buzzer sounds once.
6) Press the UNLOCK button momentarily on the
keyless transmitter. Check that the drivers door is
unlocked and hazard light blinks twice and the
buzzer sounds twice.
And press the UNLOCK button momentarily
again in 5 seconds. Check that all the doors includ-
ing rear gate are unlocked.
7) Within a distance of 10 m from a vehicle, press
keyless transmitters LOCK button three times
within 5 seconds. Check that the horn honks once
and that the hazard light blinks three times.
8) Move the power door lock switch to the lock po-
sition with one of doors (including the rear gate)
opened. Next, close all the doors including rear
gate. Check if all the doors are locked and buzzer
sounds once and the hazard light flashes once.
9) Check buzzer operation.
The buzzer sounds when the doors are locked or
unlocked. The buzzer can be turned off if desired.
Turn the buzzer off or on with following procedure.
(1) Close all the doors including rear gate, then
remove the key from ignition key lock.
(2) Press the power door lock switch to unlock
and hold it until the operation is finished.
(3) Insert the key into ignition key lock, and in-
sert and remove the key in ignition key lock 5
times in 10 seconds.
(4) When finished step (3), open and close the
drivers door once within 10 seconds.
NOTE:
When opening and closing of the door is not avail-
able within 10 seconds, hazard light blinks once
and the change over operation is cancelled. Retry
from the step (1).
(5) Hazard light blinks 3 times and the buzzer
sound turns ON or OFF.
PI-00386
PI-00387
PI-00386
PI-12
10) Press the Panic button on the keyless transmit-
ter. Check if the alarm condition happens (horn
sounds continuously, hazard light blinks, security
indicator comes on). Check whether this condition
lasts until any button on the keyless transmitter is
pressed or lasts for 30 seconds.
22.ALARM SYSTEM
NOTE:
The following inspections show the initial settings.
When the settings are different from the initial set-
tings, use Subaru Select Monitor to check the de-
tails of each setting for inspections. <Ref. to
LAN(diag)-27, OPERATION, Function Setting
(Customize).>
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 button momentarily on the
keyless transmitter. All doors are locked, and buzz-
er sounds once, hazard blinks once, security indi-
cator light blinks faster (five times per two seconds)
for 30 seconds and goes slower (twice per two sec-
onds), then the alarm system is in set condition.
4) Press the UNLOCK button momentarily on the
keyless transmitter. When the door of the drivers
seat is unlocked, the buzzer sounds twice, the haz-
ard light flashes twice, the room light turns on and
the security indicator light flashes once in three
seconds, and the alarm system enters the release
mode.
5) Close all the doors including rear gate. Press the
LOCK button momentarily on the keyless trans-
mitter. When all the doors are locked, buzzer
sounds once, hazard blinks once and the alarm
system is in set condition in 30 seconds.
6) Unlock a door using the inner lock knob and
open the door while the security system is in the set
mode. Check if the alarm condition happens (horn
sounds continuously, hazard light blinks, security
indicator illuminates). Check if this condition lasts
for a maximum of three minutes or until the UN-
LOCK button of the keyless transmitter is pressed.
NOTE:
The alarm condition will cease in 30 seconds once
the door is closed.
7) When none of above is applicable, check the
troubleshooting of security system.
PI-00389
PI-00387
PI-00388
PI-13
23.SEAT
1) Check the seat surfaces for stains or dirt.
2) Check that each seat provides full functionality in
sliding and reclining. Check that the seat position
memory for drivers power seat function properly.
Check all available functions of the rear seat such
as a trunk-through center armrest.
3) Check the passengers seat occupant detection
system.
(1) Turn the ignition switch to ON.
(2) Check that 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 illuminates again.
(3) With a person weighing approximately 70 kg
(155 lb) or more sitting in the passengers seat,
check whether the passengers airbag indicator
light illuminates or not.
(4) Empty the passenger seat, then check
whether the passengers side airbag indicator
light illuminate off.
24.SEAT BELT
1) Check installation condition of seat belt.
2) Pull out the seat belt and then release it. Check
that the belt retracts smoothly.
3) Check that the ALR seat belt operates normally.
4) Check seat belt warning system
(1) Turn the ignition switch to ON without fas-
tening drivers and passengers seat belts.
(2) Check if the seat belt warning lights of driv-
ers and passengers side blink for about six
seconds and the buzzer beeps intermittently.
(3) Then, check that the seat belt warning light
comes on blink in about 15 second cycles. (If
the passenger seat is empty, the seat belt warn-
ing light for passengers side does not operate.)
25.TEST MODE CONNECTOR
Turn the ignition switch to ON and check that the
malfunction indicator light starts blinking. If the light
blinks, return the ignition key to LOCK. Pull out the
test mode connector from the back of glove box
lower cover, and disconnect the test mode connec-
tor. Then, turn the ignition key to ON again. If the
malfunction indicator light blinks at that time in spite
of the disconnected test mode connector, carry out
an engine diagnosis.
26.IMMOBILIZER SYSTEM
1) Check that the engine starts with all keys that
are equipped on vehicle.
2) 60 seconds after turning ignition switch from ON
to ACC or OFF, or immediately after removing the
key, check that the security indicator light blinking.
NOTE:
If malfunctions occur, refer to IMMOBILIZER (DI-
AGNOSIS).
27.STARTING CONDITION
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, im-
mediately stop the engine and check and repair the
abnormal components.
28.EXHAUST SYSTEM
Listen to the exhaust noise to see if no noises are
observed. Check for exhaust leaks.
29.INDICATOR AND WARNING LIGHTS
Check that all the indicator and warning lights are
off.
30.HEATER & VENTILATION
Operate the heater & ventilation system to check
for normal airflow outlet control, air inlet control, air-
flow capacity and heating performance.
OD-00036
(A) Test mode connector (green)
PI-00201
(A)
PI-14
31.AIR CONDITIONER
Operate the air conditioner. Check that the A/C
compressor operates normally and enough cooling
is provided.
NOTE:
To prevent the insufficient lubrication of air condi-
tioner, operate the air conditioner for 5 minutes at
idling.
32.CLOCK
Check the clock for normal operations and enough
accuracy.
33.AUDIO
Check the radio for full functionality and normal
noise level. Check the CD unit operations.
34.NAVIGATION SYSTEM
1) Check all display functions for normal operation.
2) Check the map disc (DVD) are provided on vehi-
cle.
3) Check that the navigation system operates nor-
mally.
35.FRONT ACCESSORY POWER SUPPLY
SOCKET
1) Check the operation of the front accessory pow-
er supply socket.
2) Check operation of the accessory power supply
socket in console box.
36.LIGHTING SYSTEM
1) Check the headlight operations.
2) Check the stop light operation.
3) Check other lights for normal operations.
37.WIPER DEICER
Check that the wiper deicer operates normally.
38.ILLUMINATION CONTROL
Check that the illumination control operates nor-
mally.
39.WINDOW WASHER
Check that the window washer system injects
washer fluid to the specified area of the windshield
shown in the figure.
Front injection position:
A: 250 mm (9.84 in)
B: 535 mm (21.1 in)
Rear injection position:
Wagon model
A: 70 mm (2.8 in)
B: 70
40.WIPER
Check the front and rear wipers for normal opera-
tions.
41.POWER WINDOW OPERATION CHECK
Operate the power window switches one by one to
check that each of the power windows goes up and
down without noises.
42.SUNROOF
Check that the sunroof operates normally.
43.DOOR MIRROR
Check that the remote control mirror operates nor-
mally.
44.BRAKE TEST
Check the foot brake for normal operations.
(1) Nozzle
(2) Spray area (shaded area)
WW-00395
A A
(1)
(2)
B
PI-00104
A
B
PI-15
45.PARKING BRAKE
Check the parking brake for normal operations.
When pulling the parking brake lever with force of
200 N (20.4 kgf, 45.0 lb), check that the lever stroke
of parking brake lever is 5 to 6 notches.
46.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 se-
lect lever moves from P range.
4) Set the select lever to other than P range.
5) When the ignition switch is turned to OFF, check
if the ignition key switch cannot be removed.
6) Set the AT selector lever to each gear position
and check the shifting while driving the vehicle.
4AT
5AT
47.CRUISE CONTROL
Operate the cruise control system. Check that the
system is activated and deactivated correctly.
48.ATF LEVEL
After selecting all positions (P, R, N, D), set the se-
lect lever in P range. Idle the engine for 1 2
minutes, and measure the ATF level. If the amount
is insufficient, check that no leaks are found. Then,
add the necessary amount of the specified ATF.
4AT
5AT
Selector position
Gear position
1st 2nd 3rd 4th
D OK OK OK OK
Manual mode OK OK OK OK
Selector position
Gear position
1st 2nd 3rd 4th 5th
D OK OK OK OK OK
Manual mode OK OK OK OK OK
PI-00199
P
R
N
D
(A) Level gauge
(B) ATF level range at HOT [70 80C (158
176F)]
(C) Upper level
(D) Lower level
(E) ATF level range at COLD [20 30C (68
86F)]
(A) Level gauge
(B) ATF level range at HOT [70 80C (158
176F)]
(C) Upper level
(D) Lower level
(E) ATF level range at COLD [20 30C (68
86F)]
PI-00189
C
O
L
D
L
F
H
O
T
L
F
(A)
(C)
(D)
(C)
(D)
(E)
(B)
PI-00190
(A)
(C)
(D)
(E)
(D)
(C)
(B)
(A)
F
L
F
H
O
T
L
C
O
L
D
PI-16
49.POWER STEERING FLUID LEVEL
Check that the power steering fluid level is normal.
If the amount is insufficient, check that no leaks are
found. Then add the necessary amount of the
specified power steering fluid.
50.FLUID LEAK CHECK
Check entire areas of the vehicle for any trace of
coolant/oil/fluid leaks.
51.WATER LEAK TEST
Spray the vehicle with water using a hose and
check that no water enters the passenger compart-
ment.
Before performing the water leakage test, re-
move anything that may obstruct the operation or
which must be kept dry.
Close all the windows and doors securely. Close
the hood and trunk lid before starting the test.
Spray the vehicle with water using a hose. The
rate of water spray must be approx. 20 25 2 (5.3
6.6 US gal, 4.4 5.5 Imp gal) per minute.
When spraying water on areas adjacent to the floor
and wheel house, increase the pressure. When
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.
NOTE:
Be sure to keep the hose at least 10 cm (3.9 in)
away from vehicle.
Check the following areas.
Front window and body framework mating por-
tion
Door mating portions
Glass mating portions
Rear quarter window mating portions
Rear window and body framework mating por-
tion
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.
52.APPEARANCE CHECK 2
1) When vehicle body is covered with protective
film, peel it off.
NOTE:
Use of steam facilitates peeling off the wrap
guard.
For a vehicle left for a long time or at low temper-
ature, sprinkle some water heated to 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 exist on the coated sur-
face, 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.
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 in-
spection 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 careful-
ly. 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 un-
derside 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. Af-
ter 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 plated
parts for deformation or distortion. Also, check
each light lens for cracks.
PS-00463
HOT MAX
COLD MAX
HOT MIN
COLD MIN
PI-17
6) Peel the protective tape, vinyl wrapping and
identification seal attached to the following places.
Seats
Door trim
Floor carpet
Side sill
Front hood lock release lever
Edge rear
Rear wiper
Sedan rear combination light (Trunk lid opening
portion)
Roof rail
Door mirror
PI-18
PM-2
General Description
PERIODIC MAINTENANCE SERVICES
1. General Description
Be sure to perform periodic maintenance in order to
maintain vehicle performance and find problems
before they occur.
PM-3
Schedule
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. U.S.
Other than U5 model
Symbols used:
R: Replace
I: Inspection
(R) or (I): Recommended service for safe vehicle operation.
Maintenance interval
[Number of months or km (miles), whichever occurs first]
Months 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
Remarks 1,000 km 4.8 12 24 36 48 60 72 81.4 96 108 120 132 144 156 168 180 192
1,000 miles 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 Engine oil 3.0 L R R R R R R R R R R R R R R R R R
2.5 L R R R R R R R R R R R R R R R R Turbo
model
Note 6.
2 Engine oil
filter
3.0 L R R R R R R R R R R R R R R R R R
2.5 L R R R R R R R R R R R R R R R R Turbo
model
Note 6.
3 Spark plug R R R R 2.5 L
non-turbo
model
R R 2.5 L
turbo,
3.0 L
model
4 Drive belt(s) I I I R
5 Camshaft drive belt I I I R
6 Fuel line (I) (I) (I) I Note 1.
7 Air cleaner element R R R R Note 2.
8 Cooling system I I I I
9 Engine coolant R R R R
10 Clutch system I I I I I I I I
11 Transmission oil I I I I
12 ATF I I I I Note 3.
13 Front & rear
differential oil
I I I I
14 Brake line I I I I I I I I
15 Brake fluid R R R R
16 Disc brake pad
and disc
I I I I I I I I
17 Parking brake I I I I I I I I
18 Suspension I I I I I I I I
19 Wheel bearing (I) (I)
20 Axle boots and joints I I I I I I I I
21 Tire rotation I I I I I I I I I I I I I I I I Note 4.
22 Steering system
(Power steering)
I I I I I I I I
23 A/C filter Replace every 12 months or 15,000 km (9,300 miles). Note 5.
PM-4
Schedule
NOTE:
1. This inspection is not required to maintain emission warranty eligibility and it dose not affect the manufacturers obligations un-
der EPAs in-use compliance program.
2. When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
3. ATF filter is maintenance free part. ATF filter needs replacement, when it has physically rust, damaged or ATF leaked.
4. A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicators appear when
the remaining tread has been worn to 1.6 mm (0.063 in) or less.
5. When the A/C filter is installed.
6. For 2.5 L turbo model, replace every 3.75 months or 6,000 km (3,750 miles).
U5 model
Symbols used:
R: Replace
I: Inspection
NOTE:
Months 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 To be continued to the next
table
Remarks
1,000 km 4.8 12 24 36 48 60 72 81.4 96 108 120
1,000 miles 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75
1 Engine oil R R R R R R R R R R
2 Engine oil filter R R R R R R R R R R
3 Spark plug R R
4 Drive belt(s) I I
5 Camshaft drive belt I I
6 Fuel line (I) (I) Note 1.
7 Air cleaner element R R Note 2.
8 Cooling system I I
9 Engine coolant R R
10 Clutch system I I I I I
11 Transmission oil I I
12 ATF I I Note 3.
13 Front and rear
differential oil
I I
14 Brake line I I I I I
15 Brake fluid R R
16 Disc brake pad and disc I I I I I
17 Parking brake I I I I I
18 Suspension I I I I I
19 Wheel bearing (I)
20 Axle boots and joints I I I I I
21 Tire rotation I I I I I I I I I I Note 4.
22 Steering system
(Power steering)
I I I I I
PM-5
Schedule
Symbols used:
R: Replace
I: Inspection
NOTE:
Months Continued from the
previous table
82.5 90 97.5 105 112.5 120 127.5 135 142.5 150
Remarks
1,000 km 132 144 156 168 180 192 204 216 228 240
1,000 miles 82.5 90 97.5 105 112.5 120 127.5 135 142.5 150
1 Engine oil R R R R R R R R R R
2 Engine oil filter R R R R R R R R R R
3 Spark plug R R R
4 Drive belt(s) I R I
5 Camshaft drive belt I R I
6 Fuel line (I) I (I) Note 1.
7 Air cleaner element R R R Note 2.
8 Cooling system I I I
9 Engine coolant R R R
10 Clutch system I I I I
11 Transmission oil I I I
12 ATF I I I Note 3.
13 Front and rear differential
oil
I I I
14 Brake line I I I I I
15 Brake fluid R R R
16 Disc brake pad and disc I I I I I
17 Parking brake I I I I I
18 Suspension I I I I I
20 Axle boots and joints I I I I I
21 Tire rotation I I I I I I I I I I Note 4.
22 Steering system
(Power steering)
I I I I I
PM-6
Schedule
2. CANADA
Symbols used:
R: Replace
I: Inspection
NOTE:
1. This inspection is not required to maintain emission warranty eligibility and it dose not affect the manufacturers obligations under
EPAs in-use compliance program.
4. A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicators appear when the
remaining tread has been worn to 1.6 mm (0.063 in) or less.
Months 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
Remarks
1,000 km 4.8 12 24 36 48 60 72 81.4 96 108 120 132 144 156 168 180 192
1,000 miles 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 12
0
1 Engine oil 3.0 L R R R R R R R R R R R R R R R R R
2 Engine oil
filter
3 Spark plug R R R R 2.5 L
non-turbo
model
R R For 2.5 L
turbo,
3.0 L
model
4 Drive belt(s) I I I R
5 Camshaft drive belt I I I R
6 Fuel line (I) (I) (I) I Note 1.
7 Air cleaner element R R R R Note 2.
8 Cooling system I I I I
9 Engine coolant R R R R
10 Clutch system I I I I I I I I
11 Transmission oil I I I I
12 ATF I I I I Note 3.
13 Front & rear
differential oil
I I I I
14 Brake line I I I I I I I I
15 Brake fluid R R R R
16 Disc brake pad &
disc
I I I I I I I I
17 Parking brake I I I I I I I I
18 Suspension I I I I I I I I
20 Axle boots & joints I I I I I I I I
21 Tire rotation I I I I I I I I I I I I I I I I Note 4.
22 Steering system
(Power steering)
I I I I I I I I
PM-7
Schedule
B: MAINTENANCE SCHEDULE 2
Item
Maintenance
interval
Repeat short
distance drive
Repeat
rough/muddy
road drive
Extremely
cold weather
area
Salt or other
corrosive
used or
coastal area
High
humidity
or mountain
area
Repeat
towing trailer
Engine oil 3.75 months R R R
6,000 km
3,750 miles
Engine oil filter 3.75 months R R R
6,000 km
3,750 miles
Fuel line 7.5 months I
12,000 km
7,500 miles
Transmission oil 15 months R
24,000 km
15,000 miles
ATF 15 months R
24,000 km
15,000 miles
Front and rear
differential oil
15 months R
24,000 km
15,000 miles
Brake line 7.5 months I
12,000 km
7,500 miles
Brake fluid 15 months R
24,000 km
15,000 miles
Disc brake pad
& disc
7.5 months I I I I
12,000 km
7,500 miles
Parking brake 7.5 months I I I I
12,000 km
7,500 miles
Suspension 7.5 months I I I
12,000 km
7,500 miles
Axle boots & joints 7.5 months I I I I I
12,000 km
7,500 miles
Steering system
(Power steering)
7.5 months I I I
12,000 km
7,500 miles
PM-8
Engine Oil
3. Engine Oil
A: REPLACEMENT
1) Set the vehicle on a lift.
2) Open the engine oil filter cap for quick draining of
the engine oil.
2.5 L model
3.0 L model
3) Lift up the vehicle.
4) Drain the engine oil by removing the engine oil
drain plug.
NOTE:
Prepare the container for draining of engine oil.
2.5 L model
3.0 L model
(A) Oil level gauge
(B) Oil filler cap
(A) Oil level gauge
(B) Oil filler cap
(C) Upper level
(D) Lower level
PM-00161
(A) (B)
L
F
(A)
(B)
(C)
(D)
LU-00111
PM-00323
PM-00280
PM-9
Engine Oil
5) Tighten the engine oil drain plug after draining
the engine oil.
CAUTION:
If the engine oil is split over exhaust pipe or the
under cover, wipe it off with cloth to avoid emit-
ting smoke or causing a fire.
NOTE:
Use a new drain plug gasket.
Tightening torque:
44 Nm (4.5 kgf-m, 33 ft-lb)
2.5 L model
3.0 L model
6) Fill engine oil through the level gauge up to the
upper level. Place the vehicle on a level surface
when checking oil level. Use engine oil of the prop-
er quality and viscosity, selected in accordance
with the following.
Recommended oil:
Refer to RM section. <Ref. to RM-2, LUBRI-
CANTS, RECOMMENDED MATERIALS, Rec-
ommended Materials.>
NOTE:
The proper viscosity oil helps the engine maintain its
ideal temperature, and cranking speed increased by
reducing viscosity friction in hot condition.
Engine oil capacity
2.5 L model
Upper level:
Approx. 4.0 2 (4.2 US qt, 3.5 Imp qt)
Lower level:
3.0 L model
Upper level:
Lower level:
CAUTION:
It is acceptable to fill an engine with oil of an-
other brand when replacing the oil, but make
sure to use an oil with an API standard and SAE
viscosity number specified by Subaru.
NOTE:
If the vehicle is used in regions of high temperature
or in other severe environments, use oil with the
viscosities shown below. API Standard: SM SAE
Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-50
7) Close the engine oil filler cap.
8) Start the engine and warm it up for a time.
9) Stop the engine to inspect the oil level again. If
necessary, add engine oil up to the upper level on
level gauge. <Ref. to PM-10, INSPECTION, En-
gine Oil.>
PM-00323
PM-00280
PM-10
Engine Oil
B: INSPECTION
1) Park the vehicle on a level surface.
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper orientation.
4) Remove the level gauge again and record the oil
level. If the engine oil level is below the L line, add
oil to bring the level up to the F line.
2.5 L model
3.0 L model
5) Start and warm-up the engine.
6) After turning off the engine, wait a few minutes
for the oil to drain back into the oil pan before
checking the level.
NOTE:
Just after driving or while the engine is warm, en-
gine oil level may show in the range between the
F line and the notch mark. This is caused by ther-
mal expansion of engine oil. (2.5L model)
7) To prevent overfilling the engine oil, do not add
oil above the F line when the engine is cold.
CAUTION:
If the engine oil is spilt over exhaust pipe or the
NOTE:
Upper level and lower level are set when the en-
gine is cold because the oil level gauge is used for
daily maintenance.
(A) Oil level gauge
(B) Oil filler cap
(C) Upper level
(D) Lower level
(E) Approx. 1 2 (1.1 US qt, 0.9 Imp qt)
(F) Notch mark
(A) Oil level gauge
(B) Oil filler cap
(C) Upper level
(D) Lower level
(E) Approx. 1 2 (1.1 US qt, 0.9 Imp qt)
(C)
(F)
(B)
(A)
(E)
(D)
PM-00362
L
F
(A)
(B)
(C)
(E)
(D)
PM-00363
PM-11
Engine Oil Filter
4. Engine Oil Filter
A: REPLACEMENT
1) Remove the service hole cover clip.
2.5 L model
3.0 L model
2) Rotate the service hole cover in the direction of
the arrow.
2.5 L model
3.0 L model
3) Remove the oil filter using the ST.
3.0 L model
ST 49857000 OIL FILTER WRENCH (Outer
diameter: 80 mm (3.15 in))
2.5 L model
ST 18332AA000 OIL FILTER WRENCH (Outer
NOTE:
However, in 2.5 model, SUBARU genuine oil filter
having outer diameter of 68 mm (2.68 in) or 65 mm
(2.6 in) can also be used.
2.5 L model
3.0 L model
PM-00324
PM-00281
PM-00325
PM-00282
PM-00326
PM-00283
PM-12
Engine Oil Filter
4) Clean the oil filter installation surface on cylinder
block and oil cooler.
5) Obtain a new oil filter and apply a thin coat of en-
gine oil to the seal rubber.
6) To install the oil filter, turn the filter by hand while
being careful not to damage the seal rubber. When
the seal rubber just touches the oil cooler, tighten
by using a torque wrench or turn the filter by the
specified amount.
CAUTION:
Do not tighten excessively, or oil may leak.
3.0 L model
Oil filter 80 mm (3.15 in) in outer diameter
14 Nm (1.4 kgf-m, 10.3 ft-lb) or tighten 3/4 rotation.
2.5 L model
14 Nm (1.4 kgf-m, 10.3 ft-lb) or tighten 1 rotation.
12 Nm (1.2 kgf-m, 8.7 ft-lb) or tighten 2/3 3/4
rotation.
CAUTION:
7) Replace the service hole cover in the original po-
sition.
8) After installing the oil filter, run the engine and
make sure that no oil is leaking around seal rubber.
NOTE:
The filter element and filter case are permanently
jointed; therefore, interior cleaning is not necessary.
9) Check the engine oil level. <Ref. to PM-10, IN-
SPECTION, Engine Oil.>
PM-13
Spark Plug
5. Spark Plug
A: REPLACEMENT
1. 2.5 L NON-TURBO MODEL
1) Remove the intake duct and intake chamber.
2) Remove the battery.
3) Disconnect the spark plug cord.
4) Remove the spark plug with a spark plug socket.
5) Tighten the new spark plug lightly with hand, and
then secure with a spark plug socket to the speci-
fied torque.
Recommended spark plug:
NGK: FR5AP-11
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 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.
2. 2.5 L TURBO AND 3.0 L MODEL
1) Remove the battery and battery carrier.
2) Remove the air cleaner case.
3) Detach the connector from ignition coil.
4) Remove the ignition coil.
2.5 L turbo model
3.0 L model
6) Tighten the new spark plug lightly with hand, and
then secure with a spark plug socket to the speci-
fied torque.
Recommended spark plug:
2.5 L Turbo model
NGK: SILFR6A
3.0 L model
NGK: ILFR6B
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
7) Tighten the ignition coil.
Tightening torque:
16 Nm (1.6 kgf-m, 11.7 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-00001
PM-00145
(A) Bracket
(B) Connector
IG-02004
(B)
(A)
PM-00112
PM-14
V-belt
6. V-belt
A: INSPECTION
1. 2.5 L NON-TURBO AND 2.5 L TURBO
MODEL
1) Replace the belts if cracks, fraying or wear are
found.
2) Check the V-belt tension and adjust it if neces-
sary by changing the generator installing position
or idler pulley installing position. <Ref. to PM-15,
REPLACEMENT, V-belt.>
Belt tension (without belt tension gauge):
(A)
When installing new part: 7 9 mm
(0.276 0.354 in)
At inspection: 9 11 mm
(0.354 0.433 in)
(B)
When installing new part: 7.5 8.5 mm
(0.295 0.335 in)
At inspection: 9.0 10.0 mm
(0.354 0.394 in)
Belt tension (with belt tension gauge):
(A)
When installing new part: 640 785 N
(65.3 80.0 kgf, 144 176 lbf)
At inspection: 490 640 N
(50 65 kgf, 110 144 lbf)
(B)
When installing new part: 620 760 N
(63 77 kgf, 140 170 lbf)
At inspection: 350 450 N
(36 46 kgf, 79 101 lbf)
(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
C/P
P/S
A/C
GEN
(A) (B)
(C)
I/P
PM-00002
(A) Front side belt
(B) Rear side belt
C/P Crank pulley
GEN Generator
I/P Idler pulley
C/P
P/S
A/C
GEN
(A)
(B)
I/P
PM-00154
PM-15
V-belt
2. 3.0 L MODEL
1) Replace the belts if cracks, fraying or wear are
found.
2) Check that the V-belt automatic belt tensioner in-
dicator (A) is within the range (D).
B: REPLACEMENT
1. FRONT SIDE BELT (FOR POWER
STEERING OIL PUMP AND GENERATOR)
NOTE:
Wipe off any oil and water on the belt and pulley.
1) Remove the collector cover. (If equipped)
2) Remove the V-belt covers.
2.5 L non-turbo model
2.5 L turbo model
3) Loosen the lock bolt (A).
4) Loosen the slider bolt (B).
5) Remove the front side belt (C).
6) Install a new V-belt, and tighten the slider bolt so
as to obtain the specified belt tension.
7) Tighten the lock bolt (A).
8) Tighten the slider bolt (B).
Tightening torque:
Lock bolt
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Slider bolt
8 Nm (0.8 kgf-m, 5.8 ft-lb)
(A) Indicator
(B) Generator
(C) Power steering oil pump
(D) Service limit
(B)
(A)
(D)
(C)
ME-00475
PM-00003
ME-00807
PM-00004
(B)
(C)
(A)
PM-16
V-belt
2. REAR SIDE BELT (FOR A/C)
NOTE:
1) Remove the front side belts.
2) Loosen the lock nut (A).
4) Remove the rear side belt.
5) Install a new V-belt, and tighten the slider bolt so
as to obtain the specified belt tension.
6) Tighten the lock nut (A).
Tightening torque:
23 Nm (2.3 kgf-m, 17.0 ft-lb)
7) Install the front side belt.
2.5 L non-turbo model <Ref. to ME(H4SO)-38,
FRONT SIDE BELT, INSTALLATION, V-belt.>
2.5 L turbo model <Ref. to ME(H4DOTC)-38,
3. 3.0 L MODEL
1) Fit the tool to the belt tensioner mounting bolt.
2) Turn the tool clockwise, and loosen the V-belt to
remove.
3) Remove the V-belt cover.
4) Install in the reverse order of removal.
(A)
(B)
PM-00005
(1) Power steering oil pump
(2) Belt tension adjuster
(3) Crank pulley
(4) A/C compressor
(5) Belt idler
(6) Generator
ME-00473
(1)
(6)
(4)
(5)
(2)
(3)
ME-00474
PM-17
Timing Belt
7. Timing Belt
A: REPLACEMENT
1) Protect the radiator with cardboard and blanket.
3) Remove the V-belts. <Ref. to ME(H4SO)-37,
V-belt.>
4) Remove the A/C compressor V-belt tensioner.
5) Use the ST to lock the crankshaft, and remove
the pulley bolt.
ST 499977100 CRANK PULLEY WRENCH
6) Remove the crank pulley.
7) Remove the belt cover (LH).
8) Remove the front timing belt cover.
9) Remove the timing belt guide. (MT model)
PM-00003
PM-00007
ST
PM-00008
ME-03124
ME-00728
ME-00729
PM-18
Timing Belt
10) If the alignment mark (a) or arrow mark (which
indicates rotation direction) on the timing belt has
faded away, put new marks on the belt before re-
moving 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
11) Remove the belt idler.
12) Remove the belt idler (No. 2).
13) Remove the timing belt.
14) Remove the automatic belt tension adjuster
assembly.
15) Install in the reverse order of removal. <Ref. to
ME(H4SO)-43, INSTALLATION, Timing Belt.>
ME-00231
ST
(a) (b)
(c)
(d)
(e)
(f)
ME-02387
PM-00010
PM-00011
PM-19
Timing Belt
2. 2.5 L TURBO MODEL
1) Protect the radiator with cardboard and blanket.
2) Remove the V-belts. <Ref. to ME(H4DOTC)-37,
V-belt.>
3) Remove the A/C compressor V-belt tensioner.
4) Remove the pulley bolt. Using the ST, lock the
crankshaft.
6) Remove the belt cover (LH).
7) Remove the belt cover (RH).
8) Remove the front belt cover.
10) Turn the crankshaft and align the alignment
marks on crankshaft, and left and right cam sprock-
ets with notches of belt cover and cylinder block.
Use the ST to turn crankshaft.
ST
PM-00093
PM-00008
ME-03124
ME-00728
ME-00729
ME-00070
ME-03175
PM-20
Timing Belt
11) Remove the belt idler.
13) Remove the automatic belt tension adjuster
assembly.
14) Install in the reverse order of removal. <Ref. to
ME(H4DOTC)-42, Timing Belt.>
CAUTION:
When installing the timing belt, be sure to align
all alignment marks on the belt with corre-
sponding marks on the sprockets. If incorrectly
installed, interference between pistons and
valves may occur.
B: INSPECTION
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) When the side part of timing belt is abnormally
worn (fluff or jumping out of core) or damaged,
check the idlers, tensioner, water pump pulley and
cam sprocket to determine idler alignment (square-
ness). Replace the worn timing belt.
4) Install the timing belt cover (LH).
2. 2.5 L TURBO MODEL
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) When the side part of timing belt is abnormally
worn (fluff or jumping out of core) or damaged,
check the idlers, tensioner, water pump pulley and
cam sprocket to determine idler alignment (square-
ness). Replace the worn timing belt.
PM-00095
PM-00096
PM-00342
PM-00343
PM-21
Fuel Line
8. Fuel Line
A: INSPECTION
The fuel line is located mostly internally, so check
pipes, areas near pipes, and engine compartment
piping for rust, hose damage, loose band, etc. If
faulty parts are found, repair or replace them.
<Ref. to FU(H4SO)-59, Fuel Delivery and Evapora-
tion Lines.>
2.5 L turbo model
<Ref. to FU(H4DOTC)-69, Fuel Delivery, Return
and Evaporation Lines.>
3.0 L model
<Ref. to FU(H6DO)-60, Fuel Delivery and Evapora-
tion Lines.>
PM-22
Air Cleaner Element
9. Air Cleaner Element
A: REPLACEMENT
1) Disconnect the ground cable from battery.
2) Disconnect the connector from mass air flow
sensor.
Non-turbo model
Turbo model
3) Loosen the clamps (A) which connect the air
cleaner case to intake duct.
4) Remove the clips (B) on air cleaner case.
Non-turbo model
Turbo model
5) Remove the air cleaner element.
CAUTION:
When replacing the air cleaner element, use
SUBARU Genuine air cleaner element accord-
ing to the engine type. Using other air cleaner
element may affect engine performance.
NOTE:
Fasten with a clip after inserting the lower tab of
case.
Refer to COMPONENT for tightening torque.
<Ref. to IN(H4SO)-2, COMPONENT, General
Description.>
2.5 L turbo model
<Ref. to IN(H4DOTC)-2, COMPONENT, Gener-
al Description.>
3.0 L model
<Ref. to IN(H6DO)-2, COMPONENT, General
Description.>
IN-00203
PM-00374
PM-00181
(B) (A)
PM-00373
PM-00183
(A)
(B)
(B)
(A)
IN-00206
IN-00207
PM-23
Cooling System
10.Cooling System
A: INSPECTION
1) To check the radiator for leakage, fill it with en-
gine coolant, and attach the radiator cap tester (A)
to the filler neck, and apply pressure. Check the fol-
lowing points:
Non-turbo model:
157 kPa (1.6 kg/cm
2
, 23 psi)
Turbo model:
122 kPa (1.2 kg/cm
2
, 18 psi)
Each portion of radiator for leakage
Hose joints and other connections for leakage
NOTE:
For turbo model, be sure to install the tester to
filler tank side.
Be particularly careful not to deform the filler
neck of radiator when installing and removing the
tester and after testing.
Non-turbo model
Turbo model
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.
Do not remove the radiator side cap. (Turbo
model)
2) Check the radiator cap valve open pressure us-
ing radiator cap tester.
NOTE:
Rust or dirt on the cap may prevent valve from func-
tioning normally: be sure to clean the cap before
testing.
Raise the pressure until the needle of gauge stops
and see if the pressure can be retained for five to
six seconds. Replace the radiator cap if it is opened
under a pressure less than the service limit value
for this period.
Radiator cap valve open pressure
Non-turbo model
Standard:
93 123 kPa (0.95 1.25 kg/cm
2
, 14 18 psi)
Service limit:
83 kPa (0.85 kg/cm
2
, 12 psi)
Turbo model
Filler tank side
Standard:
93 123 kPa (0.95 1.25 kg/cm
2
, 14 18 psi)
Service limit:
83 kPa (0.85 kg/cm
2
, 12 psi)
Radiator side
Standard:
122 152 kPa (1.24 1.55 kg/cm
2
, 18 22 psi)
Service limit:
112 kPa (1.14 kg/cm
2
, 16 psi)
2.5 L model
PM-00128
(A)
PM-00184
(A)
PM-00023
PM-00089
(B)
(A)
(A)
PM-24
Cooling System
3.0 L model
3) Start the engine, and then check it does not over-
heat or it is cooled excessively. If it overheats or it is
cooled excessively, check the cooling system.
CAUTION:
If the engine coolant is spilt over exhaust pipe,
wipe it off with cloth to avoid emitting smoke or
causing a fire.
<Ref. to CO(H4SO)-14, Water Pump.> <Ref. to
CO(H4SO)-16, Thermostat.> <Ref. to CO(H4SO)-
18, Radiator.> <Ref. to CO(H4SO)-22, Radiator
Cap.>
2.5 L turbo model
<Ref. to CO(H4DOTC)-15, Water Pump.> <Ref. to
CO(H4DOTC)-17, Thermostat.> <Ref. to CO(H4DOTC)-
19, Radiator.> <Ref. to CO(H4DOTC)-23, Radiator
Cap.>
3.0 L model
<Ref. to CO(H6DO)-13, Water Pump.> <Ref. to
CO(H6DO)-14, Thermostat.> <Ref. to CO(H6DO)-
16, Radiator.> <Ref. to CO(H6DO)-19, Radiator
Cap.>
4) Check the radiator fan operates using Subaru
Select Monitor, when the coolant temperature ex-
ceeds 96C (205F). If it does not operate, check
the radiator fan system.
<Ref. to CO(H4SO)-8, INSPECTION, Radiator Fan
System.>
2.5 L turbo model
<Ref. to CO(H4DOTC)-9, INSPECTION, Radiator
Fan System.>
3.0 L model
<Ref. to CO(H6DO)-9, INSPECTION, Radiator Fan
System.>
(A) Check points for deformation
(B) Check points for deformation, damage, rust
(B)
(A)
PM-00369
PM-25
Engine Coolant
11.Engine Coolant
A: REPLACEMENT
1. REPLACEMENT OF ENGINE COOLANT
WARNING:
The radiator is of the pressurized type. Do not
attempt to open the radiator cap immediately
after the engine has been stopped.
CAUTION:
If the engine coolant is spilt over exhaust pipe,
wipe it off with cloth to avoid emitting smoke or
causing a fire.
2) Remove the under cover.
3) Place a container under drain pipe.
4) Remove the drain plug to drain engine coolant
into container.
5) For quick draining, open the radiator cap.
NOTE:
For turbo model, be sure to open the radiator cap
on the filler tank side.
Be careful not to spill coolant on the floor.
6) Drain the coolant from reservoir tank.
7) Tighten the radiator drain plug securely after
draining coolant.
8) Pour cooling system conditioner through the fill-
er neck.
Cooling system protective agent:
Cooling system conditioner (part No.
SOA635071)
9) Pour the engine coolant into the radiator (or the
coolant filler tank on turbo models) up to the filler
neck position.
10) Fill engine coolant into the reservoir tank up to
FULL level.
Recommended engine coolant:
Refer to RM section. <Ref. to RM-4, COOL-
ANT, RECOMMENDED MATERIALS, Recom-
mended Materials.>
Coolant capacity (fill up to FULL level):
MT model
AT model
2.5 L turbo model
MT model
AT model
3.0 L model
11) Close the radiator cap (or the coolant filler tank
cap on turbo models), and start the engine. Race 5
to 6 times at 3,000 rpm or less, then stop the en-
gine. (Complete this operation within 40 seconds.)
12) Wait for one minute after the engine stops, then
open the radiator cap (or the coolant filler tank cap on
turbo models). If the engine coolant level drops, add
engine coolant into the radiator (or the coolant filler
tank on turbo models) up to the filler neck position.
13) Perform the procedures 11) and 12) again.
14) Install the radiator cap (or the coolant filler tank
cap on turbo models) and reservoir tank cap properly.
15) Start the engine and operate the heater at max-
imum hot position and the blower speed setting to
LO.
16) Run the engine at 2,000 rpm or less until radia-
tor fan starts and stops.
NOTE:
Be careful with the engine coolant temperature
gauge to prevent overheating.
If the radiator hose becomes harden with the
pressure of engine coolant, air bleeding operation
seems to be almost completed.
17) Stop the engine and wait until the engine cool-
ant temperature lowers to 30C (86F) or less.
18) Open the radiator cap (or the coolant filler tank
cap on turbo models). If the engine coolant level
drops, add engine coolant into the coolant filler tank
up to the filler neck position and the reservoir tank
to FULL level.
19) Install the radiator cap (or the coolant filler tank
cap on turbo models) and reservoir tank cap properly.
CO-00248
PM-26
Engine Coolant
20) Set the heater setting to maximum hot position
and the blower speed setting to LO and start the
engine. Perform racing at 3,000 rpm or less. If the
flowing sound is heard from heater core, repeat the
procedures from step 16).
2. RELATIONSHIP OF SUBARU COOLANT
CONCENTRATION AND FREEZING
TEMPERATURE
The concentration and safe operating temperature
of SUBARU coolant is shown in the diagram. Mea-
suring 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
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 re-
placed 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 inter-
sects 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.
CO-02172
60%
(1.054)
1.000
1.010
1.020
1.030
1.040
1.050
1.060
1.070
1.080
1.090
1.100
Safe operating temperature
Freezing
temperature
Concentration
of coolant
S
p
e
c
i
f
i
c

g
r
a
v
i
t
y
o
f

c
o
o
l
a
n
t
Coolant temperature
B
A
C
-40
(-40) (-22) (-4) (14) (32) (50) (68) (86)
( F)
(104)
-30 -20 -10 0 10 20 30 40
(
7
7

F
)
50%
40%
30%
20%
2
5

C10%
C
CO-00012
10
0
1
2
3
(1.1,
0.9)
(2.1,
1.8)
(3.2,
2.6)
10%
15%
25%
20%
30%
35%
40%
45%
A
20 30 40 50
Concentration of coolant in vehicie
and quantity to be drained
Q
u
a
n
t
i
t
y

o
f

c
o
o
l
a
n
t

t
o

b
e
d
r
a
i
n
e
d

(
U
S

q
t
,

I
m
p

q
t
)
Necessary Concentration
of coolant
Concentration of coolant in
the vehicie cooling system %
PM-27
Clutch System
12.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 or not.
5MT model (Non-turbo model)
5MT model (Turbo model)
6MT model
2) If the fluid level rises, pedal free play is correct.
3) If the fluid level does not rise, or the push rod
cannot be retracted, adjust the clutch pedal. <Ref.
to CL-31, Clutch Pedal.>
4) Check the fluid level using the scale on the out-
side 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:
Refer to RM section. <Ref. to RM-4, FLUID,
RECOMMENDED MATERIALS, Recommend-
ed Materials.>
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.
NOTE:
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) Release lever
(B) Push rod
(C) Operating cylinder
(A) Release lever
(B) Push rod
(A) Release lever
(B) Push rod
PM-00164
(C)
(B) (A)
PM-00332
(C)
(B)
(A)
(A)
(B) (C)
PM-00322
(A) Reservoir tank
(B) MIN. level
(C) MAX. level
(A)
(C)
(B)
PM-00165
PM-28
Transmission Gear Oil
13.Transmission Gear Oil
A: REPLACEMENT
1. MANUAL TRANSMISSION
1) Drain the gear oil by removing drain plug.
CAUTION:
If the transmission gear oil is spilt over exhaust
pipe, wipe it off with cloth to avoid emitting
smoke or causing a fire.
NOTE:
Before starting work, cool off the transmission
gear oil well.
Drain the gear oil by removing drain plug using
TORX
BIT T70.
5MT
6MT
2) Replace the gasket with new part, and then tight-
en the drain plug to specified torque.
Tightening torque:
5MT (Aluminum gasket)
44 Nm (4.5 kgf-m, 32.5 ft-lb)
5MT (Copper gasket)
70 Nm (7.1 kgf-m, 51.6 ft-lb)
6MT (Oil pan side):
44 Nm (4.5 kgf-m, 32.5 ft-lb)
6MT (Clutch housing side):
70 Nm (7.1 kgf-m, 51.6 ft-lb)
3) Fill the transmission gear oil through the oil level
gauge hole up to the upper point of level gauge.
Recommended gear oil:
NOTE:
Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
Gear oil capacity:
5MT model:
3.5 2 (3.7 US qt, 3.1 Imp qt)
6MT model:
4.1 2 (4.3 US qt, 3.6 Imp qt)
5MT (Non-turbo model)
5MT (Turbo model)
(A) Drain plug (Oil pan side)
(B) Drain plug (Clutch housing side)
MT-01548
MT-01549
(A)
(B)
(A) Oil level gauge
(B) Upper level
(C) Lower level
(A) Oil level gauge
(B) Upper level
(C) Lower level
PM-00030
(B)
(C)
(A)
(B)
(C)
(A)
PI-00391
PM-29
6MT
(A) Oil level gauge
(B) Upper level
(C) Lower level
MT-00449
(A)
(A)
(B)
(C)
PM-30
Automatic Transmission Fluid
14.Automatic Transmission Fluid
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 to 10 km (3 to 6 miles). Otherwise, idle the en-
gine to raise ATF temperature to 70 80C (158
176F) on Subaru Select Monitor. <Ref. to
4AT(diag)-16, READ CURRENT DATA, OPERA-
TION, Subaru Select Monitor.>
2) Make sure the vehicle is level.
3) After selecting all positions (P, R, N, D), shift the
select lever in P range. Idle the engine for 1 2
minutes, and measure the ATF level.
4AT model
5AT model
4) Make sure that ATF level is above the center of
upper and lower marks at HOT side.
5) If the ATF level is below the center between up-
per and lower marks, add the recommended ATF
until the fluid level is found above the center be-
tween upper and lower marks.
CAUTION:
Use care not to exceed the upper limit level.
Adding ATF to the upper limit mark on HOT
side when the ATF temperature is less than
70C (158F) will overfilling of ATF, causing a
transmission failure.
6) Check ATF level 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 in the transmission. If there are
leaks, it is necessary to repair or replace gasket, oil
seals, plugs or other parts.
(A) Level gauge
(B) ATF level range at HOT
[70 80C (158 176F)]
(C) Upper level
(D) Lower level
(E) ATF level range at COLD
[20 30C (68 86F)]
PI-00189
C
O
L
D
L
F
H
O
T
L
F
(A)
(C)
(D)
(C)
(D)
(E)
(B)
(A) Level gauge
[70 80C (158 176F)]
(C) Upper level
(D) Lower level
[20 30C (68 86F)]
PI-00190
(A)
(C)
(D)
(E)
(D)
(C)
(B)
(A)
F
L
F
H
O
T
L
C
O
L
D
PM-31
B: REPLACEMENT
1. AUTOMATIC TRANSMISSION FLUID
CAUTION:
If the ATF is spilt over exhaust pipe, wipe it off
with cloth to avoid emitting smoke or causing a
fire.
1) Drain the ATF by removing drain plug.
NOTE:
Before starting work, cool off the ATF well.
4AT model
5AT model
Tightening torque:
4AT model
25 Nm (2.5 kgf-m, 18.1 ft-lb)
5AT model
20 Nm (2.0 kgf-m, 14.8 ft-lb)
3) Pour in the ATF using the oil charge pipe.
Recommended ATF:
RECOMMENDED MATERIALS,
Recommended Materials.>
Capacity:
Fill with the same amount of ATF as drained.
4) Check the ATF level. <Ref. to PM-30, INSPEC-
TION, Automatic Transmission Fluid.>
4AT model
5AT model
(A) Front differential gear oil drain plug
(B) ATF drain plug
(A) ATF drain plug
(B)
PM-00167
(A)
PM-00168
(A)
(A) Level gauge
[70 80C (158 176F)]
(C) Upper level
(D) Lower level
[20 30C (68 86F)]
(A) Level gauge
[70 80C (158 176F)]
(C) Upper level
(D) Lower level
[20 30C (68 86F)]
PI-00189
C
O
L
D
L
F
H
O
T
L
F
(A)
(C)
(D)
(C)
(D)
(E)
(B)
PI-00190
(A)
(C)
(D)
(E)
(D)
(C)
(B)
(A)
F
L
F
H
O
T
L
C
O
L
D
PM-32
2. ATF FILTER
CAUTION:
If the ATF is spilt over exhaust pipe, wipe it off
with cloth to avoid emitting smoke or causing a
fire.
NOTE:
Basically, the ATF filter is maintenance free, but
when it is rusted or physically damaged or leaking,
the ATF filter needs to be replaced.
For the replacement procedure of ATF filter, refer
to ATF FILTER.
4AT model
<Ref. to 4AT-63, ATF Filter.>
5AT model
<Ref. to 5AT-58, ATF Filter.>
PM-33
Front & Rear Differential Gear Oil
15.Front & Rear Differential Gear
Oil
A: REPLACEMENT
1. FRONT DIFFERENTIAL (MT MODEL)
Front differential gear oil for MT model lubricates
the transmission and differential together. Refer to
Transmission Oil for replacement procedure.
<Ref. to PM-28, Transmission Gear Oil.>
2. FRONT DIFFERENTIAL (AT MODEL)
1) Drain the differential gear oil by removing drain
plug using TORX
BIT T70.
CAUTION:
If the front differential gear oil is spilt over ex-
haust pipe, wipe it off with cloth to avoid emit-
NOTE:
Before starting work, cool off the differential gear
oil well.
4AT model
5AT model
Tightening torque:
4AT model
Copper gasket
70 Nm (7.1 kgf-m, 51.6 ft-lb)
Aluminum gasket
44 Nm (4.5 kgf-m, 32.5 ft-lb)
5AT model
Copper gasket
70 Nm (7.1 kgf-m, 51.6 ft-lb)
PM-00169
PM-00170
PM-34
3) Fill differential gear oil through the oil level
gauge hole up to the upper point of level gauge.
NOTE:
Gear oil capacity:
4AT model
1.1 1.3 2 (1.2 1.4 US qt, 1.0 1.1 Imp qt)
5AT model
1.3 1.5 2 (1.4 1.6 US qt, 1.1 1.3 Imp qt)
3. REAR DIFFERENTIAL
1) Drain the oil by removing drain plug.
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 for
T-type (except for turbo 6MT model).
Use a new gasket for VA-type and T-type (turbo
6MT model).
Liquid gasket:
THREE BOND 1105 (Part No. 004403010)
Tightening torque:
T-type (except for turbo 6MT model)
49.0 Nm (5.0 kgf-m, 36.2 ft-lb)
T-type (turbo 6MT model)
60 Nm (6.1 kgf-m, 44.3 ft-lb)
VA1-type
34 Nm (3.5 kgf-m, 25.3 ft-lb)
VA2-type
29 Nm (3.0 kgf-m, 21.4 ft-lb)
(A) Oil level gauge
(B) Upper level
(C) Lower level
(A) Oil level gauge
(B) Upper level
(C) Lower level
PI-00183
(B)
(C)
(A)
(A)
PI-00184
(A)
(C)
(B)
(A)
F
L
PM-35
4) Pour oil to the bottom end of filler plug hole.
Except for VA2-type
VA2-type
Oil capacity:
Except for turbo 6MT model
0.8 2 (0.8 US qt, 0.7 Imp qt)
Turbo 6MT model
1.0 2 (1.1 US qt, 0.9 Imp qt)
NOTE:
5) Install the filler plug.
NOTE:
Apply liquid gasket to the drain plug threads for
T-type (except for turbo 6MT model).
Use a new gasket for VA-type and T-type (turbo
6MT model).
Liquid gasket:
Tightening torque:
T-type (except for turbo 6MT model)
49.0 Nm (5.0 kgf-m, 36.2 ft-lb)
T-type (turbo 6MT model)
60 Nm (6.1 kgf-m, 44.3 ft-lb)
VA1-type
34 Nm (3.5 kgf-m, 25.3 ft-lb)
VA2-type
29 Nm (3.0 kgf-m, 21.4 ft-lb)
(A) Filler plug
(B) Drain plug
(A) Filler plug
(B) Drain plug
PM-00037
(A)
(B)
(B)
DI-00355
(A)
PM-36
Brake Line
16.Brake Line
A: INSPECTION
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 illuminate.
Visually check the brake hose for damage. (Use
a mirror where it is difficult to see)
2. SERVICE BRAKE
1) Check the free play of brake pedal by pulling up
the pedal with a force of 10 N (1 kgf, 2 lb) or less.
Brake pedal free play (Pulling up direction of
pedal)
0.5 2.0 mm (0.02 0.08 in)
2) If the free play is out of specifications above, ad-
just the brake pedal as follows.
(1) Make sure the engine is off. (No vacuum is
applied to brake booster.)
(2) There should be play between brake boost-
er clevis and pin at brake pedal installing por-
tion. [Pulling up the brake pedal pad with a force
of 10 N (1 kgf, 2 lb) or less to a stroke of 0.5 to
2.0 mm (0.02 to 0.08 in).]
(3) 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).
(1) Front brake hose
(2) Front brake pipe
(1) Rear brake pipe
(2) Rear brake hose
PM-00171
(2)
(1)
(2)
(1)
PM-00172
(A) Pedal free play
(A) Brake switch
(B) Adjusting nut
(C) 0.3 mm (0.012 in)
(D) Stopper
(E) Clevis pin
(F) Clevis
(G) Pedal free play
(H) Lock nut
(I) Brake booster operating rod
(J) Play at pin
PM-00185
(A)
PM-00186
(B)
(G)
(H)
(I)
(J)
(C)
(D)
(E)
(F)
(A)
PM-37
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 pedal stroke is normal if the difference be-
tween two measured values is the specified value
or less. If the measured value is the specification or
more, there is possibility of entering air in hydraulic
unit.
Brake pedal stroke A:
95 mm (3.7 in)/ 490 N (50 kgf, 110 lb) or less
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 dis-
tance on a straight road.
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 en-
gine. Make sure the pedal should move slightly to-
ward the floor.
3) With the brake pedal depressed, stop the engine
and keep the pedal depressed for 30 seconds.
Make sure the pedal height should not change.
4) A check valve is incorporated into the brake
booster nipple part. Disconnect the vacuum hose to
inspect function of check valve.
Make sure air flows from the booster end to engine
end but does not flow in the opposite direction in
the check valve.
5) Check the vacuum hose for cracks or other dam-
age.
NOTE:
When installing the vacuum hose on the engine
and brake booster, do not use soapy water or lubri-
cating oil on their connections.
6) Check the vacuum hose to make sure it is tightly
secured.
(A) Steering wheel
(B) Toe board
PM-00045
(B)
(A)
= A
1
1 2
2
(A) Brake booster
(B) Check valve
(C) Engine side
(D) Brake booster side
PM-00260
(D)
(A)
(C)
(B)
PM-38
Brake Fluid
17.Brake Fluid
A: REPLACEMENT
1) Either jack-up the vehicle and place a rigid rack
under it, or lift up the vehicle.
2) Remove all the wheels.
3) Drain the brake fluid from master cylinder.
4) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
ed Materials.>
NOTE:
Avoid mixing different brands of brake fluid to
prevent degrading the quality of fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
Perform the operation in the order from farthest
wheel cylinder to the master cylinder.
5) Install one end of a vinyl tube onto the air bleeder
and insert the other end of the tube into a container
to collect the brake fluid.
NOTE:
Cover the bleeder with cloth, when loosening it,
to prevent brake fluid from being splashed over sur-
rounding parts.
While bleeding air, keep the reservoir tank filled
with brake fluid to prevent entry of air.
Operate the brake pedal slowly.
For convenience and safety, two people should
do the work.
The amount of brake fluid required is approx.
500 m2 (16.9 US fl oz, 17.6 Imp fl oz) for total
brake system.
6) Instruct your co-worker to depress the brake
pedal slowly two or three times and then hold it de-
pressed.
7) Loosen the bleeder screw approximately 1/4
turn until a small amount of brake fluid drains into
the container, and then quickly tighten the screw.
8) Repeat steps 6) and 7) until there are no air bub-
bles in drained brake fluid and new fluid flows
through vinyl tube.
NOTE:
Add brake fluid as necessary while performing the
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold the
brake pedal depressed and tighten the screw and
install bleeder cap.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
10) Bleed air from each wheel cylinder by following
steps from 5) to 9).
11) Depress the brake pedal with a force of approx.
294 N (30 kgf, 66 lb) and hold it there for approx. 20
seconds. At this time check the pedal to see if it
makes any unusual movement. Visually inspect the
bleeder screws and brake pipe joints to confirm
there is no fluid leakage.
12) Install the wheels, and drive the vehicle for a
distance of 2 to 3 km (1 to 2 miles) to confirm that
brakes are operating properly.
PM-00048
PM-39
Disc Brake Pad and Disc
18.Disc Brake Pad and Disc
A: INSPECTION
1) Jack-up the vehicle and support with rigid racks.
Then remove the wheels.
2) Visually check the pad thickness through inspec-
tion hole of disc brake assembly. Replace the pad if
necessary.
NOTE:
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.
Front
Rear
3) Check the disc rotor, and correct or replace if it is
damaged or worn.
Front
Rear
4) Remove the caliper body. <Ref. to BR-17, Front
Disc Brake Assembly.> <Ref. to BR-25, 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 mea-
sure the disc rotor runout.
Disc rotor runout limit:
Front: 0.05 mm (0.002 in)
Rear: 0.05 mm (0.002 in)
(A) Inspection hole
Pad thickness mm (in)
Standard
16-inch 11 (0.43)
17-inch 11 (0.43)
Wear limit
16-inch 1.5 (0.059)
17-inch 1.5 (0.059)
Standard
Solid disc type 9 (0.35)
Ventilated disc type 9 (0.35)
Wear limit
Solid disc type 1.5 (0.059)
Ventilated disc type 1.5 (0.059)
(A) Pad thickness
(B) Back metal
(C) Lining
PM-00049
(A)
PM-00140
(A)
(C)
(B)
Disc rotor thickness mm (in)
Standard
16-inch 24 (0.94)
17-inch 30 (1.18)
Wear limit
16-inch 22 (0.87)
17-inch 28 (1.10)
Disc rotor thickness mm (in)
Standard
Solid disc type 10 (0.39)
Wear limit
Solid disc type 8.5 (0.34)
PM-00051
PM-40
Parking Brake
19.Parking Brake
A: INSPECTION
Inspect the brake linings and disc rotor of both
sides of the rear brake at the same time by remov-
ing disc rotor.
1) Inspect the brake shoes for damage or deforma-
tion and check the brake linings for wear.
NOTE:
Always replace both primary and secondary brake
shoes for the left and right wheels at the same time.
Thickness of brake lining (except for back metal):
Standard: 3.2 mm (0.126 in)
Wear limit: 1.5 mm (0.059 in)
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)
Wear limit: 171 mm (6.73 in)
3) If the deformation or wear of back plate, shoe,
etc. is noticeable, replace them.
4) When the shoe return spring tension is exces-
sively weakened, replace it.
B: ADJUSTMENT
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
3) Turn back (downward) the adjuster 3 to 4 notches.
4) Install the cover (rubber) in original position
correctly.
(A) Forward
(B) Brake shoe (Primary side)
(C) Brake shoe (Secondary side)
(A) Inside diameter
(B) Disc
PM-00054
(B)
(C)
(A)
PM-00055
(A)
(B)
(A) Adjuster
(B) Cover (rubber)
(C) Back plate
PM-00056
(B)
(C)
(A)
PM-41
Suspension
20.Suspension
A: INSPECTION
1. SUSPENSION BALL JOINT
1) Jack-up the vehicle until front wheels are off
ground.
2) Grasp the bottom of tire and move it in and out
along the shaft. If relative movement (B) is ob-
served between the brake disc cover (A) and the
end of front arm (D), ball joint (C) may be exces-
sively worn.
3) Grasp the end of front arm and move it up and
down. Relative movement (A) between the housing
(D) and front arm (C) boss indicates ball joint (B)
may be excessively worn.
4) If relative movement is observed in the step 2),
3), remove and inspect the ball joint. If the free play
exceeds standard value, replace the ball joint.
<Ref. to FS-18, Front Ball Joint.>
5) Damage of dust seal
Visually inspect the ball joint dust seal. If it is dam-
aged, remove the front arm. <Ref. to FS-20, Front
Arm.>Also, measure the free play of the ball joint.
<Ref. to FS-18, Front Ball Joint.>
(1) If the free play exceeds standard value, re-
place the ball joint.
(2) If the dust seal is damaged, replace with a
new ball joint.
NOTE:
When the front arm ball joint has been removed or
replaced, check the toe-in of front wheel. If the front
wheel toe-in is not at specified value, adjust the
toe-in. <Ref. to FS-8, Wheel Alignment.>
2. FRONT, REAR SUSPENSION BUSHING
Apply pressure with tire lever etc. to inspect the bush-
ing for abnormal fatigue or damage. Replace the
bushings if there is abnormal fatigue or damage.
PM-00057
(A)
(B)
(C)
(D)
PM-00058
(A)
(B)
(C)
(D)
(A) Dust seal
PM-00059
(A)
PM-00180
PM-42
Suspension
3. WHEEL ARCH HEIGHT
1) Unload the cargoes and set the vehicle in curb
weight (empty) condition.
2) Check the wheel arch height of front and rear
suspensions to ensure that they are within speci-
fied values. <Ref. to FS-8, Wheel Alignment.>
3) When the wheel arch height is out of standard,
visually inspect following components and replace
deformed parts.
Suspension components [Front strut assembly
and rear damper 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 stan-
dard. <Ref. to FS-8, Wheel Alignment.> <Ref. to
RS-7, Wheel Alignment.>
4. WHEEL ALIGNMENT OF FRONT
SUSPENSION
1) Check the alignment of front suspension to ensure
that following items conform to standard values.
Toe-in
Camber
Caster
Steering angle
<Ref. to FS-8, Wheel Alignment.>
2) When the caster angle does not conform to ref-
erence obviously, visually inspect the following
components and replace deformed parts.
Suspension components [Strut assembly, cross-
member, front arm, etc.]
3) When the toe-in and camber are out of standard
value, adjust them so that they conform to standard
value.
4) When the right-and-left turning angles of tire are
out of standard, adjust to standard value.
5. WHEEL ALIGNMENT OF REAR
SUSPENSION
1) Check the alignment of rear suspension to ensure
that following items are within standard values.
Toe-in
Camber
Thrust angle
<Ref. to RS-7, Wheel Alignment.>
2) When the camber angle does not conform to
standard value, visually inspect the following com-
ponents. If the deformation is observed, replace the
damaged parts.
Suspension components [Shock absorber, front
link, rear link, upper link, rear arm, sub frame, etc]
3) When the toe-in and thrust angle are out of stan-
dard value, adjust them so that they conform to
standard value.
6. OIL LEAKAGE OF STRUT AND SHOCK
ABSORBER
Visually inspect the front strut and rear shock ab-
sorber for oil leakage. Replace the front strut and
rear shock absorber if oil leaks excessively.
7. TIGHTNESS OF BOLTS AND NUTS
Check the bolts and nuts for looseness. Retighten
the bolts and nuts to specified torque. If the self-
locking nuts and bolts are removed, replace them
with new parts.
Front suspension
<Ref. to FS-4, COMPONENT, General Description.>
Rear suspension
<Ref. to RS-3, COMPONENT, General Description.>
8. DAMAGE TO SUSPENSION PARTS
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 formation, pitting, etc. are noted, remove the
rust and take rust prevention measure.
Front suspension
Front arm
Crossmember
Strut
Rear suspension
Sub frame
Front link
Rear link
Upper link
Rear arm
Shock absorber
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. Take rust prevention measures as required.
PM-43
Wheel Bearing
21.Wheel Bearing
A: INSPECTION
1. FRONT WHEEL BEARING
NOTE:
Inspect the condition of front wheel bearing grease.
1) Jack-up the front side of vehicle.
2) While holding the front wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts, and remove the front
wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to the hub and measure axial
play in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the bolts and self-locking nuts, and ex-
tract the front arm from front crossmember.
6) Remove the PTJ of front drive shaft from trans-
mission. <Ref. to DS-13, Front Axle.>
7) While supporting the front drive shaft horizontal-
ly with one hand, turn the hub with the other hand to
check for noise or binding.
If the hub is noisy or binds, replace the front axle.
2. REAR WHEEL BEARING
1) Jack-up the rear side of vehicle.
2) While holding the rear wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts, and remove the rear
wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to the hub and measure axial
play in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the DOJ of rear drive shaft from rear dif-
ferential. <Ref. to DS-27, Rear Drive Shaft.>
6) While supporting rear 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, replace the rear axle.
PM-00173
PM-00173
PM-44
Axle Boots & Joints
22.Axle Boots & Joints
A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
Inspect the front axle boots (A) and rear axle boots
(B) for deformation, damage or failure. If faulty, re-
place with a new part. <Ref. to DS-23, Front Drive
Shaft.> <Ref. to DS-27, Rear Drive Shaft.>
Front
Rear
2. PROPELLER SHAFT
Inspect the propeller shaft for damage or failure. If
faulty, replace with a new part. <Ref. to DS-10, Pro-
peller Shaft.>
PM-00174
(A)
PM-00175
(B)
PM-45
Tire Rotation
23.Tire Rotation
A: INSPECTION
1) When the tread has worn down to less than 1.6
mm (0.063 in) or the wear indicator appears across
the tread, replace the tire. (Replace the right and
left tire as a set.)
2) If the tire appears to be worn unevenly, adjust
the wheel alignment.
3) Next, make a tire rotation between front and rear
as shown in the figure, make sure tires are worn
evenly.
When the direction of tire rotation is not specified
With instruction for the direction of tire rotation
4) Re-register the transmitter ID when rotation was
performed. (3.0 L U4 model) <Ref. to TPM(diag)-
10, REGISTER TRANSMITTER ID, OPERATION,
Subaru Select Monitor.>
(1) Front
(1) Front
(A) New tread
(B) Damaged tread
(C) Tread wear indicator
WT-00113
1
WT-00115
1
PM-00080
(A) (B)
(C)
PM-46
Steering System (Power Steering)
24.Steering System
(Power Steering)
A: INSPECTION
1. STEERING WHEEL
1) Set the steering wheel in a straight-ahead posi-
tion, 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 at the outer periphery of wheel.
Steering wheel free play:
0 17 mm (0 0.67 in)
Move the steering wheel vertically toward the shaft
to ascertain if there is play in the direction.
Maximum permissible play:
0.5 mm (0.020 in)
3) Drive the vehicle and check the following items
during operation.
(1) Steering force:
The effort required for steering should be
smooth and even at all points, and should not
vary.
(2) 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 factor:
Steering wheel should return to its original posi-
tion after it has been turned and then released.
2. STEERING SHAFT JOINT
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 dam-
age 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, 17.7 ft-lb)
(1) Steering wheel free play
(1)
PS-00450
PM-00176
PM-47
3. GEARBOX
1) With the vehicle placed on a level surface, turn the
steering wheel 90 in both the left and right directions.
While the wheel is being rotated, reach under the
vehicle and check for looseness in gearbox.
Tightening torque:
60 Nm (6.1 kgf-m, 44.1 ft-lb)
2) Check the boot for damage, cracks or deterioration.
3) With the vehicle placed on a level surface, quick-
ly 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.
4) Apply liquid gasket to at least 1/3 of entire perim-
eter of adjusting screw thread.
5) Tighten the adjusting screw to 25 Nm (2.5 kgf-
m, 18.1 ft-lb) and then loosen.
6) Tighten the adjusting screw to 3.9 Nm (0.40 kgf-
m, 2.9 ft-lb) and then loosen 20.
7) Install the lock nut. While holding the adjusting
screw with wrench, tighten the lock nut using ST.
ST 926230000 SPANNER
Tightening torque (lock nut):
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Hold the adjusting screw with 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.
2) Check the connections of knuckle ball joints for
play, inspect for damage on dust seals, and check
free play of ball studs. If castle nut is loose, retight-
en it to the specified torque, then tighten further up
to a maximum of 60until the cotter pin hole is
aligned.
Tightening torque:
27 Nm (2.75 kgf-m, 19.9 ft-lb)
3) Check the lock nut on the tie-rod for tightness. If
it is loose, retighten it to the specified torque.
Tightening torque:
85 Nm (8.7 kgf-m, 63 ft-lb)
(A) Apply liquid gasket to at least 1/3 of entire
perimeter.
PM-00177
PM-00068
(A)
(A) Tie-rod end
(B) Knuckle arm
PM-00069
(A)
(B)
PM-48
5. POWER STEERING FLUID LEVEL
CAUTION:
If the power steering fluid is spilt over exhaust
NOTE:
Check at power steering fluid temperature 20C
(68F); read the fluid level on the COLD side.
Check at power steering fluid temperature 80C
(176F); read the fluid level on the HOT side.
1) Place the vehicle with engine OFF on a level
surface.
side of the reservoir tank (A). If the level is below
MIN (B), add fluid to bring it up to MAX (C).
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:
ed Materials.>
Fluid capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
6. POWER STEERING FLUID FOR LEAKS
CAUTION:
Inspect the underside of oil pump and gearbox of
power steering system, hoses, pipes and their cou-
plings for fluid leaks.
If the fluid leaks are found, retighten their fitting
bolts (or nuts) and/or replace their parts.
NOTE:
Wipe the leaked fluid off after correcting fluid
leaks.
Also pay attention to clearances between hoses
(or pipes) and other parts when inspecting fluid
leaks.
7. HOSES OF OIL PUMP FOR DAMAGES
CAUTION:
Check the pressure hose and return hose of oil
pump for crack, swell or damage. Replace the hose
with a new part if necessary.
NOTE:
Prevent hoses from turning and/or bending when
installing hoses.
8. POWER STEERING PIPES FOR
DAMAGES
CAUTION:
Check the power steering pipes for corrosion and
damage.
Replace the pipes with new parts if necessary.
(C)
(A)
(B)
PM-00178
PM-00179
PM-49
9. GEARBOX BOOTS
Inspect both sides of the gearbox boot as follows,
and correct the defects if necessary.
1) Positions (A) and (B) of the gearbox boot are fit-
ted correspondingly in grooves (A) and (B) of the
gearbox and rod (C).
2) Clips are fitted outside of positions (A) and (B) of
boot.
3) Boot does not have crack or hole.
NOTE:
Rotate (B) position of gearbox boot against the tor-
sion produced by the adjustment of toe-in etc. Ap-
ply grease to the groove (C).
10.FITTING BOLTS AND NUTS
Inspect the fitting bolts and nuts of oil pump and
bracket for looseness, and retighten them if neces-
sary.
Inspect and/or retighten them when engine is cold.
PM-00090
(C)
(B)
(A)
PM-50
FU(H4SO)-2
General Description
FUEL INJECTION (FUEL SYSTEMS)
A: SPECIFICATION
Fuel tank
Capacity 64 2 (16.9 US gal, 14.1 Imp gal)
Install locations Under rear seat
Fuel pump
Type Impeller
Shutoff discharge pressure 550 850 kPa (5.6 8.7 kg/cm
2
, 79.7 123.2 psi)
Discharge rate
125 2 (33 US gal, 27.5 Imp gal)/h or more.
[12 V at 300 kPa (3.06 kg/cm
2
, 43.5 psi)]
Fuel filter Intank type
FU(H4SO)-3
General Description
B: COMPONENT
1. INTAKE MANIFOLD
(19)
T1
T1
(7)
(18)
(2)
(1)
(16)
(3)
(15)
T5
T4
T1
T3
T2
T2
T2
T3
T1
T1
T4
T4
T4
(15)
(21)
(13)
(12)
(14)
(15)
(13)
(12)
(14)
(15)
(13)
(12)
(14)
(10)
(3)
(4)
T4
(9)
(17)
(13)
(12)
(14)
(6)
(6)
(4)
T4
T4
T5
(2)
(17)
(18)
T3
T4
(5)
FU-03232
T4
(8)
(11)
T4
(20)
T4
FU(H4SO)-4
General Description
2. AIR INTAKE SYSTEM
(1) Intake manifold (11) Fuel injector pipe RH (20) Fuel injector pipe LH
(2) Gasket (12) Fuel injector (21) Gasket
(3) Intake manifold (lower) (13) O-ring
(4) Gasket (14) O-ring Tightening torque:Nm (kgf-m, ft-lb)
(5) Nipple (15) O-ring T1: 6.4 (0.65, 4.7)
(6) Guide pin (16) Purge control solenoid valve T2: 8.75 (0.89, 6.5)
(7) Plug cord stay (17) Plug cord holder T3: 17 (1.7, 12.5)
(8) EGR valve (18) Nipple T4: 19 (1.9, 14.0)
(9) Fuel pipe protector RH (19) Fuel pipe ASSY T5: 25 (2.5, 18.4)
(10) Fuel pipe protector LH
(1) Gasket (4) O-ring Tightening torque:Nm (kgf-m, ft-lb)
(2) Throttle body T1: 2 (0.2, 1.5)
(3) Manifold absolute pressure sensor T2: 8 (0.8, 5.9)
FU-02560
T1
T2
(1)
(3)
(4)
(2)
FU(H4SO)-5
General Description
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
(1) Crankshaft position sensor (4) Camshaft position sensor support Tightening torque:Nm (kgf-m, ft-lb)
(2) Knock sensor T1: 6.4 (0.65, 4.7)
(3) Camshaft position sensor T2: 24 (2.4, 17.7)
FU-00414
T1
(1)
(2)
T1
T1
(3)
(4)
T2
FU(H4SO)-6
General Description
4. FUEL TANK
FU-03250
T1
(11)
(12)
(13)
(31)
(32)
(7)
T4
T1
T4
T3
T3
T3
T2
T3
T3
T4
(16)
(14)
(15)
(15)
(17)
(19)
(17)
(3)
(22)
(23)
(24)
(2)
(20)
(21)
(8)
(10)
(17)
(17)
(30)
(9)
(1)
T2
T3
(17)
(25)
(26)
(27)
(17)
(29)
(28)
(5)
(6)
(4)
(6)
(18)
(17)
(17)
FU(H4SO)-7
General Description
(1) Fuel tank (14) Fuel filler hose (27) Evaporation hose C
(2) Fuel tank band RH (15) Clamp (28) Evaporation hose D
(3) Fuel tank band LH (16) Evaporation hose A (29) Evaporation pipe
(4) Delivery tube (17) Clip (30) Evaporation hose E
(5) Jet pump tube (18) Evaporation hose F (31) Fuel sub level sensor filter
(6) Retainer (19) Fuel tank protector LH (rear) (32) Fuel sub level sensor protector
(7) Fuel pump ASSY (20) Stopper RH
(8) Fuel pump upper plate (21) Stopper LH Tightening torque:Nm (kgf-m, ft-lb)
(9) Fuel pump gasket (22) Heat shield cover T1: 4.4 (0.45, 3.2)
(10) Fuel level sensor (23) Fuel tank protector RH (front) T2: 9 (0.9, 6.6)
(11) Fuel sub level sensor (24) Fuel tank protector LH (front) T3: 17.5 (1.78, 12.9)
(12) Fuel sub level sensor upper plate (25) Evaporation hose B T4: 33 (3.4, 25)
(13) Fuel sub level sensor gasket (26) Connector
FU(H4SO)-8
General Description
5. FUEL LINE
B
A
A
C
(27)
(24)
(29)
(23)
(23)
(23)
(23)
(22)
(23)
(38)
(28)
(30)
(26)
(25)
(37)
(37)
T2
T4
T1
T2
T1
T2
T6
T2
T6
T3
(21)
(19)
(17)
(16)
(1)
(1)
(1)
(32)
(33)
(1)
(34)
(31)
(20)
(13)
(12)
(10)
(9)
(13)
(13)
(15)
(14)
(18)
T2
T2
(33)
(1)
(23)
(39)
(11) (8)
T2
(23)
(36)
(35)
(31)
(23)
C
FU-03120
(7)
(2)
(13)
(5)
(6) (3) (1)
(1)
(4)
(13)
T5
T5
FU(H4SO)-9
General Description
C: CAUTION
Wear appropriate work clothing, including a cap,
protective goggles and protective shoes when per-
forming any work.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust and dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
Vehicle components are extremely hot after driv-
ing. 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 OPEN FLAMES signs near the work-
ing area.
prevent from penetrating into floor or flowing out for
environmental protection.
cerning disposal of refuse when disposing fuel.
(1) Clip (17) Drain valve (33) Connector B
(2) Fuel damper valve (18) Drain filter (34) Canister hose B
(3) Evaporation hose A (19) Canister protector (35) Drain hose
(4) Fuel delivery hose A (20) Pressure control solenoid valve (36) Drain hose connector
(5) Fuel delivery hose B (21) Evaporation pipe A (37) Evaporation hose C
(6) Clip (22) Evaporation pipe B (38) Evaporation hose D
(7) Bracket (23) Clip (39) Evaporation hose E
(8) Evaporation tube (24) Fuel filler pipe
(9) Fuel pipe ASSY A (25) Shut valve Tightening torque:Nm (kgf-m, ft-lb)
(10) Fuel delivery hose C (26) Gasket T1: 4.4 (0.45, 3.2)
(11) Retainer (27) Filler ring T2: 7.5 (0.76, 5.5)
(12) Evaporation hose B (28) Fuel filler cap T3: 8 (0.8, 5.9)
(13) Clamp (29) Fuel tank pressure sensor T4: 17.6 (1.8, 13)
(14) Grommet (30) Evaporation pipe protector T5: 1.25 (0.13, 0.94)
(15) Fuel pipe ASSY B (31) Connector A T6: 1.0 (0.1, 0.7)
(16) Canister (32) Canister hose A
FU(H4SO)-10
General Description
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
42099AE000 CONNECTOR
REMOVER
Used for removing the quick connector.
18471AA000
(Newly adopted tool)
FUEL PIPE
ADAPTER
Used for extracting fuel.
ST42099AE000
ST18471AA000
FU(H4SO)-11
Throttle Body
2. Throttle Body
A: REMOVAL
1) Disconnect the ground cable from the battery.
2) Remove the air intake chamber. <Ref. to
IN(H4SO)-7, REMOVAL, Air Intake Chamber.>
3) Disconnect the connectors from throttle position
sensor and manifold absolute pressure sensor.
4) Disconnect the engine coolant hoses from the
throttle body.
5) Remove the bolts which secure the throttle body
to the intake manifold and remove the throttle body.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Use a new gasket.
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
(A) Throttle position sensor
(B) Manifold absolute pressure sensor
(C) Engine coolant hose
IN-00203
FU-03049
(B)
(C)
(A)
(C)
FU(H4SO)-12
Intake Manifold
3. Intake Manifold
A: REMOVAL
1) Release the fuel pressure.
<Ref. to FU(H4SO)-41, RELEASING OF FUEL
PRESSURE, PROCEDURE, Fuel.>
3) Remove the air intake duct, air cleaner case and
air intake chamber. <Ref. to IN(H4SO)-8, REMOV-
AL, Air Intake Duct.> <Ref. to IN(H4SO)-5, RE-
MOVAL, Air Cleaner Case.> <Ref. to IN(H4SO)-7,
REMOVAL, Air Intake Chamber.>
4) Remove the generator. <Ref. to SC(H4SO)-15,
REMOVAL, Generator.>
5) Remove the spark plug cords from the spark
plugs by pulling the plug caps. (Do not pull the
cord.)
6) Disconnect the engine coolant hoses (A) from
throttle body.
7) Disconnect the brake booster hose (A).
8) Disconnect the PCV hose (A) from intake mani-
fold.
9) Disconnect the engine harness connectors (B)
from bulkhead harness connectors.
10) Disconnect the connectors from the engine
coolant temperature sensor.
11) Disconnect the knock sensor connector.
12) Disconnect the connector from crankshaft posi-
tion sensor.
13) Disconnect the connector from power steering
pump switch (A).
IN-00203
FU-01085
(A)
(A)
FU-02320
(A)
(A)
(B)
FU-03234
FU-00055
FU-02713
FU-00056
FU(H4SO)-13
Intake Manifold
14) Disconnect the connector from the oil pressure
switch (B).
15) Disconnect the connector from the camshaft
position sensor.
16) Remove the EGR pipe from intake manifold.
17) Disconnect the following connector.
(1) Front oxygen (A/F) sensor connector
(2) Rear oxygen sensor connector
(3) Engine harness connectors
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 evapo-
ration hose from the pipe.
CAUTION:
Be careful not to spill fuel.
Catch the fuel from hoses using a container
or cloth.
19) Remove the bolts which secure intake manifold
to cylinder head.
20) Remove the 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, 18.4 ft-lb)
FU-03251
(B)
(A)
FU-02714
FU-02974
FU-02866
ST
FU-03252
FU-03252
FU(H4SO)-14
Intake Manifold
2) Connect the fuel hose and evaporation hose to
the fuel pipe.
NOTE:
If fuel hoses or clamps 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)
4) Connect the following connectors.
5) Connect the connectors to camshaft position
sensor.
6) Connect the connector to the power steering
pump switch (A).
7) Connect the connector to the oil pressure switch
(B).
8) Connect the connector to crankshaft position
sensor.
9) Connect the knock sensor connector.
10) Connect the connector to engine coolant tem-
perature sensor.
11) Connect the PCV hose (A) to intake manifold.
12) Connect the engine harness connectors (B) to
bulkhead harness connectors.
FU-02974
FU-02714
FU-03251
(B)
(A)
FU-00056
FU-02713
FU-00055
(A)
(B)
FU-03234
FU(H4SO)-15
Intake Manifold
13) Connect the brake booster hose (A).
14) Connect the engine coolant hoses (A) to throt-
tle body.
15) Connect the spark plug cords to spark plugs.
16) Install the generator. <Ref. to SC(H4SO)-15,
INSTALLATION, Generator.>
17) Install the air intake duct, air cleaner case and
air intake chamber. <Ref. to IN(H4SO)-8, INSTAL-
LATION, Air Intake Duct.> <Ref. to IN(H4SO)-6,
INSTALLATION, Air Cleaner Case.> <Ref. to
IN(H4SO)-7, INSTALLATION, Air Intake Cham-
ber.>
18) Install the fuse of fuel pump relay to the main
fuse box.
19) Connect the battery ground cable to battery.
C: DISASSEMBLY
1) Disconnect the engine ground terminal from in-
take manifold.
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)-
11, REMOVAL, Throttle Body.>
4) Remove the EGR valve. <Ref. to FU(H4SO)-27,
REMOVAL, EGR Valve.>
5) Remove the plug cord stay.
6) Remove the fuel pipe protector LH.
7) Remove the fuel pipe protector RH.
FU-02320
(A)
FU-01085
(A)
(A)
IN-00203
FU-01090
FU-03233
FU-02325
FU-02326
FU(H4SO)-16
Intake Manifold
8) Disconnect the connectors (A) from fuel injector.
9) Remove the harness band (B) which holds the
engine harness to injector pipe.
10) Remove the purge control solenoid valve.
<Ref. to EC(H4SO)-6, REMOVAL, Purge Control
Solenoid Valve.>
11) Remove the harness band clips which install
the engine harness.
12) Remove the bolts which hold engine harness to
intake manifold.
13) Remove the engine harness from intake mani-
fold.
14) Remove the bolts which install fuel injector pipe
on the intake manifold as shown in the figure.
RH side
LH side
15) Remove the fuel injectors from the fuel injector
pipe.
16) Disconnect the quick connector that fastens the
fuel injector pipe RH to the fuel pipe.
FU-02729
(B)
(A)
FU-02329
FU-01097
FU-02717
FU-02718
FU-02719
FU-02720
FU(H4SO)-17
Intake Manifold
17) Disconnect the quick connector that fastens the
fuel injector pipe LH to the fuel pipe.
18) Remove the fuel injector pipe RH and LH.
19) Remove the bolts which install fuel pipes on in-
take manifold.
20) Remove the fuel pipe from intake manifold.
D: ASSEMBLY
NOTE:
When assembling the nipple, apply liquid gasket.
Liquid gasket:
1) Install the intake manifold.
NOTE:
Use a new gasket.
Tightening torque:
8.75 Nm (0.89 kgf-m, 6.5 ft-lb)
2) Tighten the bolts which install fuel pipes on in-
take manifold.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
3) Connect the fuel injector pipe LH to the fuel pipe.
NOTE:
Connect the quick connector securely.
FU-02721
FU-02722
FU-01104
FU-01104
FU-02722
FU-02721
FU(H4SO)-18
Intake Manifold
4) Connect the fuel injector pipe RH to the fuel
pipe.
NOTE:
Connect the quick connector securely.
5) Install the fuel injector.
6) Tighten the bolts which install fuel injector pipes
on intake manifold.
RH side
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
LH side
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
7) Install the engine harness to the intake manifold.
8) Tighten the bolts which install engine harness on
intake manifold.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
9) Hold the engine harness using the harness band
clips.
FU-02720
FU-02717
FU-02718
FU-02719
FU-01097
FU-02329
FU(H4SO)-19
Intake Manifold
10) Install the purge control solenoid valve. <Ref.
to EC(H4SO)-6, INSTALLATION, Purge Control
Solenoid Valve.>
11) Connect the connectors (A) to fuel injector.
12) Hold the engine harness to injector pipe by har-
ness band (B).
13) Install the fuel pipe protector RH.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
14) Install the fuel pipe protector LH.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
15) Install the plug cord stay.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
16) Install the EGR valve. <Ref. to FU(H4SO)-27,
INSTALLATION, EGR Valve.>
17) Install the throttle body to the intake manifold.
<Ref. to FU(H4SO)-11, INSTALLATION, Throttle
Body.>
18) Install the ignition coil and ignitor assembly.
<Ref. to IG(H4SO)-6, INSTALLATION, Ignition Coil
and Ignitor Assembly.>
19) Install the engine ground terminal to intake
manifold.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
damaged and the connections are tightened firmly.
FU-02729
(B)
(A)
FU-02326
FU-02325
FU-03233
FU-01090
FU(H4SO)-20
Engine Coolant Temperature Sensor
4. Engine Coolant Temperature
Sensor
A: REMOVAL
3) Disconnect the connectors from the engine cool-
ant temperature sensor.
4) 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)
IN-00203
FU-00055
FU(H4SO)-21
Crankshaft Position Sensor
5. Crankshaft Position Sensor
A: REMOVAL
3) Remove the bolt which installs crankshaft posi-
tion sensor to cylinder block.
4) Remove the crankshaft position sensor, and
then disconnect the connector from it.
B: INSTALLATION
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203
FU-00056
FU-00057
FU-00058
T
FU(H4SO)-22
Camshaft Position Sensor
6. Camshaft Position Sensor
A: REMOVAL
2) Disconnect the connector from the camshaft po-
sition sensor.
3) Remove the bolt which installs camshaft position
sensor to the support.
4) Remove the bolt which installs camshaft position
sensor support to camshaft cap LH.
5) Remove the camshaft position sensor and the
support as a unit.
6) Remove the camshaft position sensor from the
camshaft position sensor support.
B: INSTALLATION
Tightening torque:
Camshaft position sensor support
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Camshaft position sensor
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203
FU-02714
FU-02724
FU-02725
FU-00179
FU(H4SO)-23
Knock Sensor
7. Knock Sensor
A: REMOVAL
4) Remove the knock sensor from the cylinder
block.
B: INSTALLATION
1) Install the knock sensor to the cylinder block.
NOTE:
Extraction area of knock sensor cord must be posi-
tioned at a 60 angle relative to the engine rear.
Tightening torque:
24 Nm (2.4 kgf-m, 17.7 ft-lb)
3) Install the air intake chamber.
<Ref. to IN(H4SO)-7, INSTALLATION, Air Intake
Chamber.>
IN-00203
FU-02713
FU-02726
(A) Front side
(A)
60
FU-02727
FU-02713
IN-00203
FU(H4SO)-24
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
procedure. <Ref. to FU(H4SO)-11, REMOVAL,
Throttle Body.> <Ref. to FU(H4SO)-11, INSTAL-
LATION, Throttle Body.>
FU(H4SO)-25
Manifold Absolute Pressure Sensor
9. Manifold Absolute Pressure
Sensor
A: REMOVAL
2) Disconnect the connector from manifold abso-
lute pressure sensor.
3) Remove the manifold absolute pressure sensor
from throttle body.
B: INSTALLATION
NOTE:
Use new O-rings.
Tightening torque:
2 Nm (0.2 kgf-m, 1.5 ft-lb)
IN-00203
FU-03047
FU(H4SO)-26
Mass Air Flow and Intake Air Temperature Sensor
10.Mass Air Flow and Intake Air
Temperature Sensor
A: REMOVAL
2) Disconnect the connectors from the mass air
flow and intake air temperature sensor.
3) Remove the mass air flow and intake air temper-
ature sensor.
B: INSTALLATION
Tightening torque:
1 Nm (0.1 kgf-m, 0.7 ft-lb)
IN-00203
FU-03253
FU(H4SO)-27
EGR Valve
11.EGR Valve
A: REMOVAL
2) Disconnect the connector from the EGR valve.
3) Remove the EGR valve from intake manifold.
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
IN-00203
FU-01152
FU-01153
FU(H4SO)-28
Fuel Injector
12.Fuel Injector
A: REMOVAL
1. RH SIDE
1) Release the fuel pressure. <Ref. to FU(H4SO)-
41, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
3) Open the fuel filler flap lid, and remove the fuel
filler cap.
4) Remove the air intake duct and air cleaner case.
<Ref. to IN(H4SO)-8, REMOVAL, Air Intake Duct.>
<Ref. to IN(H4SO)-5, REMOVAL, Air Cleaner
Case.>
5) Remove the spark plug cords from spark plugs
(#1 and #3 cylinders).
9) Remove the bolt which holds fuel injector pipe
onto intake manifold.
10) Remove the fuel injector while lifting up the fuel
injector pipe.
2. LH SIDE
DURE, Fuel.>
2) Remove the battery. <Ref. to SC(H4SO)-22,
REMOVAL, Battery.>
filler cap.
4) Remove the spark plug cords from spark plugs
(#2 and #4 cylinders).
IN-00203
FU-02326
FU-02730
(B)
(A)
FU-02717
FU-02325
FU-02729
(B)
(A)
FU(H4SO)-29
Fuel Injector
injector pipe.
B: INSTALLATION
1. RH SIDE
NOTE:
Use new O-rings.
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-02719
(A) O-ring
(B) O-ring
(C) Fuel injector
(D) O-ring
FU-02157
(A)
(B)
(D)
(C)
FU-02717
FU-02326
FU(H4SO)-30
Fuel Injector
2. LH SIDE
NOTE:
Use new O-rings.
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)
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
(A) O-ring
(B) O-ring
(C) Fuel injector
(D) O-ring
FU-02157
(A)
(B)
(D)
(C)
FU-02719
FU-02718
FU-02325
FU(H4SO)-31
Variable Valve Lift Diagnosis Oil Pressure Switch
13.Variable Valve Lift Diagnosis
Oil Pressure Switch
A: REMOVAL
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 pres-
sure switch.
LH side
RH side
B: INSTALLATION
NOTE:
Apply liquid gasket to the variable valve lift diagno-
sis 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)
IN-00203
FU-02731
FU-02732
FU(H4SO)-32
Oil Temperature Sensor
14.Oil Temperature Sensor
A: REMOVAL
bracket.
4) Disconnect the connector from the oil tempera-
ture sensor.
5) Remove the oil temperature sensor.
B: INSTALLATION
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
IN-00203
FU-02733
FU(H4SO)-33
Front Oxygen (A/F) Sensor
15.Front Oxygen (A/F) Sensor
A: REMOVAL
3) Remove the air intake duct. <Ref. to IN(H4SO)-
8, REMOVAL, Air Intake Duct.>
4) Remove the clip fastening the harness and dis-
connect the front oxygen (A/F) sensor connector.
7) Apply spray-type lubricant to the threaded por-
tion of front oxygen (A/F) sensor, and leave it for
one minute or more.
8) Remove the front oxygen (A/F) sensor.
CAUTION:
When removing the front oxygen (A/F) sensor,
wait until exhaust pipe cools, because it can
damage the exhaust pipe.
B: INSTALLATION
1) Before installing front oxygen (A/F) sensor, ap-
ply the anti-seize compound only to the threaded
portion of front oxygen (A/F) sensor. This facilitates
the next removal.
CAUTION:
Never apply anti-seize compound to the protec-
tor of front oxygen (A/F) sensor.
Anti-seize compound:
NEVER-SEEZ NSN, JET LUBE or equivalent
2) Install the front oxygen (A/F) sensor.
Tightening torque:
21 Nm (2.1 kgf-m, 15.5 ft-lb)
3) Install the under cover.
4) Lower the vehicle.
(A) Front oxygen (A/F) sensor connector
(B) Rear oxygen sensor connector
IN-00203
FU-02734
(B)
(A)
(A) Front oxygen (A/F) sensor
(B) Rear oxygen sensor
FU-02735
(A)
(B)
FU-02735
(A)
(B)
FU(H4SO)-34
5) Connect the connector of front oxygen (A/F)
sensor connector and fasten the harness with clips.
FU-02734
(B)
(A)
IN-00203
FU(H4SO)-35
Rear Oxygen Sensor
16.Rear Oxygen Sensor
A: REMOVAL
4) Remove the clip fastening the harness and dis-
connect the rear oxygen (A/F) sensor connector.
tion of rear oxygen sensor, and leave it for one
minute or more.
8) Remove the rear oxygen sensor.
CAUTION:
When removing the rear oxygen (A/F) sensor,
wait until exhaust pipe cools, because it can
B: INSTALLATION
1) Before installing rear oxygen (A/F) sensor, apply
the anti-seize compound only to the threaded por-
tion of rear oxygen (A/F) sensor. This facilitates the
next removal.
CAUTION:
tor of rear oxygen sensor.
NEVER-SEEZ NSN, JET LUBE SS-30 or
equivalent
2) Install the rear oxygen sensor.
Tightening torque:
21 Nm (2.1 kgf-m, 15.5 ft-lb)
IN-00203
FU-02734
(B)
(A)
FU-02735
(A)
(B)
FU-02735
(A)
(B)
FU(H4SO)-36
Rear Oxygen Sensor
5) Connect the connector to rear oxygen sensor
and mount the harness clips to the bracket for fas-
tening.
FU-02734
(B)
(A)
IN-00203
FU(H4SO)-37
Engine Control Module (ECM)
17.Engine Control Module (ECM)
A: REMOVAL
2) Remove the lower inner trim of passengers
side.
<Ref. to EI-61, REMOVAL, Lower Inner Trim.>
3) Detach the floor mat of passengers seat.
4) Remove the protect cover.
5) Remove the bolts and nuts which hold the ECM
to the bracket.
6) Remove the clip (A) from bracket.
7) Disconnect the ECM connectors, and take out
the ECM.
B: INSTALLATION
NOTE:
When replacing the ECM, be careful not to use
the ECM for wrong specifications to avoid any dam-
age to fuel injection system.
When replacing the ECM, be careful not to dam-
age the harnesses and connectors.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
IN-00203
FU-02090
(A)
FU-02488
FU(H4SO)-38
Main Relay
18.Main Relay
A: REMOVAL
2) Remove the glove box. <Ref. to EI-52, REMOV-
AL, Glove Box.>
3) Remove the harness cover (A).
4) Disconnect the connectors from main relay.
B: INSTALLATION
IN-00203
FU-02092
(A)
FU-02093
FU(H4SO)-39
Fuel Pump Relay
19.Fuel Pump Relay
A: REMOVAL
AL, Glove Box.>
4) Disconnect the connector from fuel pump relay.
B: INSTALLATION
IN-00203
FU-02092
(A)
FU-02094
FU(H4SO)-40
Electronic Throttle Control Relay
20.Electronic Throttle Control
Relay
A: REMOVAL
AL, Glove Box.>
4) Disconnect the connector from electric throttle
control relay.
B: INSTALLATION
IN-00203
FU-02092
(A)
FU-02095
FU(H4SO)-41
Fuel
21.Fuel
A: PROCEDURE
1. RELEASING OF FUEL PRESSURE
WARNING:
Place NO OPEN FLAMES signs near the
working area.
CAUTION:
1) Remove the fuse of fuel pump from main fuse
box.
2) Start the engine and run it until it stalls.
3) After the engine stalls, crank it for five more sec-
onds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL (WITH SUBARU SE-
LECT MONITOR)
WARNING:
working area.
CAUTION:
NOTE:
If the fuel pump is not driven, refer to DRAINING
FUEL (THROUGH THE FUEL FILLER HOSE).
<Ref. to FU(H4SO)-41, DRAINING FUEL
(THROUGH THE FUEL FILLER HOSE), PROCE-
DURE, Fuel.>
Be careful not to let the battery run out.
DURE, Fuel.>
2) Attach ST to the fuel delivery pipe and push ST
in the direction of arrow mark to disconnect the fuel
delivery hose.
CAUTION:
or cloth.
3) Connect ST to the fuel delivery hose.
ST 18471AA000 FUEL PIPE ADAPTER
4) Connect the gasoline proof hose to ST and put
the end of the hose in the container.
5) Drive the fuel pump and drain the fuel using Sub-
aru Select Monitor. <Ref. to EN(H4SO)(diag)-57,
FUEL PUMP CONTROL (ON/OFF DRIVE), OP-
ERATION, System Operation Check Mode.>
CAUTION:
3. DRAINING FUEL (THROUGH THE FUEL
FILLER HOSE)
WARNING:
working area.
CAUTION:
The fuel may remain in the fuel filler pipe.
Drain the fuel from the fuel filler pipe through
the fill opening using the gasoline proof pump
and the gasoline proof hose (10 or less) before
the operation.
3) Remove the rear exhaust pipe and muffler.
<Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust
Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muf-
fler.>
filler cap.
5) Drain the fuel from the fuel filler pipe through the
fill opening using the gasoline proof pump and the
gasoline proof hose (10 or less).
FU-01122
FU-02866
ST
FU(H4SO)-42
Fuel
6) Disconnect the fuel filler hose (A) from the fuel
filler pipe.
CAUTION:
or cloth.
7) Set the container under the vehicle and insert
the gasoline proof hose (10 or less) into the fuel
filler hose to drain the fuel.
CAUTION:
(A) Fuel filler hose
(B) Evaporation hose
(A)
FU-02394
(B)
FU(H4SO)-43
Fuel Tank
22.Fuel Tank
A: REMOVAL
WARNING:
working area.
CAUTION:
DURE, Fuel.>
3) Drain fuel from fuel tank.
<Ref. to FU(H4SO)-41, DRAINING FUEL (WITH
SUBARU SELECT MONITOR), PROCEDURE,
Fuel.>
4) Remove the rear seat.
5) Remove the service hole cover of fuel pump.
6) Disconnect the connector from fuel pump.
7) Remove the connector (A) and clip (B).
8) Remove the service hole cover of fuel sub level
sensor.
(1) Remove the bolt (A).
(2) Push the grommet (B) down and remove the
service hole cover.
9) Disconnect connector (A) from fuel sub level
sensor.
10) Disconnect the quick connector on the fuel de-
livery hose (B). <Ref. to FU(H4SO)-59, REMOVAL,
Fuel Delivery and Evaporation Lines.>
11) Remove the trunk room trim. (Sedan model)
<Ref. to EI-70, REMOVAL, Trunk Room Trim.>
12) Remove the rear quarter trim. (Wagon model)
<Ref. to EI-64, WAGON MODEL, REMOVAL, Rear
Quarter Trim.>
13) Remove the pipe protector.
FU-02387
FU-02829
FU-02389
(B)
(A)
FU-01126
(B)
(A)
(A)
FU-02830
(A)
(B)
FU-02390
FU(H4SO)-44
Fuel Tank
14) Remove the grommet and disconnect the quick
connector of the evaporation pipe. <Ref. to
FU(H4SO)-59, REMOVAL, Fuel Delivery and
Evaporation Lines.>
15) Remove the rear wheels.
17) Remove the bolts which secure the rear brake
hose mounting bracket.
18) Remove the rear brake caliper and tie it to the
body side of the vehicle.
19) Remove the parking brake cable from the park-
ing brake assembly. <Ref. to PB-6, REMOVAL,
Parking Brake Assembly (Rear Disc Brake).>
21) Remove the rear exhaust pipe. <Ref. to
EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.>
22) Remove the propeller shaft. <Ref. to DS-10,
REMOVAL, Propeller Shaft.>
23) Remove the heat shield cover.
24) Disconnect the connector from the rear ABS
wheel speed sensor.
25) Remove the bolts securing the parking brake
cable clamp.
FU-02391
FU-01128
FU-00462
FU-02894
FU-02895
FU-02896
FU(H4SO)-45
Fuel Tank
26) Remove the rear suspension assembly.
WARNING:
A helper is required to perform this work.
(1) Support the rear differential with the trans-
mission jack.
(2) Remove the bolts which hold the rear shock
absorber to the rear suspension arm.
(3) Remove the bolts which secure the rear
suspension assembly to the body.
(4) Remove the rear suspension assembly.
27) Disconnect the connector.
28) Disconnect the evaporation hose.
29) Disconnect the fuel filler hose (A) and evapora-
tion hose (B).
30) Support the fuel tank with a transmission jack,
remove the bolts from the fuel tank band, and re-
move the fuel tank from the vehicle.
WARNING:
The fuel may remain in the fuel tank. Be care-
ful not to let the fuel tank fall off when removing
as it is bad balance on either side.
FU-01132
FU-01133
FU-02891
FU-02392
FU-02393
(A)
FU-02394
(B)
FU-03293
FU(H4SO)-46
Fuel Tank
B: INSTALLATION
set the fuel tank in place, and temporarily tighten
the bolts of the fuel tank band.
WARNING:
2) Securely insert the fuel filler hose (A) and evap-
oration hose (B) to the specified position, then tight-
en the clamp.
3) Connect the evaporation hose.
4) Tighten the fuel tank band bolts.
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
5) Connect the connector.
(1) Hose
(2) Clip or clamp
(3) Pipe
FU-03293
(A)
FU-02394
(B)
( 1 )
( 2 ) ( 3 )
FU-00104
L
L/2
FU-02393
FU-02392
FU(H4SO)-47
Fuel Tank
6) Install the rear suspension assembly.
WARNING:
mission jack.
(2) Support the rear suspension assembly, and
tighten the bolts which secure the rear suspen-
sion assembly to the body.
Tightening torque:
T1: 125 Nm (12.7 kgf-m, 92.2 ft-lb)
T2: 175 Nm (17.8 kgf-m, 129 ft-lb)
(3) Tighten the bolts which hold the rear shock
absorber to the rear suspension arm. <Ref. to
RS-10, INSTALLATION, Rear Arm.>
Tightening torque:
62 Nm (6.3 kgf-m, 46 ft-lb)
7) Tighten the bolts holding the parking brake cable
clamp.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
8) Connect the connector to the rear ABS wheel
speed sensor.
9) Install the heat shield cover.
10) Install the propeller shaft. <Ref. to DS-11, IN-
STALLATION, Propeller Shaft.>
11) Install the rear exhaust pipe. <Ref. to EX(H4SO)-
8, INSTALLATION, Rear Exhaust Pipe.>
13) Connect the parking brake cable to the parking
brake assembly. <Ref. to PB-7, INSTALLATION,
14) Install the rear brake caliper.
FU-01150
T1
T1
T1
T1
FU-02892
T2
T2
FU-01132
FU-02895
FU-02896
FU-02894
FU(H4SO)-48
Fuel Tank
15) Tighten the bolts which secure the rear brake
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
17) Install the rear wheels.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
18) Connect the quick connector of the evaporation
pipe. <Ref. to FU(H4SO)-60, INSTALLATION, Fuel
Delivery and Evaporation Lines.>
19) Install the pipe protector.
Tightening torque:
T1:1 Nm (0.1 kgf-m, 0.7 ft-lb)
T2: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
20) Install the trunk room trim. (Sedan model)
<Ref. to EI-71, INSTALLATION, Trunk Room
Trim.>
21) Install the rear quarter trim. (Wagon model)
<Ref. to EI-64, INSTALLATION, Rear Quarter
Trim.>
22) Connect connector (A) to the fuel sub level sen-
sor.
23) Connect the quick connector (B) of the fuel de-
livery hose. <Ref. to FU(H4SO)-60, INSTALLA-
TION, Fuel Delivery and Evaporation Lines.>
24) Install the service hole cover of fuel sub level
sensor.
25) Connect connector (A), and install clip (B).
26) Connect the connector to the fuel pump.
FU-01128
FU-02391
FU-02868
T2
T1
(A) Bolt
(B) Grommet
FU-02830
(A)
(B)
FU-01126
(B)
(A)
(A)
FU-02389
(B)
(A)
FU-02829
FU(H4SO)-49
Fuel Tank
27) Install the service hole cover of fuel pump.
28) Install the rear seat.
29) Install the fuse of fuel pump to main fuse box.
C: INSPECTION
1) Check that the fuel tank does not have holes,
cracks or is damaged in any way.
2) Make sure that the fuel pipe and fuel hose are
not cracked and that the connections are tight.
FU-02387
FU(H4SO)-50
Fuel Filler Pipe
23.Fuel Filler Pipe
A: REMOVAL
WARNING:
working area.
CAUTION:
3) Open the fuel filler flap lid, and remove the filler
cap.
4) Remove the screws which secure gasket.
5) Remove the rear wheel RH.
7) Drain fuel from the fuel tank. <Ref. to FU(H4SO)-
41, DRAINING FUEL (WITH SUBARU SELECT
MONITOR), PROCEDURE, Fuel.>
8) Remove the mud guard. <Ref. to EI-29, RE-
MOVAL, Mud Guard.>
9) Remove the rear sub frame. <Ref. to RS-21, RE-
MOVAL, Rear Sub Frame.>
10) Remove the bolts which hold fuel filler pipe
bracket on the body.
11) Loosen the clamp, and disconnect the fuel filler
hose (A) and evaporation hose (B).
12) Remove the fuel filler pipe to the underside of
the vehicle.
B: INSTALLATION
1) Open the fuel filler flap lid.
2) Set the fuel saucer (A) with rubber seal (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 seal are folded toward inside,
straighten it with a flat tip screwdriver.
IN-00203
FU-00095
FU-02395
(A)
FU-02396
(B)
FU-02397
(B)
FU-00103
(A)
(C)
(B)
FU(H4SO)-51
Fuel Filler Pipe
en the clamp.
Tightening torque:
2.5 Nm (0.3 kgf-m, 1.8 ft-lb)
5) Tighten the bolts which hold fuel filler pipe brack-
et on the body.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
6) Install the rear sub frame. <Ref. to RS-21, IN-
STALLATION, Rear Sub Frame.>
7) Install the mud guard. <Ref. to EI-29, INSTAL-
LATION, Mud Guard.>
9) Install the rear wheel RH.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
C: INSPECTION
2) Make sure that the fuel hose is not cracked and
that the connections are tight.
(1) Hose
(2) Clip or clamp
(3) Pipe
(A)
FU-02396
(B)
FU-02397
(B)
( 1 )
( 2 ) ( 3 )
FU-00104
L
L/2
FU-02395
IN-00203
FU(H4SO)-52
Fuel Filler Pipe
D: DISASSEMBLY
1) Move the clamp and disconnect the evaporation
hose from the shut valve.
2) Remove the nut which holds the evaporation
pipe assembly to the fuel filler pipe.
3) Remove the shut valve from the fuel filler pipe.
<Ref. to EC(H4SO)-14, REMOVAL, Shut Valve.>
E: ASSEMBLY
1) Install the shut pipe to the fuel filler pipe. <Ref. to
EC(H4SO)-14, INSTALLATION, Shut Valve.>
2) Tighten the nuts which secure the evaporation
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
3) Connect the evaporation hose to the shut valve.
FU-02398
FU-02399
FU-02400
FU-02399
FU-02400
FU-02398
FU(H4SO)-53
Fuel Pump
24.Fuel Pump
A: REMOVAL
WARNING:
working area.
CAUTION:
When the fuel gauge pointer is at two third or
more, the fuel may spill out. Be sure to drain the
fuel before the operation.
NOTE:
Fuel pump assembly consists of fuel pump, fuel fil-
ter and fuel level sensor.
DURE, Fuel.>
2) Drain fuel. <Ref. to FU(H4SO)-41, DRAINING
FUEL (WITH SUBARU SELECT MONITOR),
PROCEDURE, Fuel.>
4) Remove the service hole cover.
6) Disconnect the quick connector, and then dis-
connect the fuel delivery hose and jet pump hose.
<Ref. to FU(H4SO)-59, REMOVAL, Fuel Delivery
7) Remove the nuts which install fuel pump assem-
bly onto fuel tank.
8) Remove the fuel pump assembly from the fuel
tank.
B: INSTALLATION
NOTE:
Use a new gasket.
Make sure the sealing portion is free from fuel or
foreign matter before installation.
When assembling, point the protrusion of the
gasket (A) towards the front of the vehicle.
Insert the protrusion (B) of the gasket into the up-
per plate. (3 locations)
Align the protrusion (C) of the fuel pump assem-
bly to the cut out in the upper plate.
Tighten the nuts to the specified torque in the or-
der as shown in the figure.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.2 ft-lb)
FU-02387
FU-02669
(A) Delivery hose
(B) Jet pump hose
FU-02670
(A)
(B)
FU-02835
1
2
3
4
5 6
7
8
(C)
(B)
(B)
(B)
(A)
FU(H4SO)-54
Fuel Pump
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.
WARNING:
Wipe off fuel completely.
Keep the battery as far apart from fuel pump
as possible.
Be sure to turn the battery supply to ON and
OFF on the battery side.
Do not run the fuel pump for a long time un-
der non-load condition.
FU-01330
2
4
6
1
3
5
FU(H4SO)-55
Fuel Level Sensor
25.Fuel Level Sensor
A: REMOVAL
WARNING:
working area.
CAUTION:
NOTE:
The fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(H4SO)-53, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack-
et.
3) Remove the fuel level sensor and fuel tempera-
ture sensor.
B: INSTALLATION
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.2 ft-lb)
(A) Connector
(B) Fuel temperature sensor
(C) Fuel level sensor
FU-02671
(A)
(B)
(C)
FU(H4SO)-56
Fuel Sub Level Sensor
26.Fuel Sub Level Sensor
A: REMOVAL
WARNING:
working area.
CAUTION:
Prior to start work, be sure to set the fuel vol-
ume to three-forth full of the fuel tank. If the fuel
is more than three-forth full of the fuel tank, be
careful because the fuel may spill out.
1) Drain fuel. <Ref. to FU(H4SO)-41, DRAINING
PROCEDURE, Fuel.>
(1) Remove bolt (A).
service hole cover.
4) Disconnect the connector from the fuel sub level
sensor.
5) Disconnect the quick connector, then disconnect
the fuel delivery hose and jet pump hose. <Ref. to
FU(H4SO)-59, REMOVAL, Fuel Delivery and
Evaporation Lines.>
6) Remove the nuts and bolts which install fuel sub
level sensor on fuel tank.
7) Remove the fuel sub level sensor.
B: INSTALLATION
NOTE:
Use a new gasket.
Align protrusion (A) of the gasket to the position
shown in the following figure.
Align protrusion (B) of the fuel sub level sensor to
the cut out in the fuel sublevel sensor upper plate.
Tighten the nuts and bolts to the specified torque
in the order as shown in the figure.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.2 ft-lb)
FU-01126
(B)
(A)
(A)
FU-02672
(A) Jet pump hose
(B) Delivery hose
FU-02673
(B)
(A)
FU-02836
1
6
5
2
4
3
(B)
(A)
FU-02674
FU(H4SO)-57
Fuel Filter
27.Fuel Filter
A: SPECIFICATION
Fuel filter forms a single unit with fuel pump.
Refer to Fuel Pump for removal and installation.
<Ref. to FU(H4SO)-53, REMOVAL, Fuel Pump.>
<Ref. to FU(H4SO)-53, INSTALLATION, Fuel
Pump.>
FU(H4SO)-58
Fuel Damper Valve
28.Fuel Damper Valve
A: REMOVAL
WARNING:
working area.
CAUTION:
or cloth.
DURE, Fuel.>
2) Remove the fuel damper valve from the fuel de-
livery line.
B: INSTALLATION
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
FU-02870
FU(H4SO)-59
Fuel Delivery and Evaporation Lines
29.Fuel Delivery and Evaporation Lines
A: REMOVAL
WARNING:
Place NO OPEN FLAMES signs near the working area.
CAUTION:
2) Release the fuel pressure. <Ref. to FU(H4SO)-41, 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-72, REMOVAL, Floor Mat.>
5) Disconnect the fuel delivery pipes and hoses, and then disconnect the evaporation pipes and hoses.
FU-02831
FU(H4SO)-60
6) In the engine compartment, disconnect the fuel
delivery hoses and evaporation hose.
(1) Disconnect the quick connector of the fuel
of the arrow.
CAUTION:
or cloth.
8) Remove the fuel tank. <Ref. to FU(H4SO)-43,
REMOVAL, Fuel Tank.>
9) Separate the quick connector of fuel line.
(1) Clean the pipe and connector, if they are
covered with dust.
(2) To prevent from damaging or entering for-
eign matter, wrap the pipes and connectors with
plastic bag etc.
(3) Hold the connector (A) and push the retainer
(B) down.
(4) Pull out the connector (A) from the retainer
(B).
B: INSTALLATION
1) Connect the quick connector on fuel line.
CAUTION:
Make sure there is no damage or dust on the
connections. If necessary, clean seal surface of
pipe.
NOTE:
Use a new retainer.
FU-02866
ST
FU-01333
(A) Connector
(B) Retainer
(C) Pipe
(A) Seal surface
(B) Pipe
FU-00124
( A )
( B )
( C )
FU-00125
( A )
( B )
FU(H4SO)-61
(1) Set the new retainer (B) to connector (A).
(2) Push the pipe into the connector completely.
CAUTION:
Pull the connector to ensure it is connected
securely.
Make sure the two retainer claws are en-
gaged in their mating positions in the connec-
tor.
Be sure to inspect hoses and their connec-
tions for any leakage of fuel.
2) Connect the fuel delivery hose to the pipe with
an overlap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When the amount to be inserted is speci-
fied.
Type B: When the amount to be inserted is not
specified.
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) Connect the evaporation hose to the pipe with
an overlap of approx. 15 to 20 mm (0.59 to 0.79 in).
Fuel evaporation hose:
L = 17.52.5 mm (0.6890.098 in)
C: INSPECTION
1) Make sure that there are no cracks on the fuel
pipes and fuel hoses.
2) Make sure the fuel pipe and fuel hose connec-
tions are tightened firmly.
(A) Connector
(B) Retainer
(C) Pipe
(A) Connector
(B) Retainer
(C) Pipe
FU-00126
( A )
( B )
( C )
FU-00127
( A )
( B )
( C )
(1) Type A
(2) Type B
(3) Pipe
(4) Clamp
(5) Hose
(1) Hose
(2) Clip
(3) Pipe
(3) (4) (5)
L
(1)
(2)
FU-00128
FU-00129
(1)
(2)
L/2
L
(3)
FU(H4SO)-62
Fuel System Trouble in General
30.Fuel System Trouble in General
A: INSPECTION
NOTE:
When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank.
Fill the fuel tank fully to prevent this.
In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below
0C (32F) throughout the winter season, use a 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.
Trouble and possible cause Corrective action
1. Insufficient fuel supply to injector
1) Fuel pump does not operate.
Defective terminal contact
Inspect contact, especially ground, and tighten it
securely.
Trouble in electromagnetic or electronic circuit parts Replace the faulty parts.
2) Decline of fuel pump function Replace the fuel pump.
3) Clogged fuel filter Replace the fuel filter.
4) Clogged or bent fuel pipe or hose Clean, correct or replace the fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent air breather tube or pipe Clean, correct or replace the air breather tube or pipe.
7) Damaged diaphragm of pressure regulator Replace.
2. Leakage or blow out of fuel
1) Loose joints of the fuel pipe Retighten.
2) Cracked fuel pipe, hose and fuel tank Replace.
3) Defective welding part on the fuel tank Replace.
4) Clogged air breather tube or air vent tube
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) Fuel saucer gasket air tightness fault Correct or replace the gasket.
3) Inoperative fuel pump modulator or circuit Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel level sensor Replace.
2) Defective operation of fuel meter Replace.
5. Noise
1) Large operation noise or vibration of fuel pump Replace.
EC(H4SO)-2
General Description
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
A: CAUTION
forming any work.
points.
battery.
B: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER TOOL NAME REMARKS
18353AA000 CLAMP PLIERS 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.
ST18353AA000
EC(H4SO)-3
Front Catalytic Converter
2. Front Catalytic Converter
A: REMOVAL
The front catalytic converter is integrated into the
front exhaust pipe; therefore, refer to Front Ex-
haust Pipe for the removal procedure. <Ref. to
EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
The front catalytic converter is integrated into the
front exhaust pipe; therefore, refer to Front Ex-
EX(H4SO)-5, INSTALLATION, Front Exhaust
Pipe.>
C: INSPECTION
1) Check the connections and welds for exhaust
leaks.
2) Check for hole or rust.
EC(H4SO)-4
Rear Catalytic Converter
3. Rear Catalytic Converter
A: REMOVAL
The rear catalytic converter is integrated into the
center exhaust pipe; therefore, refer to Center Ex-
EX(H4SO)-7, REMOVAL, Center Exhaust Pipe.>
B: INSTALLATION
The rear catalytic converter is integrated into the
center exhaust pipe; therefore, refer to Center Ex-
haust Pipe for the installation procedure. <Ref. to
EX(H4SO)-7, INSTALLATION, Center Exhaust
Pipe.>
C: INSPECTION
leaks.
EC(H4SO)-5
Canister
4. Canister
A: REMOVAL
3) Remove the rear wheel LH.
4) Remove the rear mud guard LH.
5) Disconnect quick connector (A).
6) Disconnect the drain valve connector (B).
7) Remove clip (C).
8) Remove the canister from body.
B: INSTALLATION
NOTE:
Check that there is no damage or dust on the quick
connector. If necessary, clean the seal surface of
the pipe.
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
C: INSPECTION
Make sure the canister and canister hoses are not
cracked or loose.
EC-02079
(A)
(A)
(C)
(B)
EC-02080
EC-02080
EC(H4SO)-6
Purge Control Solenoid Valve
5. Purge Control Solenoid Valve
A: REMOVAL
2) Disconnect the connector and evaporation hos-
es of purge control solenoid valve, and then re-
move the purge control solenoid valve.
B: INSTALLATION
Tightening torque (Purge control solenoid
valve attachment bolt):
19 Nm (1.9 kgf-m, 14.0 ft-lb)
NOTE:
Connect the evaporation hose as shown in the fig-
ure.
C: INSPECTION
Make sure the hoses are not cracked or loose.
IN-00203
EC-02253
(A) To fuel pipe (intake manifold)
(B) To fuel pipe (evaporation line)
EC-02253
(B)
(A)
EC-02254
EC(H4SO)-7
EGR Valve
6. EGR Valve
A: REMOVAL
For removal procedure, refer to FU section. <Ref.
to FU(H4SO)-27, REMOVAL, EGR Valve.>
B: INSTALLATION
For installation procedure, refer to FU section.
<Ref. to FU(H4SO)-27, INSTALLATION, EGR
Valve.>
EC(H4SO)-8
Fuel Level Sensor
7. Fuel Level Sensor
A: REMOVAL
to FU(H4SO)-55, REMOVAL, Fuel Level Sensor.>
B: INSTALLATION
<Ref. to FU(H4SO)-55, INSTALLATION, Fuel Lev-
el Sensor.>
EC(H4SO)-9
Fuel Temperature Sensor
8. Fuel Temperature Sensor
A: REMOVAL
The fuel temperature sensor is integrated into fuel
level sensor as one unit; therefore, refer to Fuel
Level Sensor for removal procedure. <Ref. to
FU(H4SO)-55, REMOVAL, Fuel Level Sensor.>
B: INSTALLATION
The fuel temperature sensor and fuel level sensor
are integrated into one unit; therefore, refer to Fuel
Level Sensor for installation procedure. <Ref. to
FU(H4SO)-55, INSTALLATION, Fuel Level Sen-
sor.>
EC(H4SO)-10
9. Fuel Sub Level Sensor
A: REMOVAL
to FU(H4SO)-56, REMOVAL, Fuel Sub Level Sen-
sor.>
B: INSTALLATION
<Ref. to FU(H4SO)-56, INSTALLATION, Fuel Sub
Level Sensor.>
EC(H4SO)-11
Fuel Tank Pressure Sensor
10.Fuel Tank Pressure Sensor
A: REMOVAL
WARNING:
working area.
filler cap.
5) Disconnect the connector from the fuel tank
pressure sensor.
6) Disconnect the pressure hose from the fuel tank
pressure sensor.
7) Remove the fuel tank pressure sensor along
with the bracket.
B: INSTALLATION
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
C: INSPECTION
IN-00203
EC-02084
EC-02084
EC(H4SO)-12
Pressure Control Solenoid Valve
11.Pressure Control Solenoid
Valve
A: REMOVAL
4) Disconnect connector (A) from the pressure con-
trol solenoid valve.
5) Disconnect the evaporation hose (B) from the
pressure control solenoid valve.
6) Remove the bolts (C) which secure the bracket
to the fuel tank.
7) Remove the pressure control solenoid valve and
bracket as a unit.
8) Remove the pressure control solenoid valve
from the bracket.
B: INSTALLATION
Tightening torque:
7.35 Nm (0.7 kgf-m, 5.4 ft-lb)
C: INSPECTION
IN-00203
(C)
(B)
EC-02086
(B)
(A)
EC-02087
EC(H4SO)-13
Drain Filter
12.Drain Filter
A: SPECIFICATION
Canister is a non-disassembled part, so do not re-
move the drain filter from canister.
Refer to Canister for removal and installation proce-
dure. <Ref. to EC(H4SO)-5, REMOVAL, Canister.>
<Ref. to EC(H4SO)-5, INSTALLATION, Canister.>
EC(H4SO)-14
Shut Valve
13.Shut Valve
A: REMOVAL
WARNING:
working area.
CAUTION:
1) Remove the fuel filler pipe.
<Ref. to FU(H4SO)-50, REMOVAL, Fuel Filler
Pipe.>
2) Disconnect the evaporation hose from the shut
valve.
B: INSTALLATION
Tightening torque:
4.5 Nm (0.46 kgf-m, 3.3 ft-lb)
C: INSPECTION
EC-02088
EC-02089
EC-02089
EC(H4SO)-15
Drain Valve
14.Drain Valve
A: SPECIFICATION
move the drain valve from canister.
Refer to Canister for removal and installation pro-
cedure. <Ref. to EC(H4SO)-5, INSTALLATION,
Canister.>
EC(H4SO)-16
PCV Hose Assembly
15.PCV Hose Assembly
A: REMOVAL
CAUTION:
Do not remove unless the PCV hose, diagnos-
tics connector and PCV valve are damaged.
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
B: INSTALLATION
NOTE:
Replace the clamp with a new part.
1) Install the PCV hose assembly, then lock by fit-
ting the ST on the clamp protrusion.
2) Install the air intake chamber. <Ref. to
ber.>
EC-02151
EC-02152
IN(H4SO)-2
General Description
INTAKE (INDUCTION)
A: COMPONENT
(19)
(18)
(15)
(10)
(11)
(12)
T1
(6)
(5)
(16)
(17)
(9)
(21)
(8)
T3
T3
T3
T2
(7)
(4)
(3)
(2)
(1)
(13)
(14)
(13)
T2
(14)
T4
T4
T4
T6
(9)
T5
(20)
IN-02263
IN(H4SO)-3
General Description
INTAKE (INDUCTION)
B: CAUTION
forming any work.
points.
the battery.
(1) Air intake duct (11) Intake boot (21) Mass air flow and intake air tem-
perature sensor
(2) Clip (12) Clamp
(3) Resonator chamber (13) Cushion
(4) Air cleaner case (front) (14) Spacer Tightening torque:Nm (kgf-m, ft-lb)
(5) Spacer (15) Air intake chamber T1: 6 (0.6, 4.4)
(6) Cushion (16) Stay LH (MT model) T2: 6.5 (0.66, 4.8)
(7) Air cleaner element (17) Stay LH (AT model) T3: 16 (1.6, 11.8)
(8) Air cleaner case (rear) (with HC
absorption filter : U5 model)
(18) Clamp T4: 3 (0.3, 2.2)
(19) Stay RH T5: 7.5 (0.76, 5.5)
(9) Clip (20) Cushion T6: 1 (0.1, 0.7)
(10) Clamp
IN(H4SO)-4
Air Cleaner Element
INTAKE (INDUCTION)
A: REMOVAL
2) Disconnect the connector from mass air flow and
intake air temperature sensor.
3) Remove the clip (A) securing upper side of air
cleaner case.
4) Pull the air cleaner case (rear) backward of the
vehicle, and remove the air cleaner element.
NOTE:
Be careful of the power steering hose fixed to the
bottom of the air cleaner case (rear).
B: INSTALLATION
CAUTION:
Be sure to use SUBARU genuine air cleaner el-
ement depending on the engine type when re-
placing the air cleaner elements. Otherwise
engine performance may be damaged.
NOTE:
case.
C: INSPECTION
1) Replace if excessively damaged or dirty.
2) Replace the air cleaner case (rear) if the HC ab-
sorption filter is damaged. (U5 model)
IN-00203
IN-02264
IN-02265
(A)
IN-02191
IN(H4SO)-5
Air Cleaner Case
INTAKE (INDUCTION)
3. Air Cleaner Case
A: REMOVAL
cleaner case and the intake boot.
5) Remove the clip (B) securing the upper side of
air cleaner case.
6) Remove the air cleaner case (rear) and air
cleaner element.
7) Remove the bolts (A) and nut (B) which secure
the air cleaner case to body.
8) Remove the air cleaner case (front).
IN-00203
IN-02264
IN-02266
(A)
(B)
IN-02192
IN-02216
(B)
(A)
IN(H4SO)-6
Air Cleaner Case
INTAKE (INDUCTION)
B: INSTALLATION
Tightening torque:
Bolt (A)
6 Nm (0.6 kgf-m, 4.4 ft-lb)
NUT (B)
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
NOTE:
case.
C: INSPECTION
Check for cracks or loose connections.
IN-02216
(B)
(A)
IN-02191
IN(H4SO)-7
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 intake
boot to air intake chamber.
3) Remove the bolt (C) which secures air intake
chamber to the stay.
4) Disconnect the connector (D).
5) Disconnect the blow-by hoses, and then remove
air intake chamber.
B: INSTALLATION
Tightening torque:
Clamp (A), (B)
3 Nm (0.3 kgf-m, 2.2 ft-lb)
Bolt (C)
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
C: INSPECTION
1) Check for cracks or loose connections.
2) Inspect that no foreign objects are mixed in the
air intake chamber.
IN-02141
(A)
(D)
(B)
(C)
(C)
IN-02142
(A)
(B)
(C)
(C)
IN(H4SO)-8
Air Intake Duct
INTAKE (INDUCTION)
5. Air Intake Duct
A: REMOVAL
1) Remove the clip which installs the air intake duct
on the front side of body.
2) Remove the air intake duct.
B: INSTALLATION
C: INSPECTION
2) Check that no foreign matter is mixed in air in-
take duct.
IN-02082
IN(H4SO)-9
Resonator Chamber
INTAKE (INDUCTION)
6. Resonator Chamber
A: REMOVAL
The resonator chamber and air cleaner case are in-
tegrated into one unit; therefore, refer to Air Clean-
er Case for the removal procedure. <Ref. to
IN(H4SO)-5, REMOVAL, Air Cleaner Case.>
B: INSTALLATION
er Case for the installation procedure. <Ref. to
IN(H4SO)-6, INSTALLATION, Air Cleaner Case.>
C: INSPECTION
IN(H4SO)-10
Resonator Chamber
INTAKE (INDUCTION)
ME(H4SO)-2
General Description
MECHANICAL
A: SPECIFICATION
NOTE:
US: Undersize OS: Oversize
Engine
Model 2.5 L
Cylinder arrangement
Valve system mechanism
Belt driven
Single overhead camshaft
4 valve/cylinder
Bore Stroke mm (in) 99.5 79.0 (3.917 3.110)
Piston displacement cm
3
(cu in) 2,457 (150)
Compression ratio 10.0
Compression pressure
(at 200 300 rpm)
kPa (kg/cm
2
, psi) 1,020 1,275 (10.4 13.0, 148 185)
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timing
Constant
Open BTDC 0
Close ABDC 58
Low
speed
Open BTDC 0
Close ABDC 10
High
speed
Open BTDC 14
Close ABDC 62
Exhaust valve timing
Open BBDC 30
Close ATDC 14
Valve clearance mm (in)
Intake 0.200.04 (0.00790.0016)
Exhaust 0.250.04 (0.00980.0016)
Idling speed [at neutral position on MT,
or P or N position on AT]
rpm
MT
650100 (No load)
850100 (A/C ON)
AT
700100 (No load)
850100 (A/C ON)
Ignition order 1 3 2 4
Ignition timing
BTDC/
rpm
MT 108/650
AT 158/700
ME(H4SO)-3
General Description
MECHANICAL
Belt tension
adjuster
Protrusion of adjuster rod mm (in) 5.2 6.2 (0.205 0.244)
Belt ten-
sioner
Spacer O.D. mm (in) 17.955 17.975 (0.7069 0.7077)
Tensioner bushing I.D. mm (in) 18.00 18.08 (0.7087 0.7118)
Clearance between spacer and
bushing
mm (in) Standard 0.025 0.125 (0.0010 0.0049)
Side clearance of spacer mm (in) Standard 0.20 0.55 (0.0079 0.0217)
Valve rocker
arm
Clearance between shaft and arm mm (in) Standard 0.020 0.054 (0.0008 0.0021)
Camshaft
Bending limit mm (in) 0.025 (0.0010)
Thrust clearance mm (in) Standard 0.030 0.090 (0.0012 0.0035)
Cam lobe
height
mm
(in)
Intake
Constant Standard 40.075 40.175 (1.5778 1.5817)
Low speed Standard 35.496 35.596 (1.3975 1.4014)
High speed Standard 40.315 40.415 (1.5872 1.5911)
Exhaust Standard 39.289 39.389 (1.5468 1.5507)
Camshaft journal O.D. mm (in) 31.928 31.945 (1.2570 1.2577)
Camshaft journal hole I.D. mm (in) 32.000 32.018 (1.2598 1.2605)
Oil clearance mm (in) Standard 0.055 0.090 (0.0022 0.0035)
Cylinder
head
Surface warpage limit
(Mating surface with cylinder block)
mm (in) 0.035 (0.0014)
Grinding limit mm (in) 0.1 (0.004)
Standard height mm (in) 97.5 (3.84)
Valve seat
Seating angle 90
Contacting width mm (in)
Intake Standard 0.8 1.4 (0.03 0.055)
Valve guide
Inside diameter mm (in) 6.000 6.012 (0.2362 0.2367)
Protrusion above head mm (in)
Intake 20.0 21.0 (0.787 0.827)
Exhaust 16.5 17.5 (0.650 0.689)
Valve
Head edge thickness mm (in)
Intake Standard 0.8 1.2 (0.03 0.047)
Stem outer diameter mm (in)
Intake 5.950 5.965 (0.2343 0.2348)
Exhaust 5.945 5.960 (0.2341 0.2346)
Valve stem gap mm (in) Standard
Intake 0.035 0.062 (0.0014 0.0024)
Exhaust 0.040 0.067 (0.0016 0.0026)
Overall length mm (in)
Intake 120.6 (4.75)
Exhaust 121.7 (4.79)
Valve spring
Free length mm (in) 55.2 (2.173)
Squareness 2.5, 2.4 (0.094) or less
Tension/
spring height
N (kgf, lb)/mm (in)
Set
235.3 270.7 (24 27.6, 52.9 60.8)/
45.0 (1.772)
Lift
578.9 639.9 (59.1 65.3, 130.3 143.9)/
34.7 (1.366)
Cylinder
block
Surface warpage limit (mating with cylinder head) mm (in) 0.025 (0.00098)
Cylinder inner diame-
ter
mm (in) Standard
A 99.505 99.515 (3.9175 3.9179)
B 99.495 99.505 (3.9171 3.9175)
Taper mm (in) Standard 0.015 (0.0006)
Out-of-roundness mm (in) Standard 0.010 (0.0004)
Piston clearance mm (in) Standard 0.010 0.010 (0.00039 0.00039)
Cylinder inner diameter boring limit (diameter) mm (in) To 100.005 (3.9372)
ME(H4SO)-4
General Description
MECHANICAL
Piston Outer diameter mm (in)
Standard
A 99.505 99.515 (3.9175 3.9179)
B 99.495 99.505 (3.9171 3.9175)
0.25 (0.0098) OS 99.745 99.765 (3.9270 3.9278)
0.50 (0.0197) OS 99.995 100.015 (3.9368 3.9376)
Piston pin
Clearance between piston and pis-
ton pin:
mm (in) Standard 0.004 0.008 (0.0002 0.0003)
Degree of fit
Piston pin must be fitted into position with
thumb at 20C (68F).
Piston ring
Ring closed gap mm (in)
Top ring Standard 0.20 0.35 (0.0079 0.0138)
Second ring Standard 0.37 0.52 (0.0144 0.0203)
Oil ring Standard 0.20 0.50 (0.0079 0.0197)
Ring groove gap mm (in)
Connecting
rod
Bend or twist per 100 mm (3.94 in)
in length
mm (in) Limit 0.10 (0.0039)
Bearing of
large end
Bearing size
(Thickness at center)
mm (in)
Standard 1.492 1.501 (0.0587 0.0591)
0.03 (0.0012) US 1.510 1.513 (0.0594 0.0596)
0.05 (0.0020) US 1.520 1.523 (0.0598 0.0600)
0.25 (0.0098) US 1.620 1.623 (0.0638 0.0639)
Bushing of
small end
Clearance between piston pin and bushing mm (in) Standard 0 0.022 (0 0.0009)
Crankshaft
Bend limit mm (in) 0.035 (0.0014)
Crank pin
Out-of-roundness mm (in) 0.003 (0.0001)
Cylindricality mm (in) 0.004 (0.0002)
Grinding limit (dia.) mm (in) To 51.750 (2.0374)
Crank journal
Crank pin outer
diameter
mm (in)
Standard 51.984 52.000 (2.0466 2.0472)
0.03 (0.0012) US 51.954 51.970 (2.0454 2.0461)
0.05 (0.0020) US 51.934 51.950 (2.0446 2.0453)
0.25 (0.0098) US 51.734 51.750 (2.0368 2.0374)
Crank journal outer
diameter
mm (in)
Standard 59.992 60.008 (2.3619 2.3625)
0.03 (0.0012) US 59.962 59.978 (2.3607 2.3613)
0.05 (0.0020) US 59.942 59.958 (2.3599 2.3605)
0.25 (0.0098) US 59.742 59.758 (2.3520 2.3527)
Main bearing
Main bear-
ing
mm
(in)
#1, #3
Standard 1.998 2.011 (0.0787 0.0792)
0.03 (0.0012) US 2.017 2.020 (0.0794 0.0795)
0.05 (0.0020) US 2.027 2.030 (0.0798 0.0799)
0.25 (0.0098) US 2.127 2.130 (0.0837 0.0839)
#2, #4, #5
Standard 2.000 2.013 (0.0787 0.0793)
0.03 (0.0012) US 2.019 2.022 (0.0795 0.0796)
0.05 (0.0020) US 2.029 2.032 (0.0799 0.0800)
0.25 (0.0098) US 2.129 2.132 (0.0838 0.0839)
ME(H4SO)-5
General Description
MECHANICAL
B: COMPONENT
1. TIMING BELT
(1) Timing belt cover No. 2 (RH) (9) Automatic belt tension adjuster
ASSY
Tightening torque:Nm (kgf-m, ft-lb)
(2) Timing belt guide (MT model) T1: 5 (0.5, 3.7)
(3) Crank sprocket (10) Belt idler No. 2 T2: 9.75 (1.0, 7.2)
(4) Timing belt cover No. 2 (LH) (11) Cam sprocket No. 2 T3: 24.5 (2.5, 18.1)
(5) Cam sprocket No. 1 (12) Timing belt T4: 39 (4.0, 28.8)
(6) Belt idler (No. 1) (13) Front timing belt cover T5: 78 (8.0, 57.5)
(7) Tensioner bracket (14) Timing belt cover (LH) T6: <Ref. to ME(H4SO)-40, INSTAL-
LATION, Crank Pulley.>
(8) Belt idler (No. 2) (15) Crank pulley
ME-03305
T5
T4
T1
T1
T6
T5
(5)
(6)
(8)
(9)
(11)
(10)
(14)
(15)
(12)
(13)
(7)
(4)
(1)
(2)
(3)
T1
T2
T1
T3
T4
T4
ME(H4SO)-6
General Description
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT
ME-03113
(17)
(21)
(10)
(11)
(30)
(19)
(28)
(27)
(29)
(12)
(13)
(14)
(15)
(16)
(18)
(3)
(31)
(8)
(5)
(1)
(2)
(3)
(4)
(8)
(8)
(6)
(7)
(26)
(24)
(23)
(22)
(7)
(10)
(19)
T2
T5
(5)
(9)
(20)
T4
T8
T7
(2)
T2
T5
T6
T1
T1
T8
T7
T3
T2
T3
T3
T4
T3
T4
T5
(25)
ME(H4SO)-7
General Description
MECHANICAL
(1) Rocker cover (RH) (17) O-ring (30) Variable valve lift diagnosis oil
pressure switch (LH)
(2) Intake valve rocker assembly (18) Rocker cover (LH)
(3) Exhaust valve rocker assembly (19) Stud bolt (31) Seal washer
(4) Camshaft cap (RH) (20) Rocker cover gasket (RH)
(5) Oil seal (21) Rocker cover gasket (LH) Tightening torque:Nm (kgf-m, ft-lb)
(6) Camshaft (RH) (22) Oil switching solenoid valve (RH) T1: <Ref. to ME(H4SO)-58, INSTAL-
LATION, Cylinder Head.>
(7) Plug (23) Oil switching solenoid valve holder
(RH)
(8) Spark plug pipe gasket T2: <Ref. to ME(H4SO)-50, INSTAL-
LATION, Valve Rocker Assem-
bly.>
(9) Cylinder head (RH) (24) Gasket
(10) Cylinder head gasket (25) Oil temperature sensor
(11) Cylinder head (LH) (26) Variable valve lift diagnosis oil
pressure switch (RH)
T3: 9.75 (1.0, 7.2)
(12) Camshaft (LH) T4: 18 (1.8, 13.3)
(13) Camshaft cap (LH) (27) Oil switching solenoid valve (LH) T5: 25 (2.5, 18.4)
(14) Oil filler cap (28) Oil switching solenoid valve holder
(LH)
T6: 6.4 (0.65, 4.7)
(15) Gasket T7: 8 (0.8, 5.9)
(16) Oil filler duct (29) Gasket T8: 10 (1.0, 7.4)
ME(H4SO)-8
General Description
MECHANICAL
3. VALVE ROCKER ASSEMBLY
(1) Intake valve rocker arm ASSY (4) Exhaust rocker shaft Tightening torque:Nm (kgf-m, ft-lb)
(2) Valve rocker nut (5) Exhaust valve rocker arm T1: 6 (0.6, 4.3)
(3) Valve rocker adjusting screw T2: 9.75 (1.0, 7.2)
T3: 25 (2.5, 18.4)
(2)
(2)
(3)
(3)
(1)
(5)
(4)
(1)
T2
T3
T2
T1
T2
T3
ME-02691
ME(H4SO)-9
General Description
MECHANICAL
4. CYLINDER HEAD AND VALVE ASSEMBLY
(1) Exhaust valve (4) Valve spring seat (7) Retainer
(2) Intake valve (5) Intake valve oil seal (8) Retainer key
(3) Valve guide (6) Valve spring (9) Exhaust valve oil seal
(2)
(2)
(6)
(6)
(3)
(3)
(4)
(4)
(5)
(9)
(7)
(8)
(7)
(8)
(1)
(1)
ME-03112
ME(H4SO)-10
General Description
MECHANICAL
5. CYLINDER BLOCK
ME-03307
(1)
(29)
(28)
(2)
(3)
(3)
(3)
(4)
(4)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(10)
(11)
(10)
(28)
(12)
(29)
(15)
(25)
(23)
(22)
T9
T10
T2
T2
T5
T6
T2
T2
T2
T4
T10
T2
T4
T4
T2
T10
T4
T5
T7
(13)
(24)
(26)
(28)
T1
T8
(17)
(18)
(19)
(20)
(30)
(21)
T2
(27)
T3
T2
(16)
(10)
(14)
T2
ME(H4SO)-11
General Description
MECHANICAL
(1) Oil pressure switch (16) Oil strainer Tightening torque:Nm (kgf-m, ft-lb)
(2) Cylinder block (RH) (17) Gasket T1: 5 (0.5, 3.7)
(3) Service hole plug (18) Oil pan T2: 6.4 (0.65, 4.7)
(4) Gasket (19) Drain plug T3: 10 (1.0, 7.4)
(5) Oil separator cover (20) Drain plug gasket T4: 25 (2.5, 18.4)
(6) Water by-pass pipe (21) Oil level gauge guide T5: <Ref. to ME(H4SO)-69, INSTAL-
LATION, Cylinder Block.>
(7) Oil pump (22) Water pump sealing
(8) Front oil seal (23) Oil filter T6: 16 (1.6, 11.8)
(9) Rear oil seal (24) Gasket T7: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(10) O-ring (25) Water pump hose
(11) Service hole cover (26) Plug T8: 44 (4.5, 32.5)
(12) Cylinder block (LH) (27) Seal T9: 45 (4.6, 33.2)
(13) Water pump (28) Seal washer T10: 70 (7.1, 51.6)
(14) Baffle plate (29) Washer
(15) Oil filter connector (30) O-ring
ME(H4SO)-12
General Description
MECHANICAL
6. CRANKSHAFT AND PISTON
(1) Flywheel (MT model) (8) Piston pin (15) Crankshaft bearing #1, #3
(2) Reinforcement (AT model) (9) Snap ring (16) Crankshaft bearing #2, #4
(3) Drive plate (AT model) (10) Connecting rod (17) Crankshaft bearing #5
(4) Top ring (11) Connecting rod bearing
(5) Second ring (12) Connecting rod cap Tightening torque:Nm (kgf-m, ft-lb)
(6) Oil ring (13) Crankshaft T1: 45 (4.6, 33.2)
(7) Piston (14) Woodruff key T2: 72 (7.3, 53.1)
ME-03292
T1
T1
(9)
(1)
(15)
(16)
(15)
(16)
(6)
(5)
(4)
(3)
(2)
(11)
(11)
(10)
(7)
(9)
(9)
(8)
(6)
(5)
(4)
(14)
(17)
(9)
(8)
(10)
(11)
(7)
(13)
(12)
T2
T2
(11)
(12)
ME(H4SO)-13
General Description
MECHANICAL
7. ENGINE MOUNTING
C: CAUTION
forming any work.
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 re-
installed 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 re-
quired, for protection.
Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
Lift up or lower the vehicle when necessary.
Make sure to support the correct positions.
(1) Front cushion rubber Tightening torque:Nm (kgf-m, ft-lb)
T1: 35 (3.6, 25.8)
T2: 75 (7.6, 55.3)
(1)
T2
T1
T1
T2
ME-02090
ME(H4SO)-14
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
18231AA010 CAM SPROCKET
WRENCH
Used for removing and installing cam sprocket.
CAMSHAFT SPROCKET WRENCH
(499207100) can also be used.
1B021XU0 SUBARU SELECT
MONITOR III KIT
Used for troubleshooting for 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
ST1B021XU0
ST-498267800
ST-498277200
ME(H4SO)-15
General Description
MECHANICAL
498457000 ENGINE STAND
ADAPTER RH
Used together with the ENGINE STAND
(499817100).
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)-16
General Description
MECHANICAL
499017100 PISTON PIN GUIDE Used for installing piston pin, piston and con-
necting rod.
499037100 CONNECTING ROD
BUSHING
REMOVER &
INSTALLER
Used for removing and installing connecting rod
bushing.
499587200 CRANKSHAFT OIL
SEAL INSTALLER
Used for installing crankshaft oil seal.
Used together with the CRANKSHAFT OIL
SEAL GUIDE (499597100).
499587500 OIL SEAL
INSTALLER
Used for installing the camshaft oil seal.
Used together with the 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)-17
General Description
MECHANICAL
499097700 PISTON PIN
REMOVER ASSY
Used for removing piston pin.
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 the camshaft oil seal.
Used together with the CAMSHAFT OIL SEAL
INSTALLER (499587500).
SEAL GUIDE
SEAL INSTALLER (499587200).
ST-499097700
ST-499497000
ST-499587100
ST-499597000
ST-499597100
ME(H4SO)-18
General Description
MECHANICAL
499718000 VALVE SPRING
REMOVER
499767200 VALVE GUIDE
REMOVER
Used for removing valve guides.
REAMER
Used for reaming valve guides.
ADJUSTER
Used for installing valve guides. (Intake side)
ADJUSTER
Used for installing valve guides. (Exhaust side)
ST-499718000
ST-499767200
ST-499767400
ST-499767700
ST-499767800
ME(H4SO)-19
General Description
MECHANICAL
499817100 ENGINE STAND Stand used for engine disassembly and
assembly.
ADAPTER RH (498457000) & LH (498457100).
499977100 CRANK PULLEY
WRENCH
Used to stop rotation of the crank pulley when
loosening or tightening crank pulley bolts.
SOCKET
Used for rotating crankshaft.
REMOVER
Used for removing the quick connector.
18354AA000 VALVE ROCKER
HOLDER
Used for installing the valve rocker assembly
(intake). (2-piece set)
ST-499817100
ST-499977100
ST-499987500
ST42099AE000
ST18354AA000
ME(H4SO)-20
General Description
MECHANICAL
2. GENERAL TOOL
E: PROCEDURE
It is possible to conduct the following service proce-
dures with engine on vehicle, however, the proce-
dures described in this section are based on the
condition that the engine is removed from vehicle.
V-belt
Timing belt
Valve rocker ASSY
Camshaft
Cylinder head
18258AA000 SPRING
INSTALLER
Used for installing the valve rocker assembly
(intake).
TOOL NAME REMARKS
Compression gauge Used for measuring compression.
Vacuum gauge Used for measuring vacuum pressure.
Oil pressure gauge Used for measuring engine oil pressure.
Fuel pressure gauge Used for measuring fuel pressure.
Timing light Used for measuring ignition timing.
ST18258AA000
ME(H4SO)-21
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measure-
ment.
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
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 perfor-
mance and operation.
7) Hold the compression gauge tightly against the
spark plug hole.
NOTE:
When using a screw-in type compression gauge,
the screw should be less than 18 mm (0.71 in) long.
8) Crank the engine by the starter motor, and read
the maximum value on the gauge when the needle
of gauge is steady.
9) Perform at least two measurements per cylinder,
and check that the values are correct.
Compression (throttle full open):
Standard
1,020 1,275 kPa (10.4 13.0 kgf/cm
2
,
148 185 psi)
Difference between cylinders
49 kPa (0.5 kgf/cm
2
, 7 psi), or less
10) After inspection, install the related parts in the
reverse order of removal.
ME-00192
ME(H4SO)-22
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
1) Before checking the idle speed, check the fol-
lowing 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) Read the engine idle speed using Subaru Select
Monitor. <Ref. to EN(H4SO)(diag)-35, READ CUR-
RENT DATA FOR ENGINE (NORMAL MODE),
OPERATION, Subaru Select Monitor.>
4) Check the idle speed when no-loaded. (Head-
light, heater fan, rear defroster, radiator fan, A/C
and etc. are OFF)
Idle speed [No load and gears in neutral, P or
N range]:
650100 rpm (MT model)
700100 rpm (AT model)
5) Check the idle speed when loaded. (Turn the A/
C switch to ON and operate the compressor for at
least one minute before measurement.)
Idle speed [A/C ON and gears in neutral, P or
N range]:
850100 rpm
NOTE:
Idle speed cannot be adjusted manually, because
the idle speed is automatically adjusted. If the pre-
scribed idle speed cannot be maintained, refer to
the General On-board Diagnosis Table under En-
gine Control System. <Ref. to EN(H4SO)(diag)-2,
Basic Diagnostic Procedure.>
ME(H4SO)-23
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
1) Before checking the ignition timing, check the
following item:
clogging, spark plugs are in good condition, and
hoses are connected properly.
not illuminate.
3) Stop the engine, and turn the ignition switch to
OFF.
4) Connect the timing light to #1 cylinder spark plug
cord, and then light the timing mark with the timing
light.
5) 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)
If the timing is not correct, check the ignition control
system. <Ref. to EN(H4SO)(diag)-2, Basic Diag-
nostic Procedure.>
ME-02676
20 10
ME(H4SO)-24
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 vac-
uum gauge indication.
By observing the gauge needle movement, the in-
ternal condition of the engine can be diagnosed as
described below.
Vacuum pressure (at idling, A/C OFF):
Less than 60.0 kPa (450 mmHg, 17.72 inHg)
ME-02694
Diagnosis of engine condition by measurement of intake manifold vacuum
Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten-
dency becomes more evident as engine temperature rises.
Air leakage around intake manifold gasket, disconnection or
damage of vacuum hose
2. Needle intermittently drops to position lower than normal
position.
Leakage around cylinder
3. Needle drops suddenly and intermittently from normal posi-
tion.
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)-25
Engine Oil Pressure
MECHANICAL
6. Engine Oil Pressure
A: INSPECTION
2) Remove the oil pressure switch. <Ref. to
LU(H4SO)-20, REMOVAL, Oil Pressure Switch.>
3) Connect the oil pressure gauge to cylinder block.
4) Connect the ground cable to battery.
5) Start the engine, and measure the oil pressure.
Oil pressure:
Standard
98 kPa (1.0 kg/cm
2
, 14 psi) or more at 600 rpm
294 kPa (3.0 kg/cm
2
, 43 psi) or more at 5,000 rpm
If the oil pressure is out of specification, check
the oil pump, oil filter and lubrication line. <Ref. to
LU(H4SO)-22, INSPECTION, Engine Lubrication
System Trouble in General.>
If the oil pressure warning light is ON and oil
pressure is within specification, check the oil pres-
sure switch. <Ref. to LU(H4SO)-22, INSPECTION,
Engine Lubrication System Trouble in General.>
NOTE:
Standard value is based on an engine oil tempera-
ture of 80C (176F).
6) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU(H4SO)-20, INSTAL-
LATION, Oil Pressure Switch.>
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
IN-00203
IN-00203
ME-00196
ME(H4SO)-26
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
CAUTION:
Before removing the fuel pressure gauge, re-
lease the fuel pressure.
or cloth.
NOTE:
Check or replace the fuel pump and fuel delivery
line if the fuel pressure is out of the standard.
2) Disconnect the fuel delivery hose from the fuel
damper, and connect the fuel pressure gauge.
4) Start the engine.
5) Measure the fuel pressure after warming up the
engine.
Fuel pressure:
Standard:
338 348 kPa (3.4 3.5 kg/cm
2
, 49 50 psi)
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kg/cm
2
, 1 to 3 psi) higher than standard val-
ues during high-altitude operations.
ME-03054
ME(H4SO)-27
Valve Clearance
MECHANICAL
8. Valve Clearance
A: INSPECTION
NOTE:
Inspection and adjustment of valve clearance
should be performed while engine is cold.
7) Remove the fuel injector. <Ref. to FU(H4SO)-
28, 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 the 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,
cover (LH).
cover (LH).
10) Set #1 cylinder piston to top dead center of
compression stroke by rotating the crank pulley
clockwise using the socket wrench.
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.
11) Measure #1 cylinder valve clearance by using
thickness gauge (A).
NOTE:
Insert the thickness gauge (A) in as horizontally
as possible with respect to the valve stem end face.
Lift up the vehicle and measure the exhaust
valve clearances.
Valve clearance:
Intake
0.200.04 mm (0.00790.0016 in)
Exhaust
0.250.04 mm (0.00980.0016 in)
12) If necessary, adjust the valve clearance. <Ref.
to ME(H4SO)-28, ADJUSTMENT, Valve Clear-
ance.>
IN-00203
ME-00199
ME-00200
( A)
ME-02696
(A)
ME(H4SO)-28
Valve Clearance
MECHANICAL
13) Measure the valve clearance in #3, #2 and #4
cylinder in the same measurement procedure as #1
cylinder in this order.
NOTE:
Be sure to set the cylinder pistons to their re-
spective 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.
B: ADJUSTMENT
NOTE:
Adjustment of valve clearance should be per-
formed while engine is cold.
1) Set #1 cylinder piston to top dead center of com-
pression stroke by rotating the crank pulley clock-
wise using the socket wrench.
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.
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 ob-
tained, tighten the valve rocker nut.
NOTE:
Insert a thickness gauge in a direction as hori-
zontal as possible with respect to the valve stem
end face.
Lift up the vehicle and adjust the exhaust valve
clearances.
Valve clearance:
Intake
0.200.04 mm (0.00790.0016 in)
Exhaust
0.250.04 mm (0.00980.0016 in)
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
3) Adjust the valve clearance in #3, #2 and #4 cyl-
inder in the same adjustment procedure as #1 cyl-
inder in this order.
NOTE:
Be sure to set the cylinder pistons to their re-
spective 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-00200
( A)
ME-00203
ME(H4SO)-29
Engine Assembly
MECHANICAL
9. Engine Assembly
A: REMOVAL
2) Open the front hood fully and support with the
front hood stay.
3) Collect the refrigerant from the A/C system.
<Ref. to AC-21, PROCEDURE, Refrigerant Recov-
ery Procedure.>
5) Disconnect the battery cable, and then remove
the battery from the vehicle body.
air intake chamber.
Case.> <Ref. to IN(H4SO)-7, REMOVAL, Air In-
take Chamber.>
8) Remove the radiator from the vehicle. <Ref. to
CO(H4SO)-18, REMOVAL, Radiator.>
9) Disconnect the A/C pressure hoses from A/C
compressor.
10) Remove the air intake chamber stay.
11) Disconnect the following connectors and ca-
bles.
(3) Engine ground terminal
(5) Generator connector and terminal
ME-00816
(A) Terminal
(B) Generator connector
FU-02734
(B)
(A)
ME-00206
ME-02697
ME-00818
(B)
(A)
ME(H4SO)-30
Engine Assembly
MECHANICAL
(6) A/C compressor connector
(7) Power steering switch connector
12) Disconnect the following hoses.
(1) Brake booster vacuum hose
(2) Heater inlet and outlet hoses
13) Remove the power steering pump.
(1) Remove the front side belts. <Ref. to
ME(H4SO)-37, FRONT SIDE BELT, REMOV-
AL, V-belt.>
(2) Remove the bolts which secure the power
steering pump to the bracket.
(3) Place the power steering pump on the right
side wheel apron.
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.
AT model
MT model
17) Remove the nuts which install front cushion
rubber onto front crossmember.
ME-00819
ME-03004
ME-02698
FU-00139
AT-00108
MT-00077
ME-02650
ME(H4SO)-31
Engine Assembly
MECHANICAL
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 con-
verter clutch to drive plate.
(4) Remove all bolts while turning the crank-
shaft with a socket wrench.
19) Remove the pitching stopper.
20) Disconnect the fuel hoses from fuel pipe.
(1) Disconnect the quick connector on the fuel
of the arrow.
CAUTION:
or cloth.
21) Support the engine with a lifting device and
wire ropes.
22) Support the transmission with a garage jack.
CAUTION:
Doing this is very important to prevent the
transmission from lowering due to its own
weight.
(A) Fuel delivery hose
ME-00212
ME-03187
FU-02715
(A)
(B)
(A) Transmission
(B) Garage jack
LU-00222
ME-00215
(B)
(A)
ME(H4SO)-32
Engine Assembly
MECHANICAL
23) Separation of engine and transmission.
CAUTION:
Before removing the engine away from trans-
mission, check to be sure no work has been
overlooked.
(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
(3) Remove the bolts which hold upper side of
transmission to engine.
AT model
MT model
24) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil level gauge, etc.
25) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the front cushion rubbers to engine.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
2) Apply a small amount of grease to splines of
main shaft. (MT model)
3) Position the engine in engine compartment and
align it with transmission.
NOTE:
4) Tighten the bolts which hold upper side of trans-
mission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
AT model
MT model
ST
ME-00217
AT-00106
MT-01524
AT-00106
MT-01524
ME(H4SO)-33
Engine Assembly
MECHANICAL
5) Remove the lifting device and wire ropes.
6) Remove the garage jack.
7) Install the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
8) Remove the ST from the torque converter clutch
case. (AT model)
NOTE:
Be careful not to drop the ST into the torque con-
verter clutch case when removing the ST.
9) Install the starter. <Ref. to SC(H4SO)-6, IN-
STALLATION, Starter.>
10) Install the torque converter clutch to drive plate.
(AT model)
(1) Tighten the bolts which hold torque convert-
er clutch to drive plate.
(2) Tighten other bolts while rotating the crank-
shaft using socket wrench.
NOTE:
Be careful not to drop bolts into the torque convert-
er clutch housing.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
(3) Install the service hole plug.
11) Install the power steering pump.
(1) Install the power steering pump to the bracket.
Tightening torque:
Refer to COMPONENT of Power Steering
for the tightening torque. <Ref. to PS-4, COM-
PONENT, General Description.>
(2) Connect the power steering switch connector.
(3) Install and adjust the front side belt. <Ref. to
ME(H4SO)-38, FRONT SIDE BELT, INSTAL-
LATION, V-belt.>
LU-00222
ME-03181
T2
T1
ME-00212
FU-00139
ME-03004
ME(H4SO)-34
Engine Assembly
MECHANICAL
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)
AT model
MT model
14) Tighten the nuts which install the front cushion
rubber onto crossmember.
NOTE:
Make sure the front cushion rubber mounting bolts
(A) and locator (B) are securely installed.
Tightening torque:
75 Nm (7.6 kgf-m, 55.3 ft-lb)
15) Install the front and center exhaust pipe.
<Ref. to EX(H4SO)-5, INSTALLATION, Front Ex-
haust Pipe.>
17) Connect the following hoses.
(1) Fuel delivery hose and evaporation hose
18) Connect the following connectors and termi-
nals.
19) Install the air intake chamber stay.
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
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-39, INSTALLATION, Hose and Tube.>
22) Install the radiator to vehicle. <Ref. to
CO(H4SO)-19, INSTALLATION, Radiator.>
23) Install the air intake duct, air cleaner case and
air intake chamber. <Ref. to IN(H4SO)-8, INSTAL-
LATION, Air Intake Duct.> <Ref. to IN(H4SO)-6,
INSTALLATION, Air Cleaner Case.> <Ref. to
ber.>
25) Install the battery in the vehicle, and connect
cables.
26) Fill engine coolant.
<Ref. to CO(H4SO)-12, FILLING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
27) Check the ATF level and replenish it if neces-
sary.
<Ref. to 4AT-28, INSPECTION, Automatic Trans-
mission Fluid.>
28) Charge the A/C system with refrigerant. <Ref.
to AC-22, PROCEDURE, Refrigerant Charging
Procedure.>
29) Remove the front hood stay, and close the front
hood.
30) Lower the vehicle from the lift.
C: INSPECTION
1) Check that pipes, hoses, connectors and clamps
are installed firmly.
2) Check the engine coolant is at specified level.
3) Check the ATF is at specified level. (AT model)
4) Start the engine and check for exhaust gas, en-
gine coolant, leaks of fuel, etc. Also check for noise
and vibrations.
AT-00108
MT-00077
ME-02651
(B) (A) (B) (A)
ME(H4SO)-35
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine unit. <Ref. to ME(H4SO)-29,
REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine as-
sembly.
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)-36
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
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 pre-
viously in order to do that particular procedure.
ME-00221
ST2
ST1
ST3
ME(H4SO)-37
V-belt
MECHANICAL
12.V-belt
A: REMOVAL
NOTE:
Perform the work with the engine installed to body
when replacing a single part.
1. FRONT SIDE BELT
2. REAR SIDE BELT
1) Remove the front side belts. <Ref. to
ME(H4SO)-37, FRONT SIDE BELT, REMOVAL,
V-belt.>
5) Remove the belt tensioner.
ME-03005
ME-02699
(B)
(C)
(A)
ME-00224
(A)
(B)
ME-00225
ME(H4SO)-38
V-belt
MECHANICAL
B: INSTALLATION
NOTE:
1. FRONT SIDE BELT
1) Install the front side belt (C), and tighten the slid-
er bolt so as to obtain the specified belt tension.
<Ref. to ME(H4SO)-39, INSPECTION, V-belt.>
Tightening torque:
Lock bolt (A)
25 Nm (2.5 kgf-m, 18.4 ft-lb)
Slider bolt (B)
8 Nm (0.8 kgf-m, 5.9 ft-lb)
2. REAR SIDE BELT
1) Install the belt tensioner.
2) Install the rear side belt, and tighten the slider
bolt (B) so as to obtain the specified belt tension.
Tightening torque:
Lock nut (A)
23 Nm (2.3 kgf-m, 17.0 ft-lb)
4) Install the front side belt. <Ref. to ME(H4SO)-38,
ME-02699
(B)
(C)
(A)
ME-00224
(A)
(B)
ME(H4SO)-39
V-belt
MECHANICAL
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)
or idler pulley installing position.
(A)
When installing new parts:
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)
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)
(A) Front side belt
(B) Rear side belt
C/P Crank pulley
GEN Generator
A/C Air conditioning compressor pulley
I/P Idler pulley
C/P
P/S
A/C
GEN
(A)
(B)
I/P
PM-00154
(A) Front side belt
(B) Rear side belt
(C) 98 N (10 kg, 22 lbf)
C/P Crank pulley
GEN Generator
I/P Idler pulley
ME-00226
(A) (B)
(C)
GEN
C/P
I/P
A/C
P/S
ME(H4SO)-40
Crank Pulley
MECHANICAL
13.Crank Pulley
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
2) Remove the crank pulley bolt. To lock the crank-
shaft, use ST.
B: INSTALLATION
1) Install the crank pulley.
2) Install the pulley bolt.
To lock the crankshaft, use ST.
(1) Clean the crankshaft thread using com-
pressed 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, 32.5 ft-lb).
(4) Tighten the crank pulley bolts.
Tightening torque:
180 Nm (18.4 kgf-m, 132.8 ft-lb)
3) Check that the tightening angle of the crank pul-
ley bolt is 65 or more. Perform the following proce-
dures when less than 65.
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
pressed air.
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.
4) Install the V-belts. <Ref. to ME(H4SO)-38, IN-
STALLATION, V-belt.>
C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. <Ref. to
ME(H4SO)-39, INSPECTION, V-belt.>
ME-00227
ST ST
ME-00227
ST ST
ME(H4SO)-41
Timing Belt Cover
MECHANICAL
14.Timing Belt Cover
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO)-
40, REMOVAL, Crank Pulley.>
4) Remove the front timing belt cover.
B: INSTALLATION
1) Install the front timing belt cover.
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
3) Install the crank pulley. <Ref. to ME(H4SO)-40,
INSTALLATION, Crank Pulley.>
C: INSPECTION
Check the cover for damage.
(A) Timing belt cover (LH)
(B) Front timing belt cover
(A) Timing belt cover (LH)
(B) Front timing belt cover
ME-00821
(A)
(B)
ME-00821
(A)
(B)
ME(H4SO)-42
Timing Belt
MECHANICAL
15.Timing Belt
A: REMOVAL
NOTE:
when replacing a single part. For operation proce-
dures, refer to Timing Belt in the PM section.
<Ref. to PM-17, Timing Belt.>
1. TIMING BELT
REMOVAL, V-belt.>
3) Remove the timing belt cover. <Ref. to
ME(H4SO)-41, REMOVAL, Timing Belt Cover.>
5) If the alignment mark (a) or arrow mark (which
indicates rotation direction) on the timing belt has
faded away, put new marks on the belt before re-
moving 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.
(2) Using white paint, put an alignment mark or
an arrow mark on timing belts in relation to the
crank sprocket and cam sprockets.
Z
1
: 46.8 teeth
Z
2
: 43.7 teeth
ME-00065
ME-00231
ST
(a) (b)
(c)
(d)
(e)
(f)
ME-02387
ME-02967
ME-02430
Z1 Z2
ME(H4SO)-43
Timing Belt
MECHANICAL
6) Remove the belt idler (A).
7) Remove the belt idler (B).
2. BELT IDLER AND AUTOMATIC BELT
TENSION ADJUSTER ASSEMBLY
1) Remove the belt idler (No. 1).
2) Remove the automatic belt tension adjuster as-
sembly.
B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUST-
ER ASSEMBLY AND BELT IDLER
1) Prepare for installation of automatic belt tension
adjuster assembly.
CAUTION:
Always use a vertical type pressing tool to
move the adjuster rod down.
Do not use a lateral type vise.
Push the adjuster rod vertically.
Press-in the push adjuster rod gradually tak-
ing three minutes or more.
Do not allow press pressure to exceed 9,807 N
(1,000 kgf, 2,205 lb).
Push in the adjuster rod to the end face of the
cylinder. However, do not push in the adjuster
rod below the end face of the cylinder. Doing so
may damage the cylinder.
Do not release the press pressure until stop-
per pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 165 N (16.8 kgf, 37.1 lb) or more un-
til the adjuster rod is aligned with the stopper
pin hole in the cylinder.
(3) With a 2 mm (0.08 in) dia. stopper pin or a
2 mm (0.08 in) (nominal) dia. hex wrench insert-
ed into the stopper pin hole in cylinder, secure
the adjuster rod.
ME-02968
(B)
(A)
ME-02388
ME-02404
ME-00238
ME-00239
ME-00350
ME(H4SO)-44
Timing Belt
MECHANICAL
2) Install the automatic belt tension adjuster as-
sembly.
Tightening torque:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
3) Install the belt idler (No. 1).
Tightening torque:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
2. TIMING BELT
1) Prepare for installation of the automatic belt ten-
sion adjuster assembly. <Ref. to ME(H4SO)-43, AU-
TOMATIC BELT TENSION ADJUSTER ASSEMBLY
AND BELT IDLER, INSTALLATION, Timing Belt.>
2) Align the mark (A) on crank sprocket with the
mark on oil pump cover at cylinder block.
3) Turn the cam sprocket No. 1 and No. 2 using the
ST1, and position the alignment marks (A) on each
at the highest positions.
ST1 18231AA010 CAM SPROCKET WRENCH
NOTE:
CAMSHAFT SPROCKET WRENCH (499207100)
can also be used.
4) While aligning the alignment mark (B) on timing
belt with the mark (A) on sprockets, position the
timing belt properly.
5) Install the belt idler (B).
Tightening torque:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
ME-00241
ME-02404
(A)
ME-00081
(A)
ME-02389
(A)
(A)
(B)
ME-02390
ME(H4SO)-45
Timing Belt
MECHANICAL
6) Install the belt idler (A).
Tightening torque:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
7) After ensuring the marks on timing belt and cam-
shaft sprockets are aligned, remove the stopper pin
from belt tension adjuster.
8) Install the timing belt guide. (MT model)
(1) Temporarily tighten the bolts mounting the
timing belt guide.
(2) Check and adjust the clearance between
timing belt and timing belt guide by using thick-
ness gauge.
Clearance:
1.00.5 mm (0.0390.020 in)
(3) Tighten the bolts mounting the timing belt
guide.
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
9) Install the timing belt cover.
<Ref. to ME(H4SO)-41, INSTALLATION, Timing Belt
Cover.>
ME-02968
(B)
(A)
ME-00245
ME-00230
ME-00246
ME-00247
ME(H4SO)-46
Timing Belt
MECHANICAL
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks or
wear. If any fault is found, replace the timing belt.
2) Check the condition on the back surface of the
timing belt. If cracks are found, replace the belt.
CAUTION:
Be careful not to let oil, grease or coolant
contact the timing 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
2. AUTOMATIC BELT TENSION ADJUSTER
1) Visually check the oil seals for leaks, and rod
ends for abnormal wear and scratches. If neces-
sary, 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 165 N (16.8 kgf, 37.1 lb) is applied to
it. This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 165 N (16.8 kgf, 37.1 lb), check it us-
ing 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 165 N (16.8 kgf, 37.1 lb) to
it. Check the adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new part.
CAUTION:
Press the adjuster rod gradually taking three
minutes or more.
(1,000 kgf, 2,205 lb).
cylinder. However, do not push in the adjuster
4) Measure the amount of rod protrusion H from
the end surface of the body. If it is not within spec-
ified range, replace with new part.
Amount of rod protrusion H:
5.2 6.2 mm (0.204 0.244 in)
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 ad-
juster assembly if faulty.
2) Check the belt tension pulley for smooth rota-
tion. 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 pul-
ley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
ME-00248
h
ME-00249
H
ME(H4SO)-47
Cam Sprocket
MECHANICAL
16.Cam Sprocket
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
4) Remove the timing belt. <Ref. to ME(H4SO)-42,
REMOVAL, Timing Belt.>
5) Remove the camshaft position sensor. <Ref. to
FU(H4SO)-22, REMOVAL, Camshaft Position
Sensor.>
6) Fasten the cam sprocket and remove from the
cam shaft using ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
can also be used.
B: INSTALLATION
1) Fasten the cam sprocket and install to the cam
shaft using ST.
NOTE:
can also be used.
Tightening torque:
78 Nm (8.0 kgf-m, 57.5 ft-lb)
NOTE:
Do not confuse left and right side cam sprockets
during installation. They should be distinguished by
the L or R indication.
2) Install the camshaft position sensor. <Ref. to
FU(H4SO)-22, INSTALLATION, Camshaft Position
Sensor.>
3) Install the timing belt. <Ref. to ME(H4SO)-43,
INSTALLATION, Timing Belt.>
<Ref. to ME(H4SO)-41, INSTALLATION, Timing
Belt Cover.>
C: INSPECTION
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 sen-
sor for damage and contamination of foreign mat-
ter.
ME-00250
ST
ME-00250
ST
ME(H4SO)-48
Crank Sprocket
MECHANICAL
17.Crank Sprocket
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
5) Remove the crank sprocket.
B: INSTALLATION
1) Install the crank sprocket.
Belt Cover.>
C: INSPECTION
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.
ME-00103
ME-00103
ME(H4SO)-49
Valve Rocker Assembly
MECHANICAL
18.Valve Rocker Assembly
A: REMOVAL
NOTE:
when replacing a single part. Refer to Valve Clear-
ance for preparation. <Ref. to ME(H4SO)-27,
Valve Clearance.>
REMOVAL, V-belt.>
5) Remove the cam sprocket. <Ref. to ME(H4SO)-
47, REMOVAL, Cam Sprocket.>
6) Disconnect the PCV hose and remove the rock-
er 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 ad-
juster pin.
ST 18258AA000 SPRING INSTALLER
(2) Remove the bolts (a) through (j) in alphabet-
ical sequence.
NOTE:
Leave two or three threads of bolts (i) and (j) en-
gaged in order to retain the valve rocker assembly.
(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
(A) Adjuster pin
(B) Spring stopper
(C) Spring
ME-02704
ST
ME-02744
(C)
(B)
(A)
(d)
(a) (j) (h)
(b)
(f)
(c)
(i) (g)
(e)
ME-02975
ME-02794
ST
ME(H4SO)-50
MECHANICAL
B: INSTALLATION
1) Install the valve rocker assembly.
(1) Temporarily tighten the bolts equally in al-
phabetical 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
(2) Tighten the bolts (a) through (h) to specified
torque.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
(3) Tighten the bolts (i) through (j) to specified
torque.
Tightening torque:
6 Nm (0.6 kgf-m, 4.3 ft-lb)
(4) Use the ST to rotate the spring stopper in
the direction of the arrow to fasten the adjuster
pin.
ST 18258AA000 SPRING INSTALLER
2) Install the cam sprocket. <Ref. to ME(H4SO)-47,
INSTALLATION, Cam Sprocket.>
4) Adjust the valve clearance. <Ref. to ME(H4SO)-
28, ADJUSTMENT, Valve Clearance.>
ME-02794
ST
ME-02703
(g)
(i) (a) (c)
(j)
(e)
(h)
(b) (d)
(f)
(A) Adjuster pin
(B) Spring stopper
(C) Spring
ME-02704
ST
ME-02705
(C)
(B)
(A)
ME(H4SO)-51
MECHANICAL
5) Install the rocker cover.
(1) Install the rocker cover gasket to the rocker
cover.
NOTE:
Use a new rocker cover gasket.
(2) Tighten the bolts in two stages in alphabeti-
cal sequence as shown in figure.
Tightening torque:
1st
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
2nd (only (a) and (b) are tightened)
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
RH side
LH side
6) Connect the PCV hose.
Belt Cover.>
C: DISASSEMBLY
NOTE:
Intake valve rocker assembly cannot be disassem-
bled.
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 ex-
haust valve rocker.
D: ASSEMBLY
NOTE:
Intake valve rocker assembly cannot be disassem-
bled.
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 identifica-
tion marks. Make sure the parts with same mark-
ings are properly assembled.
ME-02715
(a)
(b)
(c)
(d)
(e)
(f)
ME-02716
(a)
(b)
(c)
(d)
(e)
(f)
ME(H4SO)-52
MECHANICAL
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 con-
firm the difference (oil clearance) between the two
values.
Clearance between arm and shaft:
Standard
0.020 0.054 mm (0.0008 0.0021 in)
2) If the oil clearance exceeds the limit, replace the
valve rocker arm or shaft, whichever shows the
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.
ME-02706
ME-00257
ME(H4SO)-53
Camshaft
MECHANICAL
19.Camshaft
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).
NOTE:
Do not damage or lose the seal rubber when re-
moving the timing belt covers.
8) Remove the tensioner bracket.
9) Remove the camshaft position sensor support.
(LH side only)
10) Remove the valve rocker assembly. <Ref. to
ME(H4SO)-49, REMOVAL, Valve Rocker Assem-
bly.>
11) Remove the camshaft cap.
(1) Remove the bolts (a) and (b) in alphabetical
sequence.
(2) Equally loosen the bolts (c) through (j) all the
way in alphabetical sequence.
(3) Remove the bolts (k) through (p) in alpha-
betical sequence using ST.
ST 499497000 TORX
PLUS
(4) Remove the camshaft cap.
12) Remove the camshaft.
13) Remove the oil seal.
14) Remove the plug from rear side of camshaft.
CAUTION:
Do not scratch the journal surface when remov-
ing the oil seal.
15) Similarly, remove the camshafts (RH) and re-
lated parts.
ME-00258
ME-00259
ME-02707
(a)
(b)
ME-02708
(d)
(j)
(h)
(f)
(e)
(i)
(g)
(c)
ME-02709
(n) (p)
(l)
(o)
(m)
(k)
ME(H4SO)-54
Camshaft
MECHANICAL
B: INSTALLATION
1) Apply a thin coat of engine oil to camshaft jour-
nals, and install the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket to the mating surfaces of
camshaft cap.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. K0877Y0100)
NOTE:
Apply a coat of liquid gasket of 3 mm (0.12 in) in di-
ameter (A) along the edge (B) of camshaft cap (C)
mating surface.
(2) Temporarily tighten the bolts (a) through (d)
in alphabetical sequence.
(3) Install the valve rocker assembly.
<Ref. to ME(H4SO)-50, INSTALLATION, Valve
Rocker Assembly.>
(4) Tighten the TORX
bolts (e) through (j) in al-

phabetical sequence using the ST.
ST 499497000 TORX
PLUS
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(5) Tighten the bolts (k) through (r) in alphabet-
ical sequence.
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
(6) Tighten the bolts (s) and (t) in alphabetical
sequence.
NOTE:
Use a new seal washer.
Install and tighten the seal washer to the bolt.
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
ME-02710
ME-00265
(A)
(B)
(C)
ME-02711
(d)
(a)
(b)
(c)
ME-02712
(g) (e) (i)
(f)
(h)
(j)
ME-02713
(q)
(k)
(m)
(o)
(p)
(l)
(n)
(r)
ME-02714
(s)
(t)
ME(H4SO)-55
Camshaft
MECHANICAL
3) Apply a coat of engine oil to camshaft oil seal pe-
riphery and oil seal lips and install the oil seal (A) on
camshaft using ST1 and ST2.
NOTE:
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE
ST2 499587500 OIL SEAL INSTALLER
4) Apply a coat of engine oil to plug periphery and
Install the plug (A) using ST.
ST 499587700 CAMSHAFT OIL SEAL IN-
STALLER
5) Install the camshaft position sensor support. (LH
side only)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6) Similarly, install the parts on right-hand side.
7) Install the tensioner bracket.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
8) Install the timing belt cover No. 2 (RH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
9) Install the timing belt cover No. 2 (LH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
10) Install the cam sprocket. <Ref. to ME(H4SO)-
47, INSTALLATION, Cam Sprocket.>
12) Adjust the valve clearance. <Ref. to
ME(H4SO)-28, ADJUSTMENT, Valve Clearance.>
cover.
NOTE:
Tightening torque:
1st
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
RH side
LH side
(A)
ST2
ST1
ME-02596
ME-02717
ST
(A)
ME-00273
ME-00274
ME-02715
(a)
(b)
(c)
(d)
(e)
(f)
ME-02716
(a)
(b)
(c)
(d)
(e)
(f)
ME(H4SO)-56
Camshaft
MECHANICAL
Belt Cover.>
C: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if nec-
essary.
Service limit:
0.025 mm (0.00098 in)
2) Check the journal for damage and wear. Re-
place if faulty.
3) Measure the outer diameter of camshaft journal
and inner diameter of cylinder head journal, and
check the difference (oil clearance) between the
two values. If the oil clearance is not within the
standard, replace the camshaft or cylinder head as
necessary.
4) Check the cam face condition, and remove the
minor faults by grinding with oil stone. Measure the
cam height H. If it is not within the standard or offset
wear occurs, replace it.
Cam height H:
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
5) Measure the thrust clearance of camshaft with
setting the dial gauge at end of camshaft. If the
thrust clearance is not within the standard or there
is offset wear, replace the camshaft caps and cylin-
der head as a set. If necessary, replace the cam-
shaft.
Standard:
0.030 0.090 mm (0.0012 0.0035 in)
Unit: mm (in)
Oil clear-
ance
Standard 0.055 0.090 (0.0022 0.0035)
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-00275
Part Unit: mm (in)
Intake
Constant Standard
40.075 40.175
(1.5778 1.5817)
Low speed Standard
35.496 35.596
(1.3975 1.4014)
High speed Standard
40.315 40.415
(1.5872 1.5911)
Exhaust Standard
39.289 39.389
(1.5468 1.5507)
ME-00276
H
A
ME(H4SO)-57
Cylinder Head
MECHANICAL
20.Cylinder Head
A: REMOVAL
NOTE:
Valve Clearance.>
REMOVAL, V-belt.>
6) Remove the intake manifold. <Ref. to
FU(H4SO)-12, REMOVAL, Intake Manifold.>
7) Remove the bolt which installs the A/C compres-
sor bracket on cylinder head.
8) Remove the valve rocker assembly. <Ref. to
ME(H4SO)-49, REMOVAL, Valve Rocker Assem-
bly.>
9) Remove the camshaft. <Ref. to ME(H4SO)-53,
REMOVAL, Camshaft.>
10) Remove the oil level gauge guide. (LH side
only)
11) 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.
12) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block. Remove
the bolts (a) and (c) to remove cylinder head.
13) Remove the cylinder head gasket.
CAUTION:
Be careful not to scratch the mating surface of
cylinder head and cylinder block.
14) Similarly, remove the cylinder head (RH).
ME-02745
( c )
( b )
( f )
( d )
( a )
( e )
ME-02745
( c )
( b )
( f )
( d )
( a )
( e )
ME(H4SO)-58
Cylinder Head
MECHANICAL
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
CAUTION:
cylinder block and cylinder head.
NOTE:
Use a new cylinder head gasket.
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, 21.4 ft-lb)
in alphabetical order.
(4) Loosen all the bolts by 180 in the reverse order
of installing, and loosen them further by 180.
(6) Tighten all bolts by 80 to 90 in alphabetical or-
der.
(7) Tighten all bolts by 40 to 45 in alphabetical or-
der.
CAUTION:
The tightening angle of the bolt should not ex-
ceed 45.
(8) Further tighten the bolts (a) and (b) by 40
45.
CAUTION:
Make sure the total re-tightening angle of the
step (7) and (8) does not exceed 90.
3) Install the oil level gauge guide. (LH side only)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
4) Install the camshaft. <Ref. to ME(H4SO)-54, IN-
STALLATION, Camshaft.>
5) Install the valve rocker assembly. <Ref. to
ME(H4SO)-50, INSTALLATION, Valve Rocker As-
sembly.>
6) Install the A/C compressor bracket on cylinder
head.
<Ref. to FU(H4SO)-13, INSTALLATION, Intake
Manifold.>
8) Install the cam sprocket. <Ref. to ME(H4SO)-47,
ME(H4SO)-28, ADJUSTMENT, Valve Clearance.>
cover.
NOTE:
Tightening torque:
1st
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
RH side
LH side
Belt Cover.>
ME-02746
( c )
( b )
( f )
( d )
( a )
( e )
ME-02715
(a)
(b)
(c)
(d)
(e)
(f)
ME-02716
(a)
(b)
(c)
(d)
(e)
(f)
ME(H4SO)-59
Cylinder Head
MECHANICAL
C: DISASSEMBLY
1) Place the cylinder head on the ST.
ST 498267800 CYLINDER HEAD TABLE
2) Compress the valve spring and remove the
valve spring retainer key using ST. Remove each
valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
NOTE:
Keep all the removed parts in order for re-installing in their original positions.
Mark each valve to prevent confusion.
Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals.
D: ASSEMBLY
ME-00280
ST
(1) Valve (6) Retainer (11) Plug
(2) Valve guide (7) Retainer key (12) Camshaft cap
(3) Valve spring seat (8) Spark plug gasket (13) Valve rocker ASSY
(4) Oil seal (9) Camshaft (14) Seal washer
(5) Valve spring (10) Oil seal
ME-03110
(10)
(9)
(6)
(1)
(2)
(3)
(4)
(5)
(7)
(8)
(11)
(13)
(14)
(12)
ME(H4SO)-60
Cylinder Head
MECHANICAL
1) Install the valve spring and valve.
(1) Coat the stem of each valve with engine oil
and insert the valve into the valve guide.
NOTE:
When inserting the valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(2) Set the cylinder head on ST.
(3) Install the valve spring and retainer.
NOTE:
Be sure to install the valve spring with its close-
coiled end facing the seat on cylinder head.
(4) Set the ST on valve spring.
(5) Compress the valve spring and fit the valve
spring retainer key.
(6) After installing, tap the valve spring retainers
lightly with a plastic hammer for better seating.
E: INSPECTION
1. CYLINDER HEAD
1) Check for cracks or damage. Use liquid pene-
trant tester on the important sections to check for
fissures. Check that there are no marks of gas leak-
ing or water leaking on gasket installing surface.
2) Place the cylinder head on the ST.
3) Measure the warping of the cylinder head sur-
face that mates with cylinder block using a straight
edge (A) and thickness gauge (B).
If the warping exceeds the limit, correct the surface
by grinding it with a surface grinder.
Warping limit:
0.035 mm (0.0014 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder head:
97.5 mm (3.839 in)
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) Retainer key
(B) Valve spring
(C) Retainer
ME-00280
ST
ME-02816
(B)
(B)
(A)
(C)
(C)
ST
(A)
(B)
ME-00285
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 re-
placed.
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)
3. VALVE GUIDE
1) Check the clearance between valve guide and
valve stem. The clearance can be checked by mea-
suring 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:
Intake
0.035 0.062 mm (0.0014 0.0024 in)
Exhaust
0.040 0.067 mm (0.0016 0.0026 in)
W
W
(A) (B)
ME-00397
ME-00287
(A) Valve guide
ME-00763
(A)
ME-00289
X
Y
ME(H4SO)-62
Cylinder Head
MECHANICAL
2) If the clearance between valve guide and stem
exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide re-
placement.
Valve guide inner diameter:
6.000 6.012 mm (0.2362 0.2367 in)
Valve stem outer diameters:
Intake
5.950 5.965 mm (0.2343 0.2348 in)
Exhaust
5.945 5.960 mm (0.2341 0.2346 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides 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
(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
(4) Before installing a new valve guide, make
sure that neither scratches nor damages exist
on the inner surface of valve guide holes in cyl-
inder 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
(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)
(A) Valve guide
ME-00290
ST2
ST1
(A)
ME-00291
ST
(A) Valve guide
ST2
ME-00292
ST1
ME-00293
(A)
L
ME(H4SO)-63
Cylinder Head
MECHANICAL
(7) Ream the inside of valve guide using ST.
Put the ST in valve guide, and rotate the ST
slowly clockwise while pushing it lightly. Bring
the ST back while rotating it clockwise.
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 lus-
trous and the ST does not chip, use a new ST or
remedy the ST.
ST 499767400 VALVE GUIDE REAMER
(8) After reaming, clean the valve guide to re-
move chips.
(9) Recheck the contact condition between
valve and valve seat after replacing the valve
guide.
4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and stem of valve, and re-
place the valve with a new part if damaged, worn,
deformed, or if H is less than the specified limit.
Head edge thickness H:
Intake (A)
Standard:
0.8 1.2 mm (0.03 0.047 in)
Exhaust (B)
Standard:
1.0 1.4 mm (0.039 0.055 in)
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:
It is possible to differentiate between the intake
valve and the exhaust valve by their overall length.
Valve overall length:
Intake
120.6 mm (4.75 in)
Exhaust
121.7 mm (4.79 in)
ME-00294
ME-00758
H
H
(B)
(A)
ME(H4SO)-64
Cylinder Head
MECHANICAL
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.
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.
6. INTAKE AND EXHAUST VALVE OIL
SEAL
1) For the following, replace the oil seal with a new
part.
See the procedure 2) and subsequent for replace-
ment procedures.
When the lip is damaged.
When the spring is out of the specified position.
When readjusting the surfaces of valve and
valve seat.
When replacing the valve guide.
2) Place the cylinder head on ST1.
3) Using the ST2, press in the oil seal.
ST2 498857100 VALVE OIL SEAL GUIDE
NOTE:
Apply engine oil to oil seal before press-fitting.
When press-fitting the oil seal, do not use a ham-
mer or strike in.
The intake valve oil seal and exhaust valve oil
seal can be distinguished by colors.
Color of rubber part:
Intake [Gray]
Exhaust [Green]
Free length
mm
(in)
55.2 (2.173)
Tension/spring
height N (kgf,
lbf)/mm (in)
Set
235.3 270.7
(24 27.6, 52.9 60.8)/
45.0 (1.772)
Lift
578.9 639.9
(59.1 65.3, 130.3 143.9)/
34.7 (1.366)
Squareness 2.5, 2.4 mm (0.094 in) or less
ME-00283
ME-00284
ST1
ST2
ME(H4SO)-65
Cylinder Block
MECHANICAL
21.Cylinder Block
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely.
1) Remove the intake manifold. <Ref. to FU(H4SO)-
12, REMOVAL, Intake Manifold.>
2) Remove the V-belts. <Ref. to ME(H4SO)-37, RE-
MOVAL, V-belt.>
7) Remove the crank sprocket. <Ref. to
ME(H4SO)-48, REMOVAL, Crank Sprocket.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the cylinder head. <Ref. to ME(H4SO)-
57, REMOVAL, Cylinder Head.>
10) Remove the clutch disc and cover. (MT model)
<Ref. to CL-13, REMOVAL, Clutch Disc and Cov-
er.>
11) Remove the flywheel. (MT model) <Ref. to CL-
16, REMOVAL, Flywheel.>
12) Remove the drive plate. (AT model)
Using the ST, lock the crankshaft.
ST 498497100 CRANKSHAFT STOPPER
13) Remove the oil separator cover.
14) Remove the water by-pass pipe for heater.
15) Remove the water pump. <Ref. to CO(H4SO)-
14, REMOVAL, Water Pump.>
16) 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.
17) Remove the oil pump from cylinder block using
a flat tip screwdriver.
CAUTION:
cylinder block and oil pump.
18) Remove the front oil seal from the oil pump.
19) Remove the oil pan.
(1) Set the part so that the cylinder block (LH) is
on the upper side.
(2) Remove the bolts which secure oil pan to
cylinder block.
(3) Insert an oil pan cutter blade between cylin-
der block-to-oil pan clearance and remove the
oil pan.
CAUTION:
Do not use a screwdriver or similar tools in
place of oil pan cutter.
20) Remove the oil strainer stay.
21) Remove the oil strainer.
22) Remove the baffle plate.
23) Remove the oil filter. <Ref. to LU(H4SO)-21,
REMOVAL, Engine Oil Filter.>
ME-00298
LU-00015
ME-00138
ME(H4SO)-66
Cylinder Block
MECHANICAL
24) Remove the water pipe.
ME-00300
(1) Service hole plug (4) Piston pin (7) Seal washer
(2) Gasket (5) Service hole cover (8) Washer
(3) Snap ring (6) O-ring
ME-02889
(3)
(4)
(2)
(1)
(3)
(4)
(5)
(6)
(2)
(3)
(2)
(1)
(3)
(4)
(4)
(8)
(7)
(1)
ME(H4SO)-67
Cylinder Block
MECHANICAL
25) Remove the service hole plug using a hexagon
wrench (14 mm).
27) Rotate the crankshaft to bring #1 and #2 pis-
tons to bottom dead center position, then remove
the piston snap ring through service hole of #1 and
#2 cylinders.
28) 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.
29) Similarly draw out the piston pins from #3 and
#4 pistons.
30) Remove the cylinder block connecting bolt on
the RH side.
31) Loosen the cylinder block connecting bolt on
the LH side by 2-3 turns.
32) Set the part so that the cylinder block (LH) is on
the upper side, and remove the cylinder block con-
necting bolt.
ME-00140
ME-00141
ME-00142
ST
ME(H4SO)-68
Cylinder Block
MECHANICAL
33) Separate the cylinder block (RH) and (LH).
NOTE:
When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
34) Remove the rear oil seal.
35) Remove the crankshaft together with connect-
ing rod.
36) Remove the crankshaft bearings from cylinder
block using a hammer handle.
NOTE:
Be careful not to confuse the crankshaft bearing
combination. Press the bearing at the end opposite
to locking lip.
37) Remove each piston from cylinder block using
wooden bar or hammer handle.
NOTE:
of piston and cylinder.
(1) Cylinder block (4) Crankshaft bearing (6) Seal washer
(2) Rear oil seal (5) Piston (7) Washer
(3) Crankshaft
ME-02890
(2)
(3)
(4)
(4)
(5)
(6)
(5)
(1)
(1)
(7)
ME(H4SO)-69
Cylinder Block
MECHANICAL
B: INSTALLATION
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 O-ring on the cylin-
der block (RH).
3) Apply liquid gasket to the mating surfaces of cyl-
inder block (RH), and position the cylinder block
(LH).
NOTE:
Do not allow liquid gasket to jut into O-ring
grooves, oil passages, bearing grooves, etc.
Liquid gasket:
or equivalent
(1) Crankshaft bearing (4) Rear oil seal (6) Seal washer
(2) Crankshaft (5) O-ring (7) Washer
(3) Cylinder block
ME-03186
(4)
(1)
(3)
(6)
(6)
(7)
(7)
(3)
(2)
(5)
(6)
(7)
ME-00145
ME(H4SO)-70
Cylinder Block
MECHANICAL
4) Apply a coat of engine oil to the washer and bolt
thread.
NOTE:
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)
bolts on the RH side (E J) in alphabetical order.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
7) Tighten the LH side cylinder block connecting
bolts (A D) further in alphabetical order.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
8) Tighten the RH side cylinder block connecting
bolts (E J) further in alphabetical order.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A), (C): Angle tightening
Tightening angle:
90
(B), (D): Torque tightening
Tightening torque:
40 Nm (4.1 kgf-m, 29.6 ft-lb)
bolts (E J) in alphabetical order.
Tightening angle:
90
ME-02988
(A)
(B)
(D)
(C)
ME-02987
(E)
(F)
(I)
(J)
(G)
(H)
ME-02988
(A)
(B)
(D)
(C)
ME-02987
(E)
(F)
(I)
(J)
(G)
(H)
ME-02988
(A)
(B)
(D)
(C)
ME-02987
(E)
(F)
(I)
(J)
(G)
(H)
ME(H4SO)-71
Cylinder Block
MECHANICAL
11) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts on LH side (A H) in alphabetical se-
quence.
Tightening torque:
(A) (G): 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
12) Apply a coat of engine oil to the oil seal periph-
ery, then install the rear oil seal using ST1 and ST2.
NOTE:
Use new rear oil seal.
ST1 499597100 CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL IN-
STALLER
13) Position the top ring gap at (A) or (B) in the fig-
ure.
14) Position the second ring gap at 180 on the re-
verse side the top ring gap.
15) Position the upper rail gap at (C) in the figure.
16) Align the upper rail spin stopper (E) to the side
hole (D) on the piston.
17) Position the expander gap at (F) in the figure.
18) Position the lower rail gap at (G) in the figure.
NOTE:
Make sure ring gaps do not face the same direc-
tion.
Make sure ring gaps are not within the piston
skirt area.
(A) Rear oil seal
(B) Flywheel attaching bolt
ME-00147
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(A)
ME-00148
ST1
ST2
(B)
(A)
ME-02721
L H R H
(A) (B) (A) (B)
180 180
ME-02722
L H R H
(C)
(C)
25
25
ME-02471
(E) (D)
ME-02723
L H
(F)
(C)
R H
180
(F)
(C)
180
ME-02724
L H R H
(G)
(G)
(C)
(C)
120
120
ME(H4SO)-72
Cylinder Block
MECHANICAL
19) Install the snap ring.
Before installing the piston to the cylinder block, in-
stall the snap rings to the piston holes on the oppo-
site side of the service holes on the cylinder block.
NOTE:
Use new snap rings.
(A) Front side
ME-00306
#4
#3
#2
#1
(A)
(1) Piston (4) Gasket Tightening torque:Nm (kgf-m, ft-lb)
(2) Piston pin (5) Service hole plug T: 70 (7.1, 51.6)
(3) Snap ring
ME-02426
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
T
ME(H4SO)-73
Cylinder Block
MECHANICAL
20) Install the piston.
(1) Set the parts so that the #1 and #2 cylinders
are on the upper side.
(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 us-
ing ST2.
ST2 498747300 PISTON GUIDE
NOTE:
Face the piston front mark towards the front of the
engine.
21) Install piston pin.
(1) Apply a coat of engine oil to ST3.
(2) Insert ST3 into the service hole to align pis-
ton pin hole with connecting rod small end.
ST3 499017100 PISTON PIN 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.
(5) Apply liquid gasket to the threaded portion
of the service hole plug.
Liquid gasket:
equivalent
(A) Front mark
ME-00157
ST2
ST1
ME-02725
L H
(A)
R H
ME-00158
ST1
ST3
ME-00159
ME-00160
ME(H4SO)-74
Cylinder Block
MECHANICAL
(6) Install the water pump and gasket.
NOTE:
Use a new gasket.
are on the upper side. Following the same pro-
cedures as used for #1 and #2 cylinders, install
the pistons and piston pins.
(8) Install the service hole cover.
NOTE:
Use new O-rings.
ME-00140
(1) Piston (5) Service hole plug Tightening torque:Nm (kgf-m, ft-lb)
(2) Piston pin (6) Service hole cover T1: 6.4 (0.65, 4.7)
(3) Snap ring (7) O-ring T2: 70 (7.1, 51.6)
(4) Gasket
(1)
(2)
(3)
(1)
(2)
(6)
(3)
(7)
(4)
(5)
ME-02394
T2
T1
ME(H4SO)-75
Cylinder Block
MECHANICAL
22) Install the water pipe.
NOTE:
Use new O-rings.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
23) Install the baffle plate.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
24) Install the oil strainer.
NOTE:
Use new O-rings.
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
25) Install the oil strainer stay.
NOTE:
Tighten the oil strainer stay together with baffle
plate.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
26) Apply liquid gasket to the mating surfaces of
the oil pan, and install the oil pan.
NOTE:
Liquid gasket:
or equivalent
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
27) Apply liquid gasket to the mating surfaces of
the oil separator cover and the threaded portion of
bolt (A) shown in the figure (when reusing the bolt),
and then install the oil separator cover.
NOTE:
Use a new separator cover.
Liquid gasket:
Mating surface
THREE BOND 1217G (Part No.
K0877Y0100) or equivalent
(A) bolt threads (when reusing bolts)
equivalent
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
28) Install the flywheel. (MT model)
<Ref. to CL-16, INSTALLATION, Flywheel.>
29) Install the clutch disc and cover. (MT model)
<Ref. to CL-13, INSTALLATION, Clutch Disc and
Cover.>
30) Install the drive plate. (AT model)
To lock the crankshaft, use the ST.
Tightening torque:
72 Nm (7.3 kgf-m, 53.1 ft-lb)
ME-00300
ME-00162
ME-03333
(A)
ME-00298
ME(H4SO)-76
Cylinder Block
MECHANICAL
31) Install the oil pump.
(1) Using the ST, install the front oil seal.
ST 499587100 OIL SEAL INSTALLER
NOTE:
Use a new front oil seal.
(2) Apply liquid gasket to the matching surface
of oil pump.
NOTE:
Liquid gasket:
or equivalent
(3) Apply a coat of engine oil to the inside of oil
seal.
(4) Install the oil pump to cylinder block. Be
careful not to damage the oil seal during instal-
lation.
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 oil seals.
Do not forget to assemble O-rings.
(5) Apply liquid gasket to the three bolts thread
shown in figure. (when reusing bolts)
Liquid gasket:
equivalent
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
32) Install the water pump and gasket.
NOTE:
When installing the water pump, tighten bolts in
two stages in alphabetical order as shown in the
figure.
Use a new 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)
33) Install the water by-pass pipe for heater.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
34) Install the oil filter.
<Ref. to LU(H4SO)-21, INSTALLATION, Engine
Oil Filter.>
(A) O-ring
ME-00164
ME-00165
(A)
ME-00312
LU-02103
T
ME-02463
(F)
(E)
(D)
(C)
(B)
(A)
ME(H4SO)-77
Cylinder Block
MECHANICAL
35) Install the cylinder head. <Ref. to ME(H4SO)-
58, INSTALLATION, Cylinder Head.>
36) Install the camshaft. <Ref. to ME(H4SO)-54,
INSTALLATION, Camshaft.>
37) Install the valve rocker assembly. <Ref. to
ME(H4SO)-50, INSTALLATION, Valve Rocker As-
sembly.>
<Ref. to ME(H4SO)-48, INSTALLATION, Crank
Sprocket.>
39) Install the cam sprocket. <Ref. to ME(H4SO)-
41) Adjust the valve clearance. <Ref. to ME(H4SO)-
28, ADJUSTMENT, Valve Clearance.>
cover.
NOTE:
Tightening torque:
1st
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
RH side
LH side
Belt Cover.>
<Ref. to FU(H4SO)-13, INSTALLATION, Intake
Manifold.>
47) Install the generator and A/C compressor with
their brackets.
Tightening torque:
36 Nm (3.7 kgf-m, 26.6 ft-lb)
ME-02715
(a)
(b)
(c)
(d)
(e)
(f)
ME-02716
(a)
(b)
(c)
(d)
(e)
(f)
ME(H4SO)-78
Cylinder Block
MECHANICAL
C: DISASSEMBLY
1) Remove the connecting rod cap.
2) Remove the connecting rod bearing.
NOTE:
Keep the removed connecting rods, connecting rod
caps and bearings in order so that they are kept in
their original combinations/groups, and not mixed
together.
3) Remove the piston rings using piston ring ex-
pander.
4) Remove the oil ring by hand.
NOTE:
Arrange the removed piston rings in proper order,
to prevent confusion.
5) Remove the snap ring.
(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Snap ring
ME-02411
(2)
(2)
(6)
(5)
(4)
(3)
(1)
ME(H4SO)-79
Cylinder Block
MECHANICAL
D: ASSEMBLY
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) Position each connecting rod with the side with a
side mark facing forward, and install it.
3) Tighten the connecting rod cap with connecting
rod nut. Make sure the arrow mark on connecting
rod cap facing front during installation.
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.
Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
4) Install the oil ring upper rail, expander and lower
rail by hand.
5) Install the second ring and top ring using piston
ring expander.
NOTE:
Assemble so that the piston ring mark R faces the
top side of the piston.
(1) Connecting rod bearing (5) Second ring Tightening torque:Nm (kgf-m, ft-lb)
(2) Connecting rod (6) Top ring T: 45 (4.6, 33.2)
(3) Connecting rod cap (7) Snap ring
(4) Oil ring (8) Side mark
ME-03154
(2)
(4)
(5)
(6)
(1)
(1)
(7)
(8)
(3)
T
ME(H4SO)-80
Cylinder Block
MECHANICAL
E: INSPECTION
1. CYLINDER BLOCK
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.
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)
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the front
upper face of the cylinder block.
NOTE:
Measurement should be performed at a temper-
ature 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)
(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
(F) #4 cylinder bore size mark
ME-00170
#5
#4
#3
#2
#1
(A) (B)
(F)
(D)
A
B
A
B
5
4
5
4
(C) (E)
ME(H4SO)-81
Cylinder Block
MECHANICAL
2) Cylinder inner diameter measurement
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:
Measurement should be performed at a tempera-
ture of 20C (68F).
Taper:
Standard:
0.015 mm (0.0006 in)
Out-of-roundness:
Standard:
0.010 mm (0.0004 in)
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) Cylinder outer diameter measurement
Measure the outer diameter of each piston at the
height as shown in the figure. (Thrust direction)
NOTE:
ture of 20C (68F).
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)
0.50 mm (0.0197 in) oversize:
99.995 100.015 mm (3.9368 3.9376 in)
5) Calculate the clearance between cylinder and
piston.
NOTE:
ture of 20C (68F).
Cylinder to piston clearance at 20C (68F):
Standard:
0.010 0.010 mm (0.00039 0.00039 in)
(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)
ME-00171
(A) (B)
H2
H1
H3
H4
ME-00172
H
ME(H4SO)-82
Cylinder Block
MECHANICAL
6) Boring and honing
(1) If any of the measured value of taper, out-of-
roundness or cylinder-to-piston clearance is out
of standard or if there is any damage on the cyl-
inder wall, rebore it to replace with an oversize
piston.
CAUTION:
When any of the cylinders needs reboring, oth-
er cylinders must be bored at the same time,
and replaced with oversize pistons.
(2) If the cylinder inner diameter exceeds the
limit after boring and honing, replace the cylin-
der block.
NOTE:
Immediately after reboring, the cylinder diameter
may differ from its real diameter due to temperature
rise. Thus, when measuring the cylinder diameter,
wait until it has cooled to room temperature.
Cylinder inner diameter 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 dam-
age. Replace if faulty.
3) Make sure that the piston pin can be inserted
into the piston pin hole with a thumb at 20C (68F).
Replace if faulty.
Clearance between piston hole and piston pin:
Standard
0.004 0.008 mm (0.0002 0.0003 in)
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.
5) Check the piston pin snap ring for distortion,
cracks and wear.
4. PISTON RING
1) If the piston ring is broken, damaged and 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 the piston.
NOTE:
The top ring and second ring have the mark to
determine the direction to install on them. When in-
stalling them to piston, face this mark to the top
side.
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-00173
ME-00174
(A) Upper rail
(B) Expander
(C) Lower rail
ME-00175
(A)
ME-02472
(A)
(B)
(C)
(A)
(B)
(C)
ME(H4SO)-83
Cylinder Block
MECHANICAL
2) Squarely place the piston ring and oil ring in cyl-
inder using the piston, and measure the piston ring
gap with a thickness gauge.
3) Fit the piston ring straight into the piston ring
groove, then measure the clearance between pis-
ton ring and piston ring groove with a thickness
gauge.
NOTE:
Before measuring the clearance, clean the piston
ring groove and piston ring.
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)
3) Install the connecting rod fitted with bearing to
the crankshaft, and measure the thrust clearance
using a thickness gauge. If the thrust clearance ex-
ceeds the standard or uneven wear is found, re-
place the connecting rod.
Connecting rod thrust clearance:
Standard
0.070 0.330 mm (0.0028 0.0130 in)
4) Inspect the connecting rod bearing for scar,
peeling, seizure, melting, wear, etc.
Standard
mm (in)
Piston ring
gap
Top ring
0.20 0.35
(0.0079 0.0138)
Second
ring
0.37 0.52
(0.0144 0.0203)
Oil ring rail
0.20 0.50
(0.0079 0.0197)
Standard
mm (in)
Clearance
between pis-
ton ring and
piston ring
groove
Top ring
0.040 0.080
(0.0016 0.0031)
Second
ring
0.030 0.070
(0.0012 0.0028)
ME-00177
ME-00178
(A) Thickness gauge
(B) Connecting rod
( A)
( A)
( B)
( B)
ME-00179
ME-00180
ME(H4SO)-84
Cylinder Block
MECHANICAL
5) Measure the oil clearance on each connecting
rod bearing using plastigauge. If any oil clearance
is not within the standard, replace the defective
bearing with a new part of standard size or under-
size as necessary.
Connecting rod oil clearance:
Standard
0.016 0.044 mm (0.00063 0.0017 in)
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. If the measured value is not within
the standard, replace it with a new part.
Clearance between piston pin and bushing:
Standard
0 0.022 mm (0 0.0009 in)
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 BUSH-
ING REMOVER AND IN-
STALLER
(3) Make two 3 mm (0.12 in) holes in the
pressed bushing by aligning with the pre-manu-
factured holes on the connecting rod, and ream
the inside of the bushing.
(4) After completion of reaming, clean the bush-
ing to remove chips.
6. CRANKSHAFT AND CRANKSHAFT
BEARING
1) Clean the crankshaft completely, and check it for
cracks using liquid penetrant tester. If defective, re-
place the 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, using just the
#1 and #5 crankshaft bearings on cylinder block,
position the crankshaft on cylinder block. Then,
measure the crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
Unit: mm (in)
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
1.510 1.513
(0.0594 0.0596)
51.954 51.970
(2.0454 2.0461)
0.05
(0.0020)
Undersize
1.520 1.523
(0.0598 0.0600)
51.934 51.950
(2.0446 2.0453)
0.25
(0.0098)
Undersize
1.620 1.623
(0.0638 0.0639)
51.734 51.750
(2.0368 2.0374)
ME-00181
ME-00174
ME-00182
ST
ME-00183
ME(H4SO)-85
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 re-
place or grind to correct the crankshaft as neces-
sary. 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 (dia.)
To 51.750 mm (2.0374 in)
Crank journal:
Out-of-roundness
0.005 mm (0.0002 in)
Cylindricality
0.006 mm (0.0002 in)
To 59.758 mm (2.3527 in)
ME-00184
Unit: mm (in)
Crank journal outer diameter
Crank pin outer diameter
#1, #3 #2, #4, #5
Standard
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
1.998 2.011
(0.0787 0.0792)
2.000 2.013
(0.0787 0.0793)
1.492 1.501
(0.0587 0.0591)
0.03 (0.0012)
Undersize
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
2.017 2.020
(0.0794 0.0795)
2.019 2.022
(0.0795 0.0796)
1.510 1.513
(0.0594 0.0596)
0.05 (0.0020)
Undersize
Journal O.D.
59.942 59.958
(2.3599 2.3605)
59.942 59.958
(2.3599 2.3605)
51.934 51.950
(2.0446 2.0453)
Bearing size
2.027 2.030
(0.0798 0.0799)
2.029 2.032
(0.0799 0.0800)
1.520 1.523
(0.0598 0.0600)
0.25 (0.0098)
Undersize
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)
ME(H4SO)-86
Cylinder Block
MECHANICAL
4) Measure the thrust clearance of crankshaft at
center bearing by using thickness gauge. If the
thrust clearance is not within the standard, replace
the bearing.
Crankshaft thrust clearance:
Standard
0.030 0.115 mm (0.0012 0.0045 in)
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 is
out of standard, replace the defective bearing with
an undersize one, and replace or grind to correct
the crankshaft as necessary.
Crankshaft oil clearance:
Standard
0.010 0.030 mm (0.0004 0.0012 in)
ME-00322
ME(H4SO)-87
Oil Switching Solenoid Valve
MECHANICAL
22.Oil Switching Solenoid Valve
A: REMOVAL
1. RH SIDE
2) Remove the air intake chamber.
<Ref. to IN(H4SO)-7, REMOVAL, Air Intake Cham-
ber.>
bracket.
4) Disconnect the connector from the oil switching
solenoid valve.
5) Remove the oil switching solenoid valve.
sure switch.
<Ref. to FU(H4SO)-31, REMOVAL, Variable Valve
Lift Diagnosis Oil Pressure Switch.>
<Ref. to FU(H4SO)-32, REMOVAL, Oil Tempera-
ture Sensor.>
8) Remove the oil switching solenoid valve holder
from the cylinder head.
2. LH SIDE
2) Remove the V-belts.
<Ref. to ME(H4SO)-37, REMOVAL, V-belt.>
<Ref. to ME(H4SO)-40, REMOVAL, Crank Pul-
ley.>
4) Remove the timing belt cover.
<Ref. to ME(H4SO)-41, REMOVAL, Timing Belt
Cover.>
<Ref. to ME(H4SO)-42, REMOVAL, Timing Belt.>
6) Remove the cam sprocket.
<Ref. to ME(H4SO)-47, REMOVAL, Cam Sprock-
et.>
solenoid valve.
10) Remove the variable valve lift diagnosis oil
pressure switch.
<Ref. to FU(H4SO)-31, REMOVAL, Variable Valve
Lift Diagnosis Oil Pressure Switch.>
IN-00203
ME-02697
(A) Oil switching solenoid valve
(B) Variable valve lift diagnosis oil pressure switch
(C) Oil temperature sensor
(D) Oil switching solenoid valve holder
(E) Gasket
ME-02726
(C)
(D)
(E)
(A)
(B)
IN-00203
ME(H4SO)-88
MECHANICAL
B: INSTALLATION
1. RH SIDE
NOTE:
Use a new gasket.
Apply liquid gasket to variable valve lift diagnosis
oil pressure switch threads.
Install the oil switching solenoid valve to the
holder, then install it to the cylinder head.
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)
Liquid gasket
2. LH SIDE
NOTE:
Use a new gasket.
Apply liquid gasket to variable valve lift diagnosis
oil pressure switch threads.
Install the oil switching solenoid valve to the
holder, then install it to the cylinder head.
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)
Liquid gasket
(C) Oil switching solenoid valve holder
(D) Gasket
(C) Oil temperature sensor
(D) Oil switching solenoid valve holder
(E) Gasket
ME-02727
(C)
(D)
(A)
(B)
T2
T1
T4
T3
(C)
(D)
(E)
(A)
(B)
ME-03002
(C) Oil switching solenoid valve holder
(D) Gasket
(C)
(D)
(A)
(B)
T2
T1
T3
ME-03003
ME(H4SO)-89
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)-57, REMOVAL, Cylinder Head.> <Ref.
to ME(H4SO)-58, INSTALLATION, Cylinder Head.>
ME(H4SO)-90
Piston
MECHANICAL
24.Piston
A: SPECIFICATION
Refer to Cylinder Block for removal and installa-
tion procedures of pistons. <Ref. to ME(H4SO)-65,
REMOVAL, Cylinder Block.> <Ref. to ME(H4SO)-
69, INSTALLATION, Cylinder Block.>
ME(H4SO)-91
Connecting Rod
MECHANICAL
25.Connecting Rod
A: SPECIFICATION
tion procedures of connecting rod.
<Ref. to ME(H4SO)-65, REMOVAL, Cylinder Block.>
<Ref. to ME(H4SO)-69, INSTALLATION, Cylinder
Block.>
ME(H4SO)-92
Crankshaft
MECHANICAL
26.Crankshaft
A: SPECIFICATION
tion procedures of the crankshaft. <Ref. to
ME(H4SO)-65, REMOVAL, Cylinder Block.> <Ref. to
ME(H4SO)-69, INSTALLATION, Cylinder Block.>
ME(H4SO)-93
Engine Trouble in General
MECHANICAL
27.Engine Trouble in General
A: INSPECTION
NOTE:
The RANK shown in the chart shows the possibilities of the cause of trouble in order from Very often to
Rarely.
A Very often
B Sometimes
C Rarely
Symptoms Problem parts etc. Possible cause RANK
1. Engine does not start.
1) Starter does not turn. Starter Defective battery-to-starter harness B
Defective starter switch C
Defective inhibitor switch C
Defective starter B
Battery Improper connection of the terminal A
Run-down battery A
Defective charging system B
Friction Seizure of crankshaft and connecting rod bearing C
Seized camshaft C
Seized or stuck piston and cylinder C
2) Initial combustion does
not occur.
Starter Defective starter C
Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> A
Fuel line Defective fuel pump and relay A
Clogged fuel line B
Lack of or insufficient fuel B
Timing belt Degradation, etc. B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plug or defective gasket C
Loosened cylinder head bolt or defective gasket C
Improper valve sealing C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
ME(H4SO)-94
MECHANICAL
3) Initial combustion occurs. Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> A
Intake system Defective intake manifold gasket B
Defective throttle body gasket B
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Defective timing B
4) Engine stalls after initial
combustion.
Intake system Loosened or cracked intake duct B
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose C
Defective intake manifold gasket B
Dirty air cleaner element C
Fuel line Clogged fuel line C
Defective timing B
ME(H4SO)-95
MECHANICAL
2. Rough idle and engine
stall
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose A
Defective PCV valve C
Loosened oil filler cap B
Clogged fuel line C
Timing belt Defective timing C
Compression Incorrect valve clearance B
Loosened spark plug or defective gasket B
Loosened cylinder head bolt or defective gasket B
Improper valve sealing B
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing A
Lubrication system Incorrect oil pressure B
Defective rocker cover gasket C
Cooling system Overheating C
Others Evaporative emission control system malfunction A
Stuck or damaged throttle valve B
ME(H4SO)-96
MECHANICAL
3. Low output, hesitation and
poor acceleration
Loosened or cracked vacuum hose B
Defective PCV valve B
Dirty air cleaner element A
Fuel line Defective fuel pump and relay B
Clogged fuel line B
Lack of or insufficient fuel C
Timing belt Defective timing B
Over-cooling C
4. Surging Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> A
Dirty air cleaner element B
Clogged fuel line B
Worn or broken valve spring C
Cooling system Overheating B
Others Evaporative emission control system malfunction C
ME(H4SO)-97
MECHANICAL
5. Engine does not return to
idle.
Intake system Loosened or cracked vacuum hose A
Others Stuck or damaged throttle valve A
6. Dieseling (Run-on) Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> A
Others Evaporative emission control system malfunction B
7. After burning in exhaust
system
Intake system Loosened or cracked intake duct C
Loosened oil filler cap C
Lubrication system Incorrect oil pressure C
Cooling system Over-cooling C
8. Knocking Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> A
Intake system Loosened oil filler cap B
Cooling system Overheating A
9. Excessive engine oil con-
sumption
Intake system Loosened or cracked PCV hose A
Compression Defective valve stem A
Worn or stuck piston rings, cylinder and piston A
Lubrication system Loosened oil pump attaching bolts and defective gas-
ket
B
Defective oil filter gasket B
Defective crankshaft oil seal B
Defective rocker cover gasket B
Loosened oil drain plug or defective gasket B
Loosened oil pan fitting bolts or defective oil pan B
ME(H4SO)-98
MECHANICAL
10. Excessive fuel consump-
tion
Intake system Dirty air cleaner element A
ME(H4SO)-99
Engine Noise
MECHANICAL
28.Engine Noise
A: INSPECTION
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)-54, OPERATION, Clear Memory Mode.> and Inspection
Mode <Ref. to EN(H4SO)(diag)-44, PROCEDURE, Inspection Mode.> after connecting the fuel injector connector.
Type of sound Condition Possible cause
Regular clicking sound
Sound increases as engine
speed increases.
Valve mechanism is defective.
Incorrect valve clearance
Worn valve rocker
Worn camshaft
Broken valve spring
Heavy and dull clank
Oil pressure is low.
Worn crankshaft main bearing
Worn connecting rod bearing (large end)
Oil pressure is normal. Damaged engine mounting
High-pitched clank (Spark
knock)
Sound is noticeable when
accelerating with an overload
condition.
Ignition timing advanced
Accumulation of carbon inside combustion chamber
Wrong spark plug
Improper gasoline
Clank when engine speed is
1,000 to 2,000 rpm
Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*)
Knocking sound when engine
is operating under idling speed
and engine is warm
(NOTE*)
Worn cylinder liner and piston ring
Broken or stuck piston ring
Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is dis-
connected in turn. (NOTE*)
Worn cam sprocket
Worn camshaft journal bore in cylinder head
Squeaky sound Insufficient generator lubrication
Rubbing sound Poor contact of generator brush and rotor
Gear scream when starting
engine

Defective ignition starter switch
Worn gear and starter pinion
Sound like polishing glass with
a dry cloth

Loose V belt
Defective water pump shaft
Hissing sound
Insufficient compression
Air leakage in air intake system, hose, connection or manifold
Timing belt noise
Loose timing belt
Belt contacting with case/adjacent part
Valve noise Incorrect valve clearance
ME(H4SO)-100
Engine Noise
MECHANICAL
EX(H4SO)-2
General Description
EXHAUST
A: COMPONENT
T1
T1
T1
T1
T1
T5
T1
T1
T4
T4
(29)
(28)
(23)
(19) (17)
(16)
(10)
(11)
(14)
(13)
(15)
(24)
(30)
(27)
(26)
(25)
T2
(12)
T3
T1
T3
T7
T7
(5) (9)
(5)
(5)
(4)
(3)
(5)
(5)
(2)
(8)
(18)
(20)
(7)
(6)
(7)
(6)
(1)
(22)
T6
(22)
(21)
T1
EX-02221
EX(H4SO)-3
General Description
EXHAUST
B: CAUTION
forming any work.
points.
the battery.
If any fat adheres to the exhaust pipe, wipe it off.
Otherwise a fire may happen.
(1) Gasket (15) Center exhaust pipe rear lower
cover
(27) Front catalytic converter lower
cover
(2) Spring
(3) Chamber (16) Rear catalytic converter lower
cover
(28) Front exhaust pipe lower cover RH
(4) Rear exhaust pipe
(5) Cushion rubber (17) Center exhaust pipe front lower
cover
(29) Front exhaust pipe lower cover LH
(6) Self-locking nut (30) Band
(7) Gasket (18) Front oxygen (A/F) sensor
(8) Muffler (RH) (19) Front catalytic converter Tightening torque:Nm (kgf-m, ft-lb)
(9) Muffler (LH) (20) Rear oxygen sensor T1: 13 (1.3, 9.4)
(10) Center exhaust pipe front upper
cover
(21) Gasket T2: 18 (1.8, 13.3)
(22) Gasket T3: 21 (2.1, 15.5)
(11) Rear catalytic converter upper
cover
(23) Front exhaust pipe T4: 30 (3.1, 22.1)
(24) Front exhaust pipe upper cover LH T5: 35 (3.6, 25.8)
(12) Center exhaust pipe rear upper
cover
(25) Front exhaust pipe upper cover RH T6: 40 (4.1, 29.5)
(26) Front catalytic converter upper
cover
T7: 48 (4.9, 35.4)
(13) Center exhaust pipe
(14) Rear catalytic converter
EX(H4SO)-4
Front Exhaust Pipe
EXHAUST
2. Front Exhaust Pipe
A: REMOVAL
CAUTION:
Be careful not to burn yourself, because the ex-
haust pipe becomes extremely hot after run-
ning.
3) Unclip the clip fastening the harness and discon-
nect the following connectors.
5) Separate the center exhaust pipe from rear ex-
haust pipe.
7) Remove the nuts which hold front exhaust pipe
onto cylinder heads.
CAUTION:
Be careful not to pull down the front and center
exhaust pipe assembly.
8) Remove the bolt which holds center exhaust
pipe to hanger bracket.
9) Remove the front and center exhaust pipe as-
sembly from the vehicle.
CAUTION:
The front and center exhaust pipe assem-
blies are very heavy. Be careful not to drop the
exhaust pipes when removing.
After removing the front and center exhaust
pipe assemblies, do not pull on the rear ex-
haust pipe with excessive force.
10) Separate the front exhaust pipe from center ex-
haust pipe.
11) Remove the front oxygen (A/F) sensor and rear
oxygen sensor. <Ref. to FU(H4SO)-33, REMOV-
AL, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO)-35, REMOVAL, Rear Oxygen Sensor.>
IN-00203
FU-02734
(B)
(A)
EX-02121
EX-02122
EX-02123
EX-02124
EX(H4SO)-5
Front Exhaust Pipe
EXHAUST
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and rear ox-
ygen sensor to the front exhaust pipe. <Ref. to
FU(H4SO)-33, INSTALLATION, Front Oxygen (A/
F) Sensor.> <Ref. to FU(H4SO)-35, INSTALLA-
TION, Rear Oxygen Sensor.>
2) Install the front exhaust pipe to center exhaust
pipe.
NOTE:
Use a new gasket.
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
3) Install the front and center exhaust pipe assem-
bly to the vehicle.
NOTE:
Use a new gasket.
4) Temporarily tighten the nuts which hold front ex-
haust pipe to cylinder heads.
5) Tighten the bolt which holds the center exhaust
pipe to exhaust pipe.
NOTE:
Use a new gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
6) Tighten the bolt which holds center exhaust pipe
to hanger bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
7) Tighten the nuts which hold front exhaust pipe to
cylinder heads.
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
EX-02124
EX-02122
EX-02121
EX-02123
EX-02122
EX(H4SO)-6
Front Exhaust Pipe
EXHAUST
C: INSPECTION
leaks.
2) Make sure there are no holes or rusting.
FU-02734
(B)
(A)
IN-00203
EX(H4SO)-7
Center Exhaust Pipe
EXHAUST
3. Center Exhaust Pipe
A: REMOVAL
1) After removing the center and front exhaust
pipes as one unit, separate them. Refer to Front
Exhaust Pipe for the removal procedure. <Ref. to
oxygen sensor. <Ref. to FU(H4SO)-33, REMOV-
FU(H4SO)-35, REMOVAL, Rear Oxygen Sensor.>
B: INSTALLATION
ygen sensor. <Ref. to FU(H4SO)-33, INSTALLA-
TION, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO)-35, INSTALLATION, Rear Oxygen
Sensor.>
2) Install the center exhaust pipe and front exhaust
pipe as one unit. Refer to Front Exhaust Pipe for
the installation procedure. <Ref. to EX(H4SO)-5,
INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
leaks.
EX(H4SO)-8
Rear Exhaust Pipe
EXHAUST
4. Rear Exhaust Pipe
A: REMOVAL
CAUTION:
ning.
3) Separate the rear exhaust pipe from center ex-
haust pipe.
4) Separate the rear exhaust pipe from muffler.
CAUTION:
Be careful not to pull down the rear exhaust
pipe.
LH side
RH side
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.
7) Remove the rear exhaust pipe.
B: INSTALLATION
2) Install the rear exhaust pipe bracket to cushion
rubber.
NOTE:
After assembling, degrease the lubricant which
was applied to the cushion rubber while removing/
installing.
EX-02140
EX-00222
EX-00218
EX-00219
EX-00219
EX(H4SO)-9
Rear Exhaust Pipe
EXHAUST
3) Install the rear exhaust pipe to muffler.
NOTE:
Use a new gasket and self-locking nut.
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
LH side
RH side
4) Install the rear exhaust pipe to center exhaust
pipe.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
C: INSPECTION
leaks.
3) Check the cushion rubber for wear or crack.
EX-00222
EX-00218
EX-02140
EX(H4SO)-10
Muffler
EXHAUST
5. Muffler
A: REMOVAL
CAUTION:
ning.
3) Separate the muffler from rear exhaust pipe.
LH side
RH side
5) Remove the front and rear cushion rubber, and
then remove the muffler.
CAUTION:
Be careful not to drop the muffler during remov-
al.
LH side
RH side
B: INSTALLATION
NOTE:
installing.
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
LH side
RH side
C: INSPECTION
leaks.
EX-00222
EX-00218
EX-00220
EX-00221
EX-00222
EX-00218
CO(H4SO)-2
General Description
COOLING
A: SPECIFICATION
Cooling system Electric fan + Forced engine coolant circulation system
Total engine coolant capacity 2 (US qt, Imp qt)
MT: approx. 6.4 (6.8, 5.6)
AT: approx. 6.3 (6.7, 5.5)
Water pump
Type Centrifugal impeller type
Discharge
performance I
Discharge
rate
2 (US gal, Imp gal) /min. 20 (5.3, 4.4)
Pump speed Discharge pressure 760 rpm 2.9 kPa (0.3 mAq)
Engine coolant temperature 80C (176F)
Discharge
performance II
Discharge
rate
2 (US gal, Imp gal) /min. 100 (26.4, 22.0)
Pump speed Discharge pressure 3,000 rpm 49 kPa (5.0 mAq)
Discharge
performance III
Discharge
rate
2 (US gal, Imp gal) /min. 200 (52.8, 44.0)
Pump speed Discharge pressure 6,000 rpm 225.4 kPa (23 mAq)
Impeller diameter mm (in) 76 (2.99)
Number of impeller vanes 8
Pump pulley diameter mm (in) 60 (2.36)
Clearance between impeller
and case
Standard mm (in) 0.5 1.5 (0.020 0.060)
Thermostat
Type Wax pellet type
Starting temperature to open 80 84C (176 183F)
Fully opens 95C (203F)
Valve lift mm (in) 9.0 (0.354) or more
Valve bore mm (in) 35 (1.38)
Radiator fan
Motor input
Main fan 90 W
Sub fan 90 W
Fan diameter /
Blade
Main fan 300 mm (11.81 in)/4
Sub fan 300 mm (11.81 in)/5
Radiator
Type Down flow, pressure type
Core
dimensions
Width Height
Thickness
mm (in)
687.4 340 16
(27.06 13.39 0.63)
Pressure range in which cap
valve is open
kPa (kg/cm
2
, psi)
Above: 10815 or more
(1.10.15, 162)
Below: 1.0 to 4.9 or less
(0.01 0.05, 0.1 0.7)
Fins Corrugated fin type
Reservoir
tank
Capacity 2 (US qt, Imp qt) 0.45 (0.48, 0.40)
CO(H4SO)-3
General Description
COOLING
Coolant SUBARU coolant 000016218 Phosphoric acid (non-amine)
type
Water for dilution Distilled water Soft water or tap water
Cooling system protective
agent
Cooling system conditioner SOA345001 None
Vehicle speed A/C compressor load
Engine coolant temperature
Increase: 95C (203F)
or less
Decrease: 92C (198F)
or less
Increase: 96 99C
(205 210F)
Decrease: 93 94C
(199 201F)
or more
or more
Radiator fan operation Radiator fan operation Radiator fan operation
During acceleration:
19 km/h (12 MPH)
or less
During deceleration:
10 km/h (6 MPH)
or less
OFF OFF Low-Speed High-Speed
Low Low-Speed Low-Speed High-Speed
High High-Speed High-Speed High-Speed
20 69 km/h
(12 43 MPH)
11 64 km/h
(7 40 MPH)
Low High-Speed High-Speed High-Speed
70 105 km/h
(43 65 MPH)
65 103 km/h
(40 64 MPH)
Low OFF Low-Speed High-Speed
High Low-Speed High-Speed High-Speed
106 km/h (66 MPH)
or more
104 km/h (65 MPH)
or more
OFF OFF OFF High-Speed
Low OFF Low-Speed High-Speed
High OFF Low-Speed High-Speed
CO(H4SO)-4
General Description
COOLING
B: COMPONENT
1. WATER PUMP
(1) Water pump ASSY (5) Gasket Tightening torque:Nm (kgf-m, ft-lb)
(2) Gasket (6) Thermostat cover T1: First 12 (1.2, 8.9)
(3) Heater by-pass hose Second 12 (1.2, 8.9)
(4) Thermostat T2: 12 (1.2, 8.9)
CO-00265
(6)
(4)
(1)
(5)
(2)
T2
T1
T1
(3)
CO(H4SO)-5
General Description
COOLING
2. RADIATOR & RADIATOR FAN
(1) Radiator lower cushion (12) Radiator main fan shroud (22) O-ring
(2) Radiator (13) Radiator main fan, radiator main
fan motor ASSY
(23) Radiator lower bracket
(3) Radiator upper cushion (24) Radiator cap
(4) Radiator upper bracket (14) ATF hose clamp (AT model) (25) Heat shield cover
(5) Clamp (15) ATF hose A (AT model)
(6) Radiator hose A (16) ATF hose B (AT model) Tightening torque:Nm (kgf-m, ft-lb)
(7) Engine coolant reservoir tank cap (17) ATF pipe (AT model) T1: 5 (0.5, 3.7)
(8) Over flow hose (18) ATF hose C (AT model) T2: 7.5 (0.76, 5.5)
(9) Engine coolant reservoir tank (19) ATF hose D (AT model) T3: 12 (1.2, 8.9)
(10) Radiator sub fan shroud (20) Radiator hose B T4: 3.4 (0.35, 2.5)
(11) Radiator sub fan, radiator sub fan
motor ASSY
(21) Radiator drain plug T5: 3 (0.3, 2.2)
(7)
T2
T1
T1
T4
T4
T5
T3
T2
(1)
(2)
(3)
(4)
(5)
(5)
(5)
(5)
(6)
(9)
(10)
(13)
(12)
(11)
(20)
(21)
(22)
(23)
(24)
A
A
B
B
(14)
(14)
(16)
(15)
(17)
(18)
(19)
(14)
T2
T2
(8)
(25)
CO-02353
(14)
T2
CO(H4SO)-6
General Description
COOLING
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, in-
stallation, 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 bat-
tery.
D: PREPARATION TOOL
1. SPECIAL TOOL
WRENCH
Used to stop rotation of the crank pulley
when loosening or tightening crank pulley
bolts.
WRENCH
Used for removing and installing cam
sprocket.
CAM SPROCKET WRENCH (499207100)
can also be used.
ST-499977100
ST18231AA010
CO(H4SO)-7
Radiator Fan System
COOLING
2. Radiator Fan System
A: WIRING DIAGRAM
B136
F108 F16 B361
F17
F16
1
7
B360
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
F108
2 3 8
10
1
9
4
11 12 13 14 15 16
5 6 7
17 18
F27
B136
F36 F35 B143
F17
B361
1
7
2 3 4 5 6
8 9 10 11 12 13 14
F109
3 4 1 2 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
5 6 7
F27
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
3 1 2
7 4 5 6
16 7
12
2
2
1
9
1
8
1
1
1
2
2
0
2
1
1
0
1
3
E E
M
2
1
M
2
F109 B360
10 1
SBF-6 MAIN SBF
No.3
No.22
No.26
1
8
2
9
B: C: E:
ECM
No.4
BATTERY
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
20 21 22
19
18
3 4 5
7
6
10 11
12
13
15
16
17
14
2
1
9 8
E
6
E
5
C
1
0
B
7
MAIN FAN
RELAY 1
MAIN
FUSE BOX
(M/B)
B143 B:
F35 C:
F36 E:
2 1
CO-02319
MAIN FAN
MOTOR
SUB FAN MOTOR
SUB
FAN
RELAY
MAIN
FAN
RELAY
THROUGH JOINT CONNECTOR
RELAY
HOLDER
IGNITION SWITCH
THROUGH JOINT
CONNECTOR
CO(H4SO)-8
Radiator Fan System
COOLING
B: INSPECTION
DETECTING CONDITION:
Engine coolant temperature is 96C (205F) or more.
Vehicle speed is 19 km/h (12 MPH) or below.
TROUBLE SYMPTOMS:
Radiator main and sub fans do not rotate under the above conditions.
Step Check Yes No
1 CHECK OPERATION OF RADIATOR FAN.
1) Connect the test mode connector.
3) Using the Subaru Select Monitor, check the
forced operation of the radiator fan relay.
NOTE:
When performing a forced operation radiator
fan relay check using the Subaru Select Moni-
tor, the radiator main fan and sub fan will repeat
low speed revolution high speed revolution
OFF in this order.
Subaru Select Monitor
Refer to Compulsory Valve Operation Check
Mode for detailed procedures. <Ref. to
EN(H4SO)(diag)-55, Compulsory Valve Opera-
tion Check Mode.>
Do the radiator main and sub
fans rotate at low speed?
Go to step 2. Go to step 3.
NOTE:
OFF in this order.
Mode for detailed procedures. <Ref. to
tion Check Mode.>
fans rotate at high speed?
Radiator main fan
system is normal.
Go to step 27.
3 CHECK POWER SUPPLY TO SUB FAN RE-
LAY.
2) Remove the sub fan relay from the relay
holder.
3) Measure the voltage between the sub fan
relay terminal and chassis ground.
Connector & terminal
(F27) No. 10 (+) Chassis ground ():
Is the voltage 10 V or more? Go to step 4. Go to step 5.
LAY.
5 CHECK FUSE.
2) Remove the fuse No. 3.
3) Check the condition of fuse.
Is the fuse blown out? Replace the fuse. Repair the power
supply line.
CO(H4SO)-9
Radiator Fan System
COOLING
6 CHECK FUSE.
supply line.
7 CHECK SUB FAN RELAY.
2) Measure the resistance between sub fan
relay terminals.
Terminal
No. 10 No. 11:
Is the resistance 1 M or
more?
Go to step 8. Replace the sub
fan relay.
1) Connect the sub fan relay terminals No. 13
and No. 12 to the battery.
relay terminals.
Terminal
No. 10 No. 11:
Is the resistance less than 1 ? Go to step 9. Replace the sub
fan relay.
9 CHECK HARNESS BETWEEN SUB FAN RE-
LAY TERMINAL AND SUB FAN MOTOR
CONNECTOR.
1) Disconnect the connector from the sub fan
motor.
2) Measure the resistance of harness between
the sub fan relay terminal and sub fan motor
connector.
(F16) No. 2 (F27) No. 11:
Is resistance less than 1 ? Go to step 10. Repair the open
circuit of harness
between sub fan
relay terminal and
sub fan motor con-
nector.
10 CHECK HARNESS BETWEEN SUB FAN MO-
TOR CONNECTOR AND MAIN FAN RELAY 2
CONNECTOR.
1) Remove the main fan relay 2 from the relay
holder.
sub fan motor connector and main fan relay 2
connector.
(F16) No. 1 (F27) No. 18:
circuit of the har-
ness between sub
fan motor connec-
tor and main fan
relay 2 connector.
11 CHECK POOR CONTACT.
Check poor contact of sub fan motor connector.
Is there poor contact in the sub
fan motor connector?
Repair the poor
contact of sub fan
motor connector.
Go to step 12.
12 CHECK SUB FAN MOTOR.
Connect the battery positive (+) terminal to ter-
minal No. 2 of the sub fan motor, and the ground
() terminal to terminal No. 1.
Does the sub fan rotate? Go to step 13. Replace the sub
fan motor.
13 CHECK MAIN FAN RELAY 2.
Measure the resistance of main fan relay 2.
Terminal
No. 21 No. 18:
Is resistance less than 1 ? Go to step 14. Replace the main
fan relay 2.
14 CHECK HARNESS BETWEEN MAIN FAN
RELAY 2 AND MAIN FAN MOTOR CONNEC-
TOR.
1) Disconnect the connector from the main fan
motor.
2) Measure the resistance of the harness
between main fan relay 2 terminal and main fan
motor connector.
(F17) No. 2 (F27) No. 21:
circuit of the har-
ness between
main fan relay 2
terminal and main
fan motor connec-
tor.
Step Check Yes No
CO(H4SO)-10
Radiator Fan System
COOLING
15 CHECK MAIN FAN MOTOR AND GROUND
CIRCUIT.
Measure the resistance between main fan
motor connector and chassis ground.
(F17) No. 1 Chassis ground:
circuit of the har-
ness between
main fan motor
connector and
chassis ground.
Check poor contact of main fan motor connec-
tor.
Is there poor contact in the
main fan motor connector?
Repair the poor
contact of main fan
motor connector.
Go to step 17.
17 CHECK MAIN FAN MOTOR.
minal No. 2 of the main fan motor, and the
ground () terminal to terminal No. 1.
Does the main fan rotate? Go to step 18. Replace the main
fan motor.
LAY AND ECM.
1) Disconnect the connectors from the ECM.
2) Measure the resistance between the sub
fan relay terminal and ECM connector.
(B136) No. 18 (F27) No. 12:
circuit of harness
between sub fan
relay terminal and
ECM.
Check for poor contact of the ECM connector.
Is there poor contact in ECM
connector?
Repair poor con-
tact in ECM con-
nector.
Check the DTC.
Repair the trouble
cause. <Ref. to
EN(H4SO)(diag)-
43, Read Diagnos-
tic Trouble Code
(DTC).>
2) Remove main fan relay 1 from the main fuse
box.
3) Measure the resistance of terminal in main
fan relay 1 switch.
more?
Go to step 21. Replace the main
fan relay 1.
1) Connect the main fan relay 1 coil side termi-
nal to the battery.
2) Measure the resistance between terminals
of main fan relay 1 switch.
Is the resistance less than 1 ? Go to step 22. Replace the main
fan relay 1.
TOR.
motor.
motor connector.
(F17) No. 2 (F36) No. 6:
circuit of the har-
ness between
main fan relay 1
terminal and main
fan motor connec-
tor.
RELAY 1 AND ECM.
2) Measure the resistance between main fan
relay 1 terminal and ECM connector.
(B136) No. 29 (B143) No. 7:
Is the resistance less than 1 ? Go to step 24. Repair the open
circuit of the har-
ness between
main fan relay 1
terminal and ECM.
Step Check Yes No
CO(H4SO)-11
Radiator Fan System
COOLING
RELAY 2 AND ECM.
Measure the resistance between main fan relay
2 terminal and ECM connector.
(B136) No. 29 (F27) No. 22:
circuit of the har-
ness between
main fan relay 2
terminal and ECM.
25 CHECK FUSE.
2) Remove the fuse No. 4 and 26.
Is the fuse blown out? Replace the fuse. Go to step 26.
connector?
Repair the poor
contact of the ECM
connector.
Repair the power
supply circuit to the
main fuse box.
If the both fans do not rotate at high speed in the
condition of step 2, check whether the sub fan is
rotating.
Does the sub fan rotate? Go to step 20. Go to step 28.
28 CHECK GROUND CIRCUIT OF MAIN FAN
RELAY 2.
1) Remove the main fan relay 2 from A/C relay
holder.
relay 2 terminal and chassis ground.
circuit of harness
between main fan
relay 2 and chassis
ground.
29 CHECK POWER SUPPLY TO MAIN FAN RE-
LAY 2.
2) Measure the voltage between main fan
Is the voltage 10 V or more? Go to step 30. Repair the power
supply line.
2) Remove the main fan relay 2.
3) Measure the resistance of main fan relay 2.
Terminal
(F27) No. 18 (F27) No. 19:
more?
fan relay 2.
1) Connect the battery to main fan relay 2 ter-
minals No. 20 and No. 22.
Terminal
(F27) No. 18 (F27) No. 19:
fan relay 2.
Step Check Yes No
CO(H4SO)-12
Engine Coolant
COOLING
3. Engine Coolant
A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
into container.
NOTE:
Remove the radiator cap so that engine coolant will
drain faster.
4) Install the drain plug.
2. FILLING OF ENGINE COOLANT
er neck.
Refer to SPECIFICATION for the cooling
system protective agent. <Ref. to CO(H4SO)-
2, SPECIFICATION, General Description.>
2) Pour engine coolant into the radiator up to the
filler neck position.
Refer to SPECIFICATION for the recom-
mended engine coolant. <Ref. to CO(H4SO)-
Coolant level:
mended engine coolant. <Ref. to CO(H4SO)-
FULL level.
4) Close the radiator cap and start the engine.
Race 5 to 6 times at 3,000 rpm or less, then stop
the engine. (Complete this operation within 40 sec-
onds.)
5) Wait for one minute after the engine stops, open
the radiator cap. If the engine coolant level drops,
add engine coolant into radiator up to the filler neck
position.
7) Attach the radiator cap and reservoir tank cap
properly.
imum hot position and the blower speed setting at
LO
9) Run the engine at 2,000 rpm or less until radiator
fan starts and stops.
NOTE:
ant temperature drops to 30C (86F) or less.
11) Open the radiator cap. If the engine coolant lev-
el drops, add engine coolant into radiator up to the
filler neck position and reservoir tank to the FULL
level.
properly.
flowing sound is heard at this time, perform the pro-
cedures from 9) again.
(A) Drain plug
CO-02096
(A)
CO-00269
FULL
FULL
LOW
LOW
CO(H4SO)-13
Engine Coolant
COOLING
B: INSPECTION
1. RELATIONSHIP OF ENGINE COOLANT
CONCENTRATION AND FREEZING TEM-
PERATURE
of engine coolant is shown in the diagram 1. Mea-
[Example]
If the coolant temperature is 25C (77F) and its spe-
cific 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).
Diagram 1
2. PROCEDURE TO ADJUST THE CON-
CENTRATION OF THE COOLANT
temperature, find the proper engine coolant con-
centration in the diagram 1 and replace the neces-
sary amount of coolant with an undiluted solution of
engine coolant (concentration 50%).
placed can be determined using the diagram 2.
[Example]
coolant concentration, and read the scale on the ver-
tical 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)
undiluted engine coolant solution.
only.
Diagram 2
CO-02172
60%
(1.054)
1.000
1.010
1.020
1.030
1.040
1.050
1.060
1.070
1.080
1.090
1.100
Freezing
temperature
Concentration
of coolant
S
p
e
c
i
f
i
c

g
r
a
v
i
t
y
o
f

c
o
o
l
a
n
t
Coolant temperature
B
A
C
-40
(-40) (-22) (-4) (14) (32) (50) (68) (86)
( F)
(104)
-30 -20 -10 0 10 20 30 40
(
7
7

F
)
50%
40%
30%
20%
2
5

C10%
C
CO-00012
10
0
1
2
3
(1.1,
0.9)
(2.1,
1.8)
(3.2,
2.6)
10%
15%
25%
20%
30%
35%
40%
45%
A
20 30 40 50
Q
u
a
n
t
i
t
y

o
f

c
o
o
l
a
n
t

t
o

b
e
d
r
a
i
n
e
d

(
U
S

q
t
,

I
m
p

q
t
)
of coolant
CO(H4SO)-14
Water Pump
COOLING
4. Water Pump
A: REMOVAL
1) Remove the radiator. <Ref. to CO(H4SO)-18,
REMOVAL, Radiator.>
REMOVAL, V-belt.>
TIMING BELT, REMOVAL, Timing Belt.>
5) Remove the automatic belt tension adjuster.
6) Remove the belt idler No. 2.
7) Remove the cam sprocket (LH) using ST. <Ref.
to ME(H4SO)-47, REMOVAL, Cam Sprocket.>
8) Remove the belt cover (LH) No. 2.
10) Disconnect the hose from water pump.
11) Remove the water pump.
CO-00016
CO-00017
CO-00019
CO-00020
CO-00021
CO(H4SO)-15
Water Pump
COOLING
B: INSTALLATION
1) Install the water pump onto cylinder block (LH).
NOTE:
Use a new gasket.
When installing the water pump, tighten the bolts
in two stages in alphabetical sequence as shown in
figure.
Tightening torque:
First:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
Second:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
2) Install the hose to water pump.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
4) Install the belt cover No. 2 (LH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
5) Install the cam sprocket (LH) using ST. <Ref. to
ME(H4SO)-47, INSTALLATION, Cam Sprocket.>
6) Install the belt idler No. 2.
Tightening torque:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
7) Install an automatic belt tension adjuster with the
tension rod held by a pin. <Ref. to ME(H4SO)-43,
AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, INSTALLATION, Tim-
ing Belt.>
TIMING BELT, INSTALLATION, Timing Belt.>
11) Install the radiator. <Ref. to CO(H4SO)-19, IN-
STALLATION, Radiator.>
C: INSPECTION
1) Check the water pump bearing for smooth rota-
tion.
2) Check the water pump pulley for abnormalities.
3) Make sure the impeller is not deformed or dam-
aged.
4) Inspect the clearance between impeller and
pump case.
Clearance between impeller and pump case:
Standard
0.5 1.5 mm (0.020 0.060 in)
5) After water pump installation, check pulley shaft
for engine coolant leaks. If leaks are noted, replace
the water pump assembly.
ME-02463
(F)
(E)
(D)
(C)
(B)
(A)
CO-00020
CO-00019
CO-00017
CO-00293
CO(H4SO)-16
Thermostat
COOLING
5. Thermostat
A: REMOVAL
4) Drain engine coolant completely. <Ref. to
CO(H4SO)-12, DRAINING OF ENGINE COOL-
ANT, REPLACEMENT, Engine Coolant.>
5) Remove the front exhaust pipe. <Ref. to
6) Disconnect the radiator outlet hose from thermo-
stat cover.
7) Remove the thermostat cover, and then remove
the gasket and thermostat.
B: INSTALLATION
1) Install a gasket to thermostat.
NOTE:
Use a new gasket.
2) Install the thermostat and thermostat cover.
NOTE:
The thermostat must be installed with the jiggle pin
facing upward.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
3) Connect the radiator outlet hose to thermostat
cover.
4) Install the front exhaust pipe. <Ref. to EX(H4SO)-
5, INSTALLATION, Front Exhaust Pipe.>
7) Fill engine coolant. <Ref. to CO(H4SO)-12, FILL-
ING OF ENGINE COOLANT, REPLACEMENT, En-
gine Coolant.>
(A) Thermostat cover
(B) Gasket
(C) Thermostat
CO-00270
CO-02336
(A)
(C)
(B)
(B) Gasket
(C) Thermostat
(D) Jiggle pin
CO-02337
(A)
T
(B)
(C)
(D)
CO(H4SO)-17
Thermostat
COOLING
C: INSPECTION
Replace the thermostat if the valve does not close
completely at an ambient temperature or if the fol-
lowing test shows unsatisfactory results.
Inspection method
Immerse the thermostat and a thermometer in wa-
ter. Raise water temperature gradually, and mea-
sure the temperature and valve lift when the valve
begins to open and when the valve is fully opened.
During the test, agitate the water for even temper-
ature distribution. The measured value should
meet the specification.
NOTE:
Leave the thermostat in the boiling water for
five minutes or more before measuring valve lift.
Hold the thermostat with a wire or the like to
avoid contacting with container bottom.
Opening start temperature:
80 84C (176 183F)
Full open temperature:
95C (203F)
Valve lift:
9.0 mm (0.354 in) or more
(A) Thermometer
(B) Thermostat
CO-00033
( A)
( B)
CO(H4SO)-18
Radiator
COOLING
6. Radiator
A: REMOVAL
CAUTION:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
5) Remove the heat shield cover from radiator. (AT
model)
6) Drain engine coolant completely.
<Ref. to CO(H4SO)-12, DRAINING OF ENGINE
7) Disconnect the radiator main fan motor connec-
tor (A) and sub fan motor connector (B).
stat cover.
9) Disconnect the ATF cooler hoses from ATF
pipes. (AT model)
Plug the ATF pipe to prevent ATF from leaking.
11) Disconnect the over flow hose.
12) Remove the reservoir tank. <Ref. to CO(H4SO)-
27, REMOVAL, Reservoir Tank.>
IN-00203
CO-02355
(A)
CO-02097
CO-00275
(B)
CO-00270
CO-00253
CO(H4SO)-19
Radiator
COOLING
13) Remove the hood stay holder.
15) Disconnect the radiator inlet hoses from the en-
gine.
16) Remove the radiator upper brackets.
17) Lift the radiator up and away from vehicle.
B: INSTALLATION
1) Attach the radiator lower cushion to the hole on
the radiator lower bracket.
2) Install the radiator to vehicle.
NOTE:
Make pins on the lower side of radiator be fitted into
the radiator lower cushions on body side.
3) Install the radiator upper brackets and tighten
the bolts.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
4) Connect the radiator inlet hose.
5) Install the air intake duct. <Ref. to IN(H4SO)-8,
INSTALLATION, Air Intake Duct.>
CO-00276
CO-00277
CO-00278
CO-00041
CO-00278
CO-00277
CO(H4SO)-20
Radiator
COOLING
6) Install the hood stay holder.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
7) Install the reservoir tank. <Ref. to CO(H4SO)-
27, INSTALLATION, Reservoir Tank.>
8) Connect the over flow hose.
10) Connect the ATF cooler hoses. (AT model)
11) Connect the radiator outlet hose.
12) Connect the radiator main fan motor connector
(A) and sub fan motor connector (B).
13) Install the heat shield cover. (AT model)
Tightening torque:
3 Nm (0.3 kgf-m, 2.2 ft-lb)
17) Fill engine coolant. <Ref. to CO(H4SO)-12,
FILLING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
18) Check the ATF level. <Ref. to 4AT-28, IN-
SPECTION, Automatic Transmission Fluid.>
CO-00276
CO-00253
CO-00270
(A)
CO-02097
CO-00275
(B)
CO-02355
IN-00203
CO(H4SO)-21
Radiator
COOLING
C: INSPECTION
1) Remove the radiator cap, fill the radiator with en-
gine coolant, and then install the tester to the instal-
lation position of cap.
2) Apply a pressure of 157 kPa (1.6 kg/cm
2
, 23 psi)
to the radiator and check the following points:
Leakage from the radiator or its vicinity
Leakage from the hose or its connections
CAUTION:
Engine should be turned off.
Wipe engine coolant from check points in ad-
vance.
Be careful of engine coolant from spurting
out when removing the tester.
Be careful not to deform the filler neck of ra-
diator when installing and removing the tester.
CO-00094
CO(H4SO)-22
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
1) Attach the radiator cap to tester.
2) Increase pressure until the tester gauge pointer
stops. Radiator cap is functioning properly if it holds
the service limit pressure for five to six seconds.
Replace the cap if it is opened under a pressure
less than the service limit value.
Standard:
93 123 kPa (0.95 1.25 kg/cm
2
, 14 18 psi)
Service limit:
83 kPa (0.85 kg/cm
2
, 12 psi)
CAUTION:
Be sure to remove foreign matter and rust from
the cap in advance. Otherwise, results of pres-
sure test will be incorrect.
CO-00044
CO(H4SO)-23
Radiator Main Fan and Fan Motor
COOLING
8. Radiator Main Fan and Fan
Motor
A: REMOVAL
5) Disconnect the connector (A) of the main fan
motor.
6) Remove the heat shield cover. (AT model)
7) Remove the ATF hose from the clip of the radia-
tor main fan motor assembly. (AT model)
10) Remove the reservoir tank. <Ref. to CO(H4SO)-
11) Remove the bolts which hold the radiator main
fan shroud to the radiator.
12) Remove the radiator main fan motor assembly.
B: INSTALLATION
NOTE:
If the installation of the radiator main fan motor as-
sembly is difficult, attempt installation after loosen-
ing the bolts which hold the radiator sub fan motor
assembly.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
IN-00203
(A)
CO-02097
CO-02355
CO-00096
CO-00096
CO(H4SO)-24
COOLING
C: DISASSEMBLY
1) Remove the clip which holds motor connector
onto the shroud.
2) Remove the nuts which hold the fan to the fan
motor.
3) Remove the bolts which hold fan motor onto
shroud.
D: ASSEMBLY
Assemble in the reverse order of disassembly.
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
CO-00102
CO-00098
CO-00098
CO-00102
CO(H4SO)-25
Radiator Sub Fan and Fan Motor
COOLING
9. Radiator Sub Fan and Fan
Motor
A: REMOVAL
5) Remove the connector (B) of sub fan motor.
6) Remove the heat shield cover. (AT model)
tor sub fan motor assembly. (AT model)
10) Remove the bolts which hold the radiator sub
fan shroud to the radiator.
11) Remove the radiator sub fan motor assembly
from underneath the vehicle.
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
IN-00203
CO-00275
(B)
CO-02355
CO-00101
CO-00101
CO(H4SO)-26
COOLING
C: DISASSEMBLY
1) Remove the clip which holds the fan motor con-
nector to the shroud.
2) Remove the nuts which hold the fan motor.
shroud.
D: ASSEMBLY
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
CO-00097
CO-00098
CO-00098
CO-00097
CO(H4SO)-27
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
1) Disconnect the over flow hose connected to the
radiator filler neck.
2) Push in the hook (A), and pull the reserve tank in
the direction of the arrow to remove.
B: INSTALLATION
C: INSPECTION
Make sure the engine coolant level is between
FULL and LOW.
(A)
CO-00279
CO(H4SO)-28
Engine Cooling System Trouble in General
COOLING
11.Engine Cooling System Trouble in General
A: INSPECTION
Trouble Possible cause Corrective action
Overheat
a. Insufficient engine coolant
Replenish engine coolant, inspect for leakage, and
repair it if necessary.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on timing belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timing
Inspect and repair ignition control system.
<Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Proce-
dure.>
h. Clogged or leaking radiator Clean, repair or replace.
i. Engine oil mixed in engine coolant
Replace the engine coolant. If it is ineffective, inspect
and repair the engine side.
j. Air/fuel mixture ratio too lean
Inspect and repair the fuel injection system. <Ref. to
EN(H4SO)(diag)-2, Basic Diagnostic Procedure.>
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Correct or replace.
n. Dragging brake Adjust.
o. Defective radiator fan
Inspect the radiator fan relay, engine coolant tempera-
ture sensor or fan motor and replace them.
Over-cooling
a. Ambient temperature extremely low Partly cover radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks
a. Loosened or damaged connecting units on hoses Correct or replace.
b. Leakage from water pump Replace.
c. Leakage from water pipe Correct or replace.
d. Leakage around cylinder head gasket Retighten the cylinder head bolts or replace the gasket.
e. Cylinder head and block damaged or cracked Correct or replace.
f. Damaged or cracked thermostat case Correct or replace.
g. Leakage from radiator Correct or replace.
Abnormal noise
a. Timing belt problem Replace.
b. Defective radiator fan Replace.
c. Defective water pump bearing Replace water pump.
d. Defective water pump mechanical seal Replace water pump.
LU(H4SO)-2
General Description
LUBRICATION
A: SPECIFICATION
Lubrication method Forced lubrication
Oil pump
Pump type Trochoid type
Number of teeth
Inner rotor 9
Outer rotor 10
Outer rotor diameter thickness mm (in) 76 10 (2.99 0.47)
Tip clearance between inner and outer rotors mm (in) 0.04 0.14 (0.0016 0.0055)
Side clearance between inner rotor and pump case mm (in) 0.02 0.07 (0.0008 0.0028)
Case clearance between outer rotor
and pump case
Standard mm (in) 0.10 0.175 (0.0039 0.0069)
Performance
(Oil temperature 80C
(176F))
600 rpm
Discharge
pressure
kPa (kg/cm
2
, psi) 98 (1.0, 14)
Discharge
rate
2 (US qt, Imp qt)/min. 4.6 (4.9, 4.0) or more
5,000 rpm
Discharge
pressure
kPa (kg/cm
2
, psi) 294 (3.0, 43)
Discharge
rate
Relief valve working pressure kPa (kg/cm
2
, psi) 588 (6.0, 85)
Oil filter
Filter type Full-flow filter type
Filtration area cm
2
(sq in)
Outer diameter: 68 mm
(2.68 in)
800 (124)
(2.56 in)
470 (72.9)
By-pass valve opening pressure kPa (kg/cm
2
, psi) 160 (1.63, 23.2)
Outer diameter width mm (in)
(2.68 in)
68 65 (2.68 2.56)
(2.56 in)
65 74.4 (2.56 2.93)
Installation screw specifications M 20 1.5
Oil pres-
sure switch
Type Immersed contact point type
Operating voltage power consumption 12 V 3.4 W or less
Warning light operating pressure kPa (kg/cm
2
, psi) 14.7 (0.15, 2.1)
Proof pressure kPa (kg/cm
2
, psi) 981 (10, 142) or more
Engine oil
Total capacity (Overhaul) 2 (US qt, Imp qt) 5.0 (5.3, 4.4)
When replacing engine oil and oil filter 2 (US qt, Imp qt) 4.2 (4.4, 3.7)
When replacing engine oil only 2 (US qt, Imp qt) 4.0 (4.2, 3.5)
LU(H4SO)-3
General Description
LUBRICATION
Recommended oil:
Items having the API standard SM Energy
Conserving logo or ILSAC standard GF-4
Starburst mark label on the container
CAUTION:
NOTE:
If the vehicle is used in regions with high tempera-
tures or in other severe environments, use oil with
the viscosities shown below. API standard: SM or
SL
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-
50
(1) SAE viscosity No. and applicable temperature
(2) Recommended
( C) -30 -20 -15 0 15 30 40
-22 -4 5 32 59 86 104
SAE (1)
( F)
10W-30, 10W-40 , 10W-50
5W-30 (2)
LU-02329
LU(H4SO)-4
General Description
LUBRICATION
B: COMPONENT
(1) Plug (14) Oil filler duct (27) Gasket
(2) Gasket (15) Gasket (28) Seal
(3) Relief valve spring (16) Oil filler cap (29) Rocker cover
(4) Relief valve (17) O-ring (30) O-ring
(5) Front oil seal (18) Baffle plate
(6) Oil pump case (19) O-ring Tightening torque:Nm (kgf-m, ft-lb)
(7) Inner rotor (20) Oil strainer T1: 5 (0.5, 3.7)
(8) Outer rotor (21) Oil level gauge guide T2: 6.4 (0.65, 4.7)
(9) Oil pump cover (22) O-ring T3: 10 (1.0, 7.2)
(10) Oil filter (23) Oil pan T4: 25 (2.5, 18.4)
(11) O-ring (24) Oil level gauge T5: 44 (4.5, 32.5)
(12) Oil pump ASSY (25) Drain plug T6: 5.4 (0.55, 4.0)
(13) Oil pressure switch (26) Drain plug gasket
LU-02354
(12)
(11)
T4
T2
T6
T2
T1
T5
T5
T2
T2
(13)
(9)
(8)
(7)
(6)
(27)
(17)
(15)
(14)
(29)
(16)
(24)
(30)
(23)
(10)
(25)
(26)
(5)
(4)
(3)
(2)
(1)
(22)
(21)
T2
(28)
T3
T2
(20)
(19)
(18)
T2
LU(H4SO)-5
General Description
LUBRICATION
C: CAUTION
forming any work.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
points.
the battery.
under cover, wipe it off with cloth to avoid emitting
LU(H4SO)-6
General Description
LUBRICATION
D: PREPARATION TOOL
WRENCH
18332AA000 OIL FILTER
WRENCH
Used for removing and installing oil filter. (Outer
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
E
i3
B38
B21
E2
1
7
E11
No.5
SBF-6 MAIN SBF
B72
3 1
B72
A
1
5
i10
3
1
i10
A
3
1 3
4 5 6
2 2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B38
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
A:
LU-02355
IGNITION
SWITCH BATTERY
COMBINATION
METER
O
I
L

P
R
E
S
S
U
R
E

W
A
R
N
I
N
G

L
I
G
H
T
OIL PRESSURE
SWITCH
LU(H4SO)-8
Oil Pressure System
LUBRICATION
B: INSPECTION
Step Check Yes No
1 CHECK COMBINATION METER.
1) Turn the ignition switch to ON (engine OFF).
2) Check other warning lights.
Does the warning light illumi-
nate?
Go to step 2. Repair or replace
the combination
meter. <Ref. to IDI-
4, INSPECTION,
Combination Meter
System.>
2 CHECK THE HARNESS CONNECTOR BE-
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 voltage 10 V or more? Replace the oil
pressure switch.
Go to step 3.
2) Remove the combination meter.
3) Measure the resistance of combination
meter.
Terminal
(i10) No. 3 No. 15:
Is the resistance less than 10 ? Repair the harness
and connector.
NOTE:
In this case, repair
the following item:
Open circuit of
harness between
combination meter
and oil pressure
switch
Poor contact in
combination meter
connector
Poor contact in
oil pressure switch
connector
Poor contact in
coupling connector
Repair or replace
the combination
4, INSPECTION,
Combination Meter
System.>
LU(H4SO)-9
Engine Oil
LUBRICATION
3. Engine Oil
A: INSPECTION
2) Remove the oil level gauge and wipe away the
oil.
3) Reinsert the oil level gauge all the way. Be sure
that the oil level gauge is correctly inserted and
properly orientated.
4) Remove the oil level gauge again and check the
reading. If the engine oil level is below L line, add
oil to bring the level up to F line.
for the oil to return to the oil pan before checking
the level.
7) Just after driving or while the engine is warm, en-
gine oil level shows in the range between F line and
cutout portion. This is caused by thermal expansion
of engine oil.
NOTE:
To prevent overfilling of engine oil, do not add oil
above F line when the engine is cold.
As the oil level gauge is used for daily mainte-
nance, the upper level and the lower level is set as-
suming that the engine is cold.
B: REPLACEMENT
2) Open the engine oil filler cap for quick draining of
engine oil.
4) Drain engine oil by loosening the engine oil drain
plug.
CAUTION:
NOTE:
engine oil.
NOTE:
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
(A) Oil level gauge
(C) Upper level
(D) Lower level
LU-00213
(C)
(B)
(A)
(E)
(D)
(A) Drain plug
(A) Drain plug
LU-02189
(A)
LU-02189
(A)
LU(H4SO)-10
Engine Oil
LUBRICATION
6) Using engine oil of proper quality and viscosity,
fill engine oil through the filler duct to the F line on
the oil level gauge. Make sure that the vehicle is
parked on a level surface when checking oil level.
Recommended oil:
mended oil. <Ref. to LU(H4SO)-2, SPECIFI-
CATION, General Description.>
Engine oil capacity:
Refer to SPECIFICATION for the engine oil
capacity. <Ref. to LU(H4SO)-2, SPECIFICA-
TION, General Description.>
9) After the engine stops, recheck the oil level. If
necessary, add engine oil up to the F line on the
oil level gauge.
(A) Oil level gauge
(C) Upper level
(D) Lower level
LU-00213
(C)
(B)
(A)
(E)
(D)
LU(H4SO)-11
Oil Pump
LUBRICATION
4. Oil Pump
A: REMOVAL
6) Remove the radiator. <Ref. to CO(H4SO)-18,
REMOVAL, Radiator.>
7) Remove the crankshaft position sensor.
<Ref. to FU(H4SO)-21, REMOVAL, Crankshaft Po-
sition Sensor.>
REMOVAL, V-belt.>
10) Remove the crank pulley using ST. <Ref. to
ME(H4SO)-40, REMOVAL, Crank Pulley.>
11) Remove the water pump. <Ref. to CO(H4SO)-
cylinder block.
NOTE:
pump.
IN-00203
LU-00011
LU-00012
LU-00013
LU-02111
LU-00015
LU(H4SO)-12
Oil Pump
LUBRICATION
15) Remove the oil pump by using flat tip screw-
driver.
CAUTION:
Be careful not to scratch mating surfaces of
B: INSTALLATION
Perform the following.
1) Using the ST, install the front oil seal.
NOTE:
2) Apply liquid gasket to the mating surfaces of oil
pump.
NOTE:
Liquid gasket:
or equivalent
3) Apply a coat of engine oil to the inside of the front
oil seal.
4) Install the oil pump to cylinder block. Be careful
not to damage the front oil seal during installation.
NOTE:
Make sure the front oil seal lip is not folded.
Use a new O-ring when installing the oil pump.
5) Apply liquid gasket to the three bolts thread
shown in figure. (when reuse the bolts)
Liquid gasket:
equivalent
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(A) O-ring
LU-00016
LU-00021
ST
ME-00165
(A)
ME-00312
LU-02103
T
LU(H4SO)-13
Oil Pump
LUBRICATION
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 reas-
sembly.
NOTE:
Before disassembling the oil pump, remove the re-
lief valve.
D: ASSEMBLY
1) Assemble the front oil seal by using ST.
NOTE:
2) Apply a coat of engine oil to inner and outer ro-
tors.
3) Assemble the inner and outer rotors in their orig-
inal positions.
4) Assemble the oil relief valve and install relief
valve spring and plug.
NOTE:
Use a new gasket.
(A) Front 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-00020
(E)
(D)
(C)
(B)
(A)
(F)
(G)
(I)
(H)
LU-00021
ST
LU(H4SO)-14
Oil Pump
LUBRICATION
5) Assemble the oil pump cover.
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)
E: INSPECTION
1. TIP CLEARANCE
Measure the tip clearance of rotors. If the clearance
exceeds the limit, replace rotors as a matched set.
Tip clearance:
Standard:
0.04 0.14 mm (0.0016 0.0055 in)
2. CASE CLEARANCE
Measure the clearance between the outer rotor and
the oil pump case. If the clearance is not within the
limit, replace the rotor.
Case clearance:
Standard:
0.10 0.175 mm (0.0039 0.0069 in)
(A) Front oil seal
(B) Oil pump case
(C) Inner rotor
(D) Outer rotor
(E) Oil pump cover
(F) Relief valve
(H) Plug
(I) Gasket
LU-02134
T1
T2
(G)
(F)
(I)
(H)
(A)
(B)
(C)
(D)
(E)
LU-00023
LU-00024
LU(H4SO)-15
Oil Pump
LUBRICATION
3. SIDE CLEARANCE
Measure the gap between the inner rotor and the
oil pump to measure the clearance between the in-
ner rotor and the oil pump cover as shown in the fig-
ure. If the clearance is not within the limit, replace
the rotor or the oil pump case.
Side clearance:
Standard:
0.02 0.07 mm (0.0008 0.0028 in)
4. OIL RELIEF VALVE
Check the valve for assembly condition and dam-
age, and the relief valve spring for damage and de-
terioration. 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 lbf)
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-00025
LU(H4SO)-16
Oil Pan and Strainer
LUBRICATION
5. Oil Pan and Strainer
A: REMOVAL
2) Remove the front wheels.
Case.>
ber.>
7) Remove the hood stay holder (A) and radiator
upper brackets (B).
8) Support the engine with a lifting device and wire
ropes.
CAUTION:
When lifting up the vehicle, raise up wire ropes
at the same time.
11) Drain the engine oil. <Ref. to LU(H4SO)-9, RE-
PLACEMENT, Engine Oil.>
Pipe.>
14) Remove the bolts which install oil pan on cylin-
der block with the engine raised up.
15) 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.
IN-00203
ME-00213
LU-00232
(A)
(B)
(B)
LU-00222
ME-02650
LU(H4SO)-17
LUBRICATION
B: INSTALLATION
NOTE:
Before installing the oil pan, clean the mating sur-
face of oil pan and engine block.
1) Make sure that the seals (A) are installed se-
curely on the baffle plate in a direction as shown in
the figure below.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
3) Install the oil strainer to the cylinder block.
NOTE:
Use new O-rings.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
4) Tighten the oil strainer stay together with the baf-
fle plate.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
5) Apply liquid gasket to the mating surfaces, and
install the oil pan.
NOTE:
Use a new gasket.
Liquid gasket:
or equivalent
(A) Oil pan
(B) Oil strainer
(C) Baffle plate
(D) Cylinder block
(A)
(C)
(D)
(B)
LU-02334
(A) Gasket
LU-00052
(A)
LU-02353
(A)
LU(H4SO)-18
LUBRICATION
6) Tighten the bolts which install the oil pan to the
cylinder block.
Tightening torque:
T1: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
T2: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
T3: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
7) Lower the engine onto front crossmember.
8) Tighten the nuts which install front cushion rub-
ber onto front crossmember.
NOTE:
Tightening torque:
85 Nm (8.7 kgf-m, 62.7 ft-lb)
9) Install the front and center exhaust pipe. <Ref. to
EX(H4SO)-5, INSTALLATION, Front Exhaust
Pipe.>
CAUTION:
When lowering the vehicle, lower the lift up de-
vice and wire ropes at the same time.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
14) Install the hood stay holder (A) and radiator up-
per brackets (B).
Chamber.>
16) Install the air intake duct and air cleaner case.
Duct.> <Ref. to IN(H4SO)-6, INSTALLATION, Air
Cleaner Case.>
(A) Oil pan
(B) Oil strainer
(C) Baffle plate
(D) Cylinder block
T2
T2
T3
T1
(A)
(C)
(D)
(B)
T1
LU-02335
ME-02651
(B) (A) (B) (A)
LU-00222
ME-03181
T2
T1
LU-00232
(A)
(B)
(B)
LU(H4SO)-19
LUBRICATION
17) Install the front wheels.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
19) Refill the engine oil. <Ref. to LU(H4SO)-9, IN-
C: INSPECTION
Visually check that the oil pan, oil strainer, oil
strainer stay and baffle plate are not damaged.
IN-00203
LU(H4SO)-20
Oil Pressure Switch
LUBRICATION
6. Oil Pressure Switch
A: REMOVAL
1) Remove the generator from the bracket. <Ref. to
SC(H4SO)-15, REMOVAL, Generator.>
2) Disconnect the terminal from oil pressure switch.
3) Remove the oil pressure switch.
B: INSTALLATION
1) Apply liquid gasket to the oil pressure switch
threads.
Liquid gasket:
equivalent
2) Install the oil pressure switch to the cylinder
block.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
3) Connect the terminal to the oil pressure switch.
4) Install the generator to the bracket. <Ref. to
SC(H4SO)-15, INSTALLATION, Generator.>
C: INSPECTION
Check the oil pressure switch installation portion for
oil leakage and oil seepage.
LU-00036
LU-00037
LU-00038
LU-00037
LU-00036
LU(H4SO)-21
Engine Oil Filter
LUBRICATION
A: REMOVAL
3) Remove the clip.
the arrow.
diameter: 68 mm (2.68 in) for
oil filter)
diameter: 65 mm
(2.56 in) for oil filter)
CAUTION:
B: INSTALLATION
CAUTION:
block or oil cooler.
3) Install the oil filter turning it by hand, being care-
ful not to damage the seal rubber.
Tighten the oil filter 65 mm (2.56 in) in diameter
(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).
Tighten the oil filter 68 mm (2.68 in) in diameter (ap-
prox. 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).
4) Put the service hole cover back.
C: INSPECTION
NOTE:
jointed; therefore, interior cleaning is not neces-
sary.
2) Check the engine oil level. <Ref. to LU(H4SO)-9,
INSPECTION, Engine Oil.>
(A) Oil filter
LU-02190
LU-02191
LU-02192
(A)
LU(H4SO)-22
Engine Lubrication System Trouble in General
LUBRICATION
8. 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.
1. Warning light remains
ON.
1) Oil pressure switch
failure
Cracked diaphragm or oil leakage within switch Replace.
Broken spring or seized contacts Replace.
2) Low oil pressure
Clogging of oil filter Replace.
Malfunction of oil by-pass valve in oil filter Clean or replace.
Malfunction of oil relief valve in oil pump Clean or replace.
Clogged oil passage Clean.
Excessive tip clearance and side clearance of oil
pump rotor and gear
Replace.
Clogged oil strainer or broken pipe Clean or replace.
3) No oil pressure
Insufficient engine oil (including deterioration) Replace.
Broken pipe of oil strainer Replace.
Stuck oil pump rotor Replace.
2. Warning light does
not illuminate.
1) Malfunction of combination meter Replace.
2) Poor contact of switch contact points Replace.
3) Disconnection of wiring Repair.
3. Warning light flickers
momentarily.
1) Poor contact of terminals Repair.
2) Defective wiring harness Repair.
3) Low oil pressure
Check for the same
possible causes as
listed 1. 2.
SP(H4SO)-2
General Description
SPEED CONTROL SYSTEMS
A: SPECIFICATION
B: COMPONENT
C: CAUTION
any work.
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, dis-
assembly and replacement.
tery.
Accelerator pedal Stroke At pedal pad 50 63 mm (1.97 2.48 in)
(1) Accelerator pedal ASSY (4) Accelerator stopper Tightening torque:Nm (kgf-m, ft-lb)
(2) Clip (5) Accelerator pedal bracket T: 18 (1.8, 13.3)
(3) Accelerator plate
SP-02049
T
T
(1)
(5)
(4)
T
T
(3)
(2)
SP(H4SO)-3
Accelerator Pedal
2. Accelerator Pedal
A: REMOVAL
2) Disconnect the connector (A).
3) Remove the nut (B) securing accelerator pedal
assembly.
B: INSTALLATION
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
C: DISASSEMBLY
NOTE:
The accelerator pedal cannot be disassembled.
FU-00009
SP-02050
(B)
(A)
SP(H4SO)-4
Accelerator Pedal
IG(H4SO)-2
General Description
IGNITION
A: SPECIFICATION
B: COMPONENT
Item Specification
Engine Model 2.5 L SOHC Non-turbo
Ignition coil & ignitor
assembly
Type FH 0286/FH 0363
Manufacturer Diamond Electric
Secondary coil resistance 11.2 k15%
Spark plug
Manufacturer and type NGK: FR5AP-11
Thread size (diameter, pitch, length) mm 14, 1.25, 19
Spark plug gap mm (in) 1.0 1.1 (0.039 0.043)
Electrode Platinum
(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque:Nm (kgf-m, ft-lb)
(2) Spark plug cord (#1, #3) T1: 8 (0.8, 5.9)
(3) Ignition coil and ignitor ASSY T2: 21 (2.1, 15.5)
IG-02063
T2
T2
T1
(2)
(2)
(4)
(4)
(1)
(3)
(1)
(1)
(1)
IG(H4SO)-3
General Description
IGNITION
C: CAUTION
forming any work.
points.
the battery.
IG(H4SO)-4
Spark Plug
IGNITION
2. Spark Plug
A: REMOVAL
Spark plug:
mended spark plug. <Ref. to IG(H4SO)-2,
SPECIFICATION, General Description.>
1. RH SIDE
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.)
2. LH SIDE
1) Remove the battery. <Ref. to SC(H4SO)-22,
REMOVAL, Battery.>
2) Remove the spark plug cords by pulling the boot.
(Do not pull the cord itself.)
B: INSTALLATION
1. RH SIDE
Tightening torque:
21 Nm (2.1 kgf-m, 15.5 ft-lb)
2. LH SIDE
Tightening torque:
21 Nm (2.1 kgf-m, 15.5 ft-lb)
IN-00203
IG-00017
IG-00018
IG-02049
IG-00022
IG(H4SO)-5
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.
1) Normal:
Brown to grayish-tan deposits and slight electrode
wear indicate correct spark plug heat range.
2) Carbon fouled:
Dry fluffy carbon deposits on insulator and elec-
trode are mostly caused by slow speed driving in
the city, weak ignition, too rich fuel mixture and dirty
air cleaner.
3) Oil fouled:
Wet black deposits show oil entrance into the com-
bustion chamber through worn rings or pistons, or
excessive clearance between valve guides and
stems.
4) Overheating:
White or light gray insulator with black or brown
spots and bluish burnt electrodes indicate engine
overheating, incorrect ignition timing, wrong selec-
tion of fuel, and loose spark plugs.
D: ADJUSTMENT
Clean spark plugs with a nylon brush, etc. Clean
and remove the carbon or oxide deposits. If depos-
its are too stubborn, replace the spark plugs. After
cleaning the spark plugs, measure the spark plug
gap using a gap gauge.
NOTE:
Never use plug cleaner.
Do not use metal brush or it will wear insulator.
Spark plug gap L:
1.0 1.1 mm (0.039 0.043 in)
(A) Spark plug gap
(B) Carbon accumulation or wear
(C) Cracks
(D) Damage
(E) Damaged gasket
IG-00010
(A)
(B)
(C)
(D)
(E)
IG-00011
IG-00012
IG-00013
IG-00014
IG-02035
L
IG(H4SO)-6
Ignition Coil and Ignitor Assembly
IGNITION
3. Ignition Coil and Ignitor
Assembly
A: REMOVAL
2) Disconnect the spark plug cords from ignition
coil and ignitor assembly.
3) Disconnect the connector from the ignition coil &
ignitor assembly.
4) Remove the bolt which secures the ignition coil
and ignitor assembly to the intake manifold.
B: INSTALLATION
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
CAUTION:
Connect the spark plug cords to correct posi-
tions. Failure to do so will damage the unit.
C: INSPECTION
Check the secondary coil resistance using a tester.
Replace if defective.
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:
[Secondary side]
Between (A) and (B)
11.2 k15%
Between (C) and (D)
11.2 k15%
IN-00203
IG-02064
IG-02065
(A)
(B)
(B)
IG-02066
(D)
(B)
(C)
(A)
IG(H4SO)-7
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)-8
Spark Plug Cord
IGNITION
SC(H4SO)-2
General Description
STARTING/CHARGING SYSTEMS
A: SPECIFICATION
Item Specification
Vehicle model MT AT
Starter
Type Reduction type
Model 428000-4780 428000-4790
Manufacturer DENSO
Voltage and output 12 V 1.6 kW 12 V 1.6 kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 9 9
No-load
characteristics
Voltage 11 V 11 V
Current 90 A or less 90 A or less
Rotating speed 1,900 rpm or more 1,900 rpm or more
Load
characteristics
Voltage 8 V 8 V
Current 370 A 370 A
Torque 11.1 Nm (1.1 kgf-m, 8.2 ft-lb) or more 11.1 Nm (1.1 kgf-m, 8.2 ft-lb) or more
Rotating speed 910 rpm or more 910 rpm or more
Lock
characteristics
Voltage 3 V 3 V
Current 750 A or less 750 A or less
Torque 15.5 Nm (1.6 kgf-m, 11.4 ft-lb) or more 15.5 Nm (1.6 kgf-m, 11.4 ft-lb) or more
Generator
Type
Rotating-field three-phase type, voltage regulator built-in type, with load
response control system
Model
2.5 L Non-turbo A003TG2391ZC
3.0 L Non-turbo A003TG0591
2.5 L Turbo A003TG0491
Manufacturer Mitsubishi Electric
Voltage and output 12V 110A
Polarity on ground side Negative
Direction of rotation Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
Output current
1,500 rpm 50 A or more
Regulated voltage 14.1 14.8 V [20C (68F)]
Battery Type and capacity 12 V 48 AH (55D23L) 12 V 52 AH (75D23L)
SC(H4SO)-3
General Description
B: COMPONENT
1. STARTER
(1) Starter housing (10) Internal gear (18) Magnet switch ASSY
(2) Snap ring (11) Shaft (19) Drain duct
(3) Stopper (12) Planetary gear
(4) Overrunning clutch (13) Starter plate Tightening torque:Nm (kgf-m, ft-lb)
(5) Snap ring (14) Yoke T1: 1.4 (0.14, 1.03)
(6) Shift lever (15) Armature T2: 6 (0.6, 4.4)
(7) Starter seal (16) Brush holder ASSY T3: 7.5 (0.8, 5.5)
(8) Shock absorber bearing (17) Starter cover T4: 10 (1.0, 7.4)
(9) Shock absorber
SC-02127
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
T1
T2
T4
T3
(1)
(18)
(19)
SC(H4SO)-4
General Description
2. GENERATOR
(1) Pulley nut (7) Bearing (13) Terminal
(2) Pulley (8) Stator coil
(3) Front cover (9) IC regulator with brush Tightening torque:Nm (kgf-m, ft-lb)
(4) Ball bearing (10) Brush T1: 4.7 (0.48, 3.5)
(5) Bearing retainer (11) Rectifier T2: 108 (11.0, 79.8)
(6) Rotor (12) Rear cover
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
T1
T1
T2
SC-02121
SC(H4SO)-5
General Description
C: CAUTION
forming any work.
points.
the battery.
SC(H4SO)-6
Starter
2. Starter
A: REMOVAL
2) Remove the air intake chamber. (Non-turbo
model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake
Chamber.> <Ref. to IN(H6DO)-7, REMOVAL, Air
Intake Chamber.>
3) Remove the intercooler. (Turbo model)
<Ref. to IN(H4DOTC)-12, REMOVAL, Intercool-
er.>
4) Remove the air intake chamber stay LH. (2.5 L
non-turbo model)
5) Disconnect the connector and terminal from
starter.
6) Remove the starter from transmission.
B: INSTALLATION
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
C: DISASSEMBLY
1) Loosen the nut which holds terminal M (A) of
magnet switch assembly, and then disconnect the
harness from terminal.
2) Remove the nuts which secure the magnet
switch assembly and remove the magnet switch
assembly.
3) Remove the starter seal.
(A) Terminal
(B) Connector
IN-00203
SC-02038
(A)
(B)
SC-02128
(A)
SC-02129
SC-02130
SC(H4SO)-7
Starter
4) Remove the through bolts on both sides, and
then remove the starter housing.
5) Remove the shift lever.
6) Remove the overrunning clutch, shock absorber
bearing and shaft from the yoke as an assembly.
SC-02131
SC-02132
SC-02133
SC-02136
SC(H4SO)-8
Starter
7) Remove the overrunning clutch from shaft as-
sembly as follows:
(1) Using a plastic hammer, remove the stopper
from snap ring by lightly tapping the stopper
with an appropriate tool (such as a fit socket
wrench).
(2) Remove the snap ring (A) from the shaft,
and then remove the stopper (B).
(3) Remove the overrunning clutch from the
shaft.
8) Remove the shock absorber as follows:
(1) Remove the starter plate.
(2) Remove the planetary gear.
(A) Appropriate tool
(B) Snap ring
(C) Shaft
(D) Stopper
SC-02148
(A)
(B)
(C)
(D)
SC-02134
(A)
(B)
SC-02135
SC-02138
SC-02139
SC(H4SO)-9
Starter
(3) Remove the snap ring, and then remove the
shaft.
(4) Separate the shock absorber bearing (A)
from the internal gear (B), and then remove the
shock absorber (C).
9) Remove the screws to remove the starter cover
from the brush holder assembly.
NOTE:
Hold the screws down and separate the starter cov-
er so that the brush holder assembly remains on
the armature side.
10) Remove the brush holder assembly from the
armature.
NOTE:
Push the brushes against the springs by hand to
avoid the damage to the brushes.
11) Remove the armature from yoke.
SC-02137
SC-02140
SC-02141
(A)
(C)
(B)
SC-02142
SC-02143
SC-02144
SC-02145
SC(H4SO)-10
Starter
D: ASSEMBLY
1) Install the armature to yoke.
2) Install the brush holder assembly to the arma-
ture.
NOTE:
Push the brushes against the springs by hand to
avoid the damage to the brushes.
3) Install the starter cover, and then secure it to the
brush holder assembly with the screws.
4) Assemble the shock absorber as follows:
(1) Apply grease to the shock absorber (C), and
install the internal gear (B) to the shock absorb-
er bearing (A).
NOTE:
Align with the claw position of internal gear to install
shock absorber bearing.
Grease:
DENSO HL50
(2) Install the shaft to the internal gear.
NOTE:
Apply grease to the sliding part for the shaft inside
the internal gear.
Grease:
DENSO HL50
(3) Install the snap ring to shaft.
NOTE:
Use new snap rings.
SC-02145
SC-02144
SC-02142
SC-02141
(A)
(C)
(B)
SC-02140
SC-02137
SC(H4SO)-11
Starter
5) Install the planetary gear to the internal gear.
(1) Apply grease to the installation part of the
planetary gear.
Grease:
DENSO HL50
(2) Install the planetary gear to pin.
(3) Apply grease to the planetary gear, internal
gear and upper part of the pin.
NOTE:
Apply grease so that it contacts each gear.
Be careful not to allow dirt to get in.
Grease:
DENSO HL50
(4) Install the starter plate.
6) Assemble the overrunning clutch as follows:
(1) Apply grease to the spline portion of the
shaft.
Grease:
DENSO HL50
(2) Install the overrunning clutch to shaft.
(3) Install the stopper (B) to the shaft, and install
the snap ring (A).
(4) Press-fit the stopper (B) to snap ring (A) us-
ing a press.
7) Assemble the overrunning clutch, shock absorb-
er and shaft to the yoke as one unit.
SC-02139
SC-02138
SC-02135
SC-02134
(A)
(B)
SC-00068
(A)
(B)
SC-02136
SC(H4SO)-12
Starter
8) Install the shift lever.
NOTE:
Apply grease to the contact portion of the shift le-
ver.
Grease:
DENSO HL50
9) Install the starter housing, and tighten the
through bolts on both sides.
Tightening torque:
6 Nm (0.6 kgf-m, 4.4 ft-lb)
10) Install the starter seal.
11) Install the magnet switch assembly to the start-
er housing, and tighten the nuts.
NOTE:
Apply grease to the installation part of the shift le-
ver.
Grease:
DENSO HL50
Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
12) Install the harness to the terminal M (A) of the
magnet switch assembly, and tighten the nut.
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
SC-02133
SC-02132
SC-02131
SC-02130
SC-02129
SC-02128
(A)
SC(H4SO)-13
Starter
E: INSPECTION
1. SWITCH ASSEMBLY
Using a circuit tester (set to ohm), 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 be-
tween terminal M and B.
Terminal/Resistance:
S M/1 or less
S Ground/1 or less
M B/1 M or more
2. SWITCH ASSEMBLY OPERATION
NOTE:
Test period of each test must be within short time (3
5 seconds).
1) Vacuum test
Disconnect the harness from terminal M and con-
nect it as shown in the figure. Make sure the pinion
gear sticks out.
2) Hold test
Make sure the pinion gear remains stick out even
after disconnecting terminal M in the above condi-
tion.
3) Return test
Connect the positive terminal to terminal S and the
negative terminal to terminal M and starter body to
pull the pinion gear at the main contact point. Make
sure the pinion gear returns to its original position
when the terminal S is disconnected.
(A) Terminal S
(B) Terminal M
(C) Terminal B
(A) Terminal S
(B) Terminal M
SC-00181
(A)
(B)
(C)
SC-02086
(A)
(B)
(A) Terminal S
(B) Terminal M
(A) Terminal S
(B) Terminal M
SC-02087
(B)
(A)
SC-02088
(A)
(B)
SC(H4SO)-14
Starter
3. 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.
1) No-load test
With switch on, adjust the variable resistance until
the voltage is 11 V, read the value of ammeter to
measure rotating speed. Compare these values
with the standard.
No-load test (standard):
Voltage/Current
MT model
Max. 11 V/90 A or less
AT model
Max. 11 V/90 A or less
Rotating speed
MT model
1,900 rpm or more
AT model
1,900 rpm or more
2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and ro-
tating speed are within specifications.
Load test (standard):
Voltage/Load
MT model
8 V/11.1 Nm (1.1 kgf-m, 8.2 ft-lb)
AT model
8 V/11.1 Nm (1.1 kgf-m, 8.2 ft-lb)
Current/Speed
MT model
370 A/910 rpm or more
AT model
370 A/910 rpm or more
3) Lock test
With the starter stalled, or not rotating, measure the
torque developed and current draw when the volt-
age is adjusted to standard voltage.
Lock test (standard):
Voltage/Current
MT model
3 V/750 A or less
AT model
3 V/750 A or less
Torque
MT model
15.5 Nm (1.6 kgf-m, 11.4 ft-lb)
AT model
15.5 Nm (1.6 kgf-m, 11.4 ft-lb)
(A) Variable resistance
(B) Starter body
(C) Magnetic switch
SC-00077
(A)
(B)
(C)
12V
+
A V
B
S
M
SC(H4SO)-15
Generator
3. Generator
A: REMOVAL
2) Disconnect the connector and terminal from
generator.
2.5 L Non-turbo model
3.0 L Non-turbo model
Turbo model
4) Remove the front side belts.
<Ref. to ME(H4SO)-37, FRONT SIDE BELT, RE-
MOVAL, V-belt.> or <Ref. to ME(H4DOTC)-37,
FRONT SIDE BELT, REMOVAL, V-belt.> <Ref. to
ME(H6DO)-40, REMOVAL, V-belt.>
5) Remove the bolts which install the generator
onto bracket.
B: INSTALLATION
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
CAUTION:
Check and adjust the V-belt tension.
<Ref. to ME(H4DOTC)-39, INSPECTION, V-belt.>
<Ref. to ME(H6DO)-40, INSPECTION, V-belt.>
IN-00203
SC-00178
SC-02003
ME-00830
SC-00179
SC-00179
SC(H4SO)-16
Generator
C: DISASSEMBLY
1) Remove the four through-bolts.
2) Use a drier to heat the rear cover (A) portion to
50C (122F).
3) Insert the end of a flat tip screwdriver into the
gap between stator core and front cover. Pry them
apart to disassemble.
4) Using a vise, support the rotor and remove the
pulley bolt.
CAUTION:
When holding the rotor with a vise, place alumi-
num plates or wooden pieces on the vise jaws
to prevent rotor from damage.
(A) Screwdriver
SC-00078
SC-00079
(A)
SC-00080
(A)
(A)
(A) Front cover
(B) Pulley
(C) Nut
(D) Rotor
SC-00035
(A)
(B)
(C)
(D)
SC-00036
SC(H4SO)-17
Generator
5) Use the following procedures to remove the ball
bearings.
(1) Remove the bolt, and then detach the bear-
ing retainer.
(2) Firmly attach an appropriate tool (such as a
correct size socket wrench) to the bearing inner
race.
(3) Use the press to push the ball bearings out
from the front cover.
6) Using the bearing puller, remove the bearings
from the rotor.
7) Disconnect the connection between the rectifier
and stator coil, then remove the stator coil.
CAUTION:
The rectifier is easily damaged by heat. Do not
allow a 180 270 W soldering iron to contact
the terminals for 5 seconds or more at a time.
8) Use the following procedures to remove the IC
regulator.
(1) Remove the screws which secure the IC
regulator to the rear cover.
(2) Disconnect the connection between the IC
regulator and rectifier, then remove the IC reg-
ulator.
SC-00081
SC-00082
SC-00046
SC-00083
SC-00084
SC-00085
SC(H4SO)-18
Generator
9) Use the following procedures to remove the
brush.
(1) Remove the cover A.
(2) Remove the cover B.
(3) Disconnect the connection and remove the
brush.
10) Remove the rectifier as follows.
(1) Remove the bolts which secure the rectifier.
(2) Remove the cover on terminal B.
(3) Remove the nuts of terminal B, then remove
the rectifier.
(A) Cover A
(A) Cover B
SC-00086
(A)
SC-00087
(A)
SC-00088
SC-00089
SC-00090
SC-00091
SC(H4SO)-19
Generator
D: ASSEMBLY
1) Pull-out of the brush
Before assembling, press the brush down into the
brush holder, then fix the brush in that position by
inserting a [1 mm (0.08 in) dia., 40 to 50 mm (1.6 to
2.0 in) long] wire through the hole as shown in the
figure.
CAUTION:
After re-assembling, remove the wire.
2) Install the ball bearings.
(1) Set the ball bearings in the front cover, then
securely install an appropriate tool (such as a
socket wrench of proper size) to the bearing
outer race.
(2) Using a press to press the ball bearings into
the specified location.
(3) Install the bearing retainer.
3) Use a press to install the bearings (rear side) to
the rotor shaft.
4) Heat the bearing box in rear cover [50 to 60C
(122 to 140F)], and then press the rear bearing
into rear cover.
CAUTION:
Do not apply grease to the rear bearings. If
there is any oil on the bearing box, remove it
completely.
5) After re-assembling, manually turn the pulley to
check that the rotor rotates smoothly.
E: INSPECTION
1. DIODE
CAUTION:
There is the possibility of damaging the diodes
if a mega-tester (used to measure high voltag-
es) or a similar measuring instrument is used.
Never use a mega tester or equivalent for this
test.
1) Check the positive diode
Check for 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 OK.
2) Check negative diode
Check for continuity between the negative side
heat sink and diode lead. If resistance is 1 or less
only in the direction from the heat sink to the diode
lead, the negative diode is OK.
(A) Wire
SC-00092
(A)
(A) Diode lead
(B) Heat sink (positive side)
(A) Diode lead
(B) Heat sink (negative side)
SC-00042
(B)
(A)
(A)
(B)
SC-00043
SC(H4SO)-20
Generator
2. ROTOR
1) Slip ring surface
Inspect the slip rings for contamination or any
roughness on 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)
Limit
22.1 mm (0.870 in)
3) Continuity test
Using a circuit tester, check the resistance between
slip rings.
If the resistance is not within the standard, replace
the rotor assembly.
Approximately 1.6 1.9
4) Insulation test
Check the continuity between slip ring and rotor
core or shaft. If the resistance is 1 or less, re-
place the rotor assembly because the rotor coil is
grounded.
5) Ball bearings (rear side)
Check the rear ball bearing. If there is any noise, or
the rotor does not rotate smoothly, replace the
bearings.
3. STATOR
1) Continuity test
Inspect continuity between the stator coil lead wire
terminals. If the resistance is 1 M or more, the
lead wire is damaged. Replace the stator assem-
bly.
2) Insulation test
Inspect the continuity between the stator coil stator
core and lead wire terminals. If the resistance is 1
or less, the stator coil is grounded. Replace the sta-
tor assembly.
SC-00044
SC-00045
(A) Stator
(A)
SC-00047
SC-00048
SC(H4SO)-21
Generator
4. BRUSH
1) Measure the length of each brush. Replace the
brush if wear exceeds service limits. There is a ser-
vice limit mark (A) on each brush.
Brush length:
Service limit (1)
5.0 mm (0.197 in)
Standard (2)
18.5 mm (0.728 in)
2) Check that there is appropriate pressure on the
brush spring.
Using a spring pressure indicator, push the brush
into the brush holder until its tip protrudes 2 mm
(0.08 in). Then measure the pressure of brush
spring. If the pressure is 2.2 N (0.224 kgf, 7.91 oz)
or less, replace the brush spring with a new one. 4.8
6.0 N (0.489 0.612 kgf, 17. 26 21.58 oz)
pressure is required on the new spring.
5. BEARING (FRONT SIDE)
Check the front ball bearing. Replace the ball bear-
ings if there is resistance in the rotation, or if there
is any abnormal noise.
SC-00162
(A)
(1)
(2)
SC-00093
SC(H4SO)-22
Battery
4. Battery
A: REMOVAL
1) Disconnect the positive (+) terminal after discon-
necting the negative () terminal of battery.
2) Remove the flange nut from battery rod and re-
move battery holder.
B: INSTALLATION
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
NOTE:
Clean the battery cable terminals and apply
grease to retard the formation of corrosion.
Connect the battery positive (+) terminal, and
then connect the negative () terminal.
After the battery is installed, initial diagnosis of
the electronic throttle control is performed. For this
reason, start the engine 10 seconds or more after
the ignition switch was turned to ON.
C: INSPECTION
WARNING:
Electrolyte is corrosive acid, and has toxici-
ty; be careful of handling the fluid.
Make sure the electrode does not come into
contact with skin, eyes or clothing. Especially
at contact with eyes, flush with water for 15
minutes and get prompt medical attention.
In addition, be careful not to let the electrode
contact with the coated parts.
Be careful when handling the batteries be-
cause they produce explosive gases.
Be sure to keep battery away from any fire.
For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. In addition, never
lean over the battery.
Ventilate sufficiently when using or charging
battery in enclosed space.
Before starting work, remove rings, metal
watch-bands, and other metal jewelry.
Never allow metal tools to contact the posi-
tive battery terminal and anything connected to
it while you are at the same time in contact with
any other metallic portion of the vehicle.
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
Check the electrolyte level in each cell. If the level
is below MIN level, bring the level to MAX level by
pouring distilled water into the battery cell. Do not
fill beyond MAX level.
SC-00180
SC(H4SO)-23
Battery
3. SPECIFIC GRAVITY OF ELECTROLYTE
1) Measure specific gravity of electrolyte using a
hydrometer and a thermometer.
Specific gravity varies with temperature of electro-
lyte so that it must be corrected at 20C (68F) us-
ing the following equation:
S
20
= St + 0.0007 (t 20)
S
20
: Specific gravity corrected at electrolyte
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
[20C (68F)]
2) Measuring the specific gravity of the electrolyte
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.
D: MEASUREMENT
WARNING:
Do not bring an open flame close to the battery
when working.
CAUTION:
Prior to charging, corroded terminals should
be cleaned with a brush and common caustic
soda solution.
Be careful since battery electrolyte overflows
while charging the battery.
Observe instructions when handling the bat-
tery charger.
Before charging the battery on the vehicle,
disconnect the battery ground terminal to pre-
vent damage of generator diodes or other elec-
trical units.
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
one hour or more.
2) Voltage per battery cell should be held at a spe-
cific value in a range from 2.5 to 2.8 V for one hour
or more.
2. CHECK CONDITION OF CHARGE WITH
HYDROMETER
3. NORMAL CHARGING
Charge the battery at the current value specified by
manufacturer or at approximately 1/10 of batterys
ampere-hour rating.
4. QUICK CHARGING
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 temper-
ature, 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 cur-
rent range that will not increase the electrolyte tem-
perature 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:
Observe the items in 3. NORMAL CHARGING.
Never use 10 A or more when charging the
battery because it will shorten the battery life.
SC-00054
0 10 20 30 40 50 60 70 80 90 100
1.12
1.20
1.16
1.24
1.28
1.22
1.08
1.04
Amount of discharge (%)
S
p
e
c
i
f
i
c

g
r
a
v
i
t
y

2
0

(

C
)
Battery with standard specific gravity 1,280 (20 C)
G
o
o
d
N
e
e
d

t
o

c
h
a
r
g
e
Hydrometer
indicator
State of charge Corrective action
Green dot 65% or more Load test
Dark dot 65% or less Charge battery
Clear dot Low electrolyte
Replace the battery.*
(If cranking is difficult)
* Check electrical system before replacement.
SC(H4SO)-24
Battery
EN(H4SO)(diag)-2
Basic Diagnostic Procedure
ENGINE (DIAGNOSTICS)
1. Basic Diagnostic Procedure
A: PROCEDURE
1. ENGINE
Step Check Yes No
1 CHECK ENGINE START FAILURE.
1) Ask the customer when and how the trouble
occurred using the interview checklist. <Ref. to
EN(H4SO)(diag)-3, CHECK, Check List for
Interview.>
Does the engine start? Go to step 2. Inspection using
Diagnostics for
Engine Start Fail-
ure. <Ref. to
EN(H4SO)(diag)-
68, Diagnostics for
Engine Starting
Failure.>
2 CHECK ILLUMINATION OF MALFUNCTION
INDICATOR LIGHT.
Does the malfunction indicator
light illuminate?
Go to step 3. Inspection using
General Diagnos-
tic Table. <Ref. to
EN(H4SO)(diag)-
307, INSPEC-
TION, General
Diagnostic Table.>
3 CHECK INDICATION OF DTC ON DISPLAY.
2) Connect the Subaru Select Monitor or gen-
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 DTC using Subaru Select Monitor or
general scan tool.
NOTE:
Refer to Read Diagnostic Trouble Code for
detailed operation procedure. <Ref. to
EN(H4SO)(diag)-43, Read Diagnostic Trouble
Code (DTC).>
General scan tool
For detailed operation procedures, refer to the
general scan tool operation manual.
Is DTC displayed on the Sub-
aru Select Monitor or general
scan tool?
Record the DTC.
Repair the trouble
cause. <Ref. to
EN(H4SO)(diag)-
83, List of Diagnos-
tic Trouble Code
(DTC).> Go to
step 4.
Repair the related
parts.
NOTE:
If DTC is notshown
on displayalthough
the malfunction in-
dicatorlight illumi-
nates,perform the
diagnosis of mal-
function indicator
lightcircuit or com-
bination meter.
<Ref. to
EN(H4SO)(diag)-
59, Malfunction In-
dicator Light.>
4 PERFORM DIAGNOSIS.
1) Perform the Clear Memory Mode. <Ref. to
EN(H4SO)(diag)-54, Clear Memory Mode.>
2) Perform the Inspection Mode. <Ref. to
EN(H4SO)(diag)-44, Inspection Mode.>
Is DTC displayed on the Sub-
aru Select Monitor or general
scan tool?
Inspect using
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
90, Diagnostic Pro-
cedure with Diag-
nostic Trouble
Code (DTC).>
Finish the diagno-
sis.
EN(H4SO)(diag)-3
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 Engine No.
Date of purchase Fuel brand
Date of repair
Odometer reading
km
V.I.N. miles
Weather Fine
Cloudy
Rainy
Snowy
Various/Others:
Ambient air temperature C ( F)
Hot
Warm
Cool
Cold
Place Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others:
Engine temperature Cold
Warming-up
After warming-up
Any temperature
Others:
Engine speed rpm
Vehicle speed km/h (MPH)
Driving conditions Not affected
At starting
While idling
At racing
While accelerating
While cruising
While decelerating
While turning (RH/LH)
Headlight ON/ OFF Rear defogger ON/ OFF
Blower ON/ OFF Audio ON/ OFF
A/C compressor ON/ OFF CD/Cassette ON/ OFF
Radiator fan ON/ OFF Car phone ON/ OFF
Front wiper ON/ OFF Wireless device ON/ OFF
Rear wiper ON/ OFF
EN(H4SO)(diag)-4
2. CHECK LIST NO. 2
Check the following item about the vehicles state when malfunction indicator light illuminates.
NOTE:
a) Other warning lights or indicators illuminate. Yes / No
Low fuel warning light
Charge indicator light
AT diagnostic indicator light
ABS warning light
Oil pressure indicator 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: Yes / No
What:
d) Intentional connecting or disconnecting of hoses: Yes / No
What:
e) Installing of parts other than genuine parts: Yes / No
What:
Where:
f) Occurrence of noise: Yes / No
From where:
What kind:
g) Occurrence of smell: Yes / No
From where:
What kind:
h) Intrusion of water into engine compartment or passenger compartment: Yes / No
i) Troubles occurred
Engine does not start.
Engine stalls during idling.
Engine stalls while driving.
Engine speed decreases.
Engine speed does not decrease.
Rough idling
Poor acceleration
Back fire
After fire
Does not shift.
Excessive shift shock
EN(H4SO)(diag)-5
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 con-
nectors 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.
Failure to do so will damage the ECM instantly, and
the fuel injector and other parts will also be dam-
aged.
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. Perform the Clear Memory Mode after con-
necting the connectors. <Ref. to EN(H4SO)(diag)-
54, Clear Memory Mode.>
5) Measure the voltage or resistance of individual
sensor or all electrical control modules using a ta-
pered pin with a diameter of less than 0.6 mm
(0.024 in). Do not insert the pin 4 mm (0.16 in) or
more into the part.
CAUTION:
the wrong spec. ECM to avoid any damage on
the fuel injection system.
NOTE:
When replacing the ECM of the models with immo-
bilizer, immobilizer system must be registered. To
do so, all ignition keys and ID cards need to be pre-
pared. Refer to the IMMOBILIZER TEACHING
OPERATION MANUAL.
6) Take care not to allow water to get into the con-
nectors when servicing or washing the vehicle in
rainy weather. Avoid exposure to water even if the
connectors are waterproof.
7) Use ECM mounting stud bolts at the body side
grounding point when measuring voltage and resis-
tance inside the passenger compartment.
8) Use the engine ground terminal or engine as-
sembly for the grounding point to chassis when
measuring the voltage and resistance in engine
compartment.
9) Every MFI-related part is a precision part. Do not
drop them.
10) Observe the following cautions when installing
a radio in MFI equipped models.
CAUTION:
The antenna must be kept as far apart as pos-
sible from control unit. (The ECM is located un-
der the passengers seat floor mat.)
The antenna feeder must be placed as far
apart as possible from the ECM and MFI har-
ness.
Carefully adjust the antenna for correct
matching.
When mounting a large power type radio, pay
special attention to the three items mentioned
above.
Incorrect installation of the radio may affect
the operation of ECM.
11) When disconnecting the fuel hose, release the
fuel pressure. <Ref. to FU(H4SO)-41, RELEASING
OF FUEL PRESSURE, PROCEDURE, Fuel.>
(A) Stud bolt
EN-00001
(A)
FU-01090
EN(H4SO)(diag)-6
General Description
12) 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 self-
diagnosis 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 the 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
Check if the engine ground terminal is properly
connected to engine.
C: NOTE
1. GENERAL DESCRIPTION
The on-board diagnostic (OBD) system detects
and indicates a fault in various inputs and outputs
of the complex electronic throttle control. Malfunc-
tion indicator light in the combination meter indi-
cates 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 reg-
ulations. The OBD system monitors the compo-
nents and the system malfunction listed in Engine
Section which affects on emissions.
When the system decides that a malfunction oc-
curs, malfunction indicator light illuminates. At the
same time of the malfunction indicator light illumi-
nation or blinking, a DTC and a freeze frame en-
gine conditions are stored into on-board computer.
The OBD system stores freeze frame engine
condition data (engine load, engine coolant tem-
perature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer first when it
detects a malfunction.
If the OBD system detects malfunctions such as
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 indi-
cator light is turned off, but DTC remains at on-
board computer.
When troubleshooting the vehicle which com-
plies with OBD-II regulations, connect the Subaru
Select Monitor or general scan tool to the vehicle.
FU-01090
EN(H4SO)(diag)-7
General Description
2. ENGINE AND EMISSION CONTROL SYSTEM
The Multipoint Fuel Injection (MFI) system is a system that supplies the optimum air-fuel mixture to the en-
gine 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
D: PREPARATION TOOL
MONITOR III KIT
Used for troubleshooting the electrical system.
SOCKET
ST1B021XU0
ST-499987500
EN(H4SO)(diag)-8
Electrical Component Location
4. Electrical Component Location
A: LOCATION
1. ENGINE
Control module
(1) Engine control module (ECM) (3) Delivery (test) mode connector (4) Data link connector
(2) Malfunction indicator light
EN-05727
(1)
(2) (4)
(3)
(1)
EN-01147
CHECK
ENGINE
(2)
EN-05735
EN-02975
(3)
AT-01877
(4)
EN(H4SO)(diag)-9
Sensor
(1) Mass air flow and intake air tem-
perature sensor
(4) Electronic throttle control (7) Crankshaft position sensor
(5) Knock sensor (8) Oil temperature sensor
(2) Manifold absolute pressure sen-
sor
(6) Camshaft position sensor
(3) Engine coolant temperature sen-
sor
EN-05728
(1) (3) (4)
(7)
(2)
(5) (6)
(8)
EN(H4SO)(diag)-10
(1)
EN-05729 EN-01971
(2)
(3)
EN-02179 EN-01972
(4)
(5)
EN-00010
(6)
EN-00011
(7)
EN-00012
EN-04089
(8)
EN(H4SO)(diag)-11
(1) Front oxygen (A/F) sensor (3) Front catalytic converter (4) Rear catalytic converter
(2) Rear oxygen sensor
(1) Fuel level sensor (3) Fuel tank pressure sensor (4) Fuel sub level sensor
(2) Fuel temperature sensor
EN-03847
(1)
(4) (2) (3)
EN-05730
(1)
(4)
(2) (3)
EN(H4SO)(diag)-12
EN-05725
(2)
(1)
EN-03003
(3)
EN-03132
(4)
EN(H4SO)(diag)-13
Solenoid valve, actuator, emission control system parts and ignition system parts
(1) Purge control solenoid valve (4) Fuel injector (6) Variable valve lift diagnosis oil
pressure switch
(2) EGR valve (5) Oil switching solenoid valve
(3) Ignition coil and ignitor ASSY
EN-05731
(4) (3) (2)
(1)
(4) (6) (5)
(6) (5)
EN(H4SO)(diag)-14
(1)
EN-05732 EN-01976
(2)
EN-03105
(3)
EN-03106
(4)
EN-04985
(5)
(6)
EN(H4SO)(diag)-15
(1) Pressure control solenoid valve (3) Drain valve (4) Drain filter
(2) Canister
EN-05733
(1)
(2) (3) (4)
EN-02980
(1)
EN-02981
(4)
(3)
(2)
EN(H4SO)(diag)-16
(1) Inhibitor switch (4) Fuel pump relay (7) Radiator sub fan relay
(2) Fuel pump (5) Electronic throttle control relay (8) Radiator main fan relay 2
(3) Main relay (6) Radiator main fan relay 1 (9) Starter
EN-05734
(3)
(2)
(7) (8) (6) (9)
(1)
(4) (5)
EN(H4SO)(diag)-17
Transmission serial No. 4078112 or earlier Transmission serial No. 4078113 or later
EN-00178
(1)
EN-06888
(1)
(2)
EN-05726 EN-03150
(3)
(4)
(5)
EN-06796
(6)
(8)
(7)
EN-02096
(9)
EN(H4SO)(diag)-18
Engine Control Module (ECM) I/O Signal
5. Engine Control Module (ECM) I/O Signal
A: ELECTRICAL SPECIFICATION
Contents
Connector
No.
Terminal
No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
Crankshaft
position sensor
Signal (+) B134 13 0 7 +7 Waveform
Signal () B134 14 0 0
Shield B134 24 0 0
Camshaft
position sensor
Signal () B134 22 0 0
Shield B134 24 0 0
Electronic throttle
control
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 5 5
GND
(sensor)
B134 29 0 0
Electronic throttle control motor
(+)
B137 5 Duty waveform Duty waveform Drive frequency: 500 Hz
()
power supply
B136 1 10 13 12 14
relay
B136 21
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
When ignition switch is
turned to ON: ON
EN-05288
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
TO A: TO B: TO C: TO D:
EN(H4SO)(diag)-19
Accelerator
pedal position
sensor
Main sensor
signal
B135 23
Fully closed: 1.0
Fully opened: 3.5
Fully closed: 1.0
Fully opened: 3.5

Main power
supply
B135 21 5 5
GND
(Main sensor)
B135 29 0 0
Sub sensor
signal
B135 31
Fully closed: 1.0
Fully opened: 3.5
Fully closed: 1.0
Fully opened: 3.5

Sub power
supply
B135 22 5 5
GND
(Sub sensor)
B135 30 0 0
Rear oxygen
sensor
Signal B135 4 0 0 0.9
Shield B135 1 0 0
Front oxygen (A/
F) sensor heater
Signal 1 B136 3 10 13 1 14 Duty waveform
Signal 2 B136 2 10 13 1 14 Duty waveform
Rear oxygen sensor heater
signal
B136 4 10 13 1 14 Duty waveform
sensor
B134 34 1.0 1.4 1.0 1.4 After engine is warmed-up.
Starter switch B136 32 0 0
AT model
Cranking: 8 14
MT model
Cranking with the clutch
pedal pressed: 8 14
Starter relay control B136 20
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 12 14

A/C switch B136 24
ON: 10 13
OFF: 0
ON: 12 14
OFF: 0

Ignition switch B135 19 10 13 12 14
Neutral
position switch
AT
B136 31
ON: 0
OFF: 120.5
For AT model, switch is
ON when select lever is
shifted into P or N
range.
MT
ON: 0
OFF: 120.5
For MT model, switch is
ON when select lever is
shifted into N range.
Delivery (test) mode connector B135 27 10 13 13 14 When connected: 0
Knock sensor
Signal B134 15 2.5 2.5
Shield B134 25 0 0
Back-up power supply B135 5 10 13 12 14
Ignition switch OFF
: 10 13
Control module power
supply
B134 7 10 13 12 14
B135 2 10 13 12 14
Ignition control
#1, #2 B137 18 0 1 3.4 Waveform
#3, #4 B137 19 0 1 3.4 Waveform
Fuel injector
#1 B137 8 10 13 1 14 Waveform
#2 B137 9 10 13 1 14 Waveform
#3 B137 10 10 13 1 14 Waveform
#4 B137 11 10 13 1 14 Waveform
Fuel pump relay control B136 12
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 12 14

Contents
Connector
No.
Terminal
No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
EN(H4SO)(diag)-20
A/C relay control B136 9
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 12 14

Radiator fan relay 1 control B136 18
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 12 14

ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 12 14

Self-shutoff control B136 23 0.5 or less 0.5 or less
Malfunction indicator light B136 11
Light ON: 1 or less
Light OFF: 10 14
Engine speed output B136 22 0 13 or more Waveform
Oil temperature sensor signal B134 23 1.0 1.4 1.0 1.4 After engine is warmed-up.
PCV diagnosis connector B134 30 0 0
Purge control solenoid valve B137 29
ON: 1 or less
OFF: 10 13
ON: 1 or less
OFF: 12 14
Duty waveform
EGR valve
Signal 1 B134 8 0 or 10 13 0 or 12 14 Waveform
Power steering oil pressure
switch
B134 33
ON: 1 or less
OFF: 10 13
ON: 1 or less
OFF: 12 14

Blower fan switch B135 11
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14

A/C middle pressure switch B136 33
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14

Oil switching
solenoid valve
RH
Signal (+) B137 25 0 Duty waveform Drive frequency: 300 Hz
Signal () B137 24 0 0
Oil switching
solenoid valve
LH
Signal (+) B137 31 0 Duty waveform Drive frequency: 300 Hz
Signal () B137 30 0 0
Variable valve lift diagnosis oil
pressure switch RH
B134 31 0 0
pressure switch LH
B134 32 0 0
Front oxygen
(A/F) sensor
Signal (+) B135 9 2.7 2.9
Signal () B135 8 2.35 2.25
Shield B135 1 0 0
Manifold absolute pressure
sensor
B134 6 3.4 3.8 1.4 1.8
Air flow sensor
Signal B135 26 0.3 4.5
Shield B135 35 0 0
GND B135 34 0 0
Intake air temperature sensor
signal
B135 18 0.3 4.6 0.3 4.6
Immobilizer communication 1 B136 26
1 or less 4 or
more
1 or less 4 or
more

Immobilizer communication 2 B136 34
1 or less 4 or
more
1 or less 4 or
more

SSM communication line B136 16
1 or less 4 or
more
1 or less 4 or
more

Contents
Connector
No.
Terminal
No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
EN(H4SO)(diag)-21
Sensor power supply
B134 19 5 5
B135 22 5 5
GND (sensor)
B134 29 0 0
B135 30 0 0
GND
(Engine 1) B134 5 0 0
(Engine 2) B137 7 0 0
(Engine 3) B137 2 0 0
(Engine 4) B137 1 0 0
(Engine 5) B137 3 0 0
(Ignition 1) B137 26 0 0
(Ignition 2) B137 6 0 0
(Body) B136 6 0 0
Clutch switch B136 25
When clutch pedal
is depressed: 0
When brake pedal
is released: 10
13
When clutch pedal
is depressed: 0
When brake pedal
is released
: 12 14

Brake switch 1 B135 20
When brake pedal
is depressed: 0
When brake pedal
is released: 10
13
When brake pedal
is depressed: 0
When brake pedal
is released
: 12 14

When brake pedal
is depressed: 10
13
When brake pedal
is released: 0
When brake pedal
is depressed
: 12 14
When brake pedal
is released: 0

Cruise control main switch B135 12
ON: 0
OFF: 5
ON: 0
OFF: 5

Cruise control command switch B135 24
When operating
nothing: 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
When operating
nothing: 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

Fuel temperature sensor B135 17 2.5 3.8 2.5 3.8
Ambient temperature:
25C (77F)
Fuel tank pressure sensor B135 32 2.3 2.7 2.3 2.7
Value after removing fuel
filler cap and installing
again
Pressure control solenoid valve 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

CAN communication line (+) B136 27 2.5 3.5 2.5 3.5 Waveform
CAN communication line () B136 35 1.5 2.5 1.5 2.5 Waveform
AT/MT identification line B136 15 MT model: 1 or less
Contents
Connector
No.
Terminal
No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
EN(H4SO)(diag)-22
Input/output name Measuring condition Waveform
1. Crankshaft position sensor During idling
2. Camshaft position sensor During idling
EN-05322
ONE CRANK ROTATION
5V
10ms
0
EN-05323
ONE CAM ROTATION
5V
50ms
0
EN(H4SO)(diag)-23
EN-05693
MT 1
9 14 3
AT
1
C25
C16
C6
B21
B29
B22
B32
B30
B31
B27
B23
MT
M
T
MT
M
T
M
T
M
T
AT
A33
C32
B5
B19
C12
C31
C20
NEUTRAL
POSITION SWITCH
STARTER
MOTOR
IGNITION
SWITCH
F/B FUSE No.21
M/B FUSE No.13
F/B FUSE No.12
M/B FUSE No.11
STARTER
RELAY
CLUTCH SWITCH
FUEL
PUMP
RELAY
INHIBITOR
SWITCH
FUEL
PUMP
FUEL
PUMP
CONDENSER
POWER STEERING
OIL PRESSURE
SWITCH
F/B FUSE No.4
DATA LINK
CONNECTOR
CLUTCH
SWITCH
TEST MODE
CONNECTOR
TEST MODE
SUB CONNECTOR
JOINT
CONNECTOR
A
C
C
E
L
E
R
A
T
O
R

P
E
D
A
L

P
O
S
I
T
I
O
N

S
E
N
S
O
R
FUEL TANK
PRESSURE SENSOR
JOINT
CONNECTOR
EN(H4SO)(diag)-24
EN-05694
D18
D19
C11
C22
D26
D6
C1
C21
C23
B2
D29
A8
A9
A10
A20
A7
I/F
I/F
I/F
ABS
4
SBF No. 7
SBF No. 5
5
MAIN
RELAY
ELECTRONIC
THROTTLE
CONTROL
RELAY
RELAY
HOLDER
A/F &
OXYGEN
SENSOR
RELAY
PURGE CONTROL
SOLENOID VALVE
EGR VALVE
IGNITION COIL
& IGNITOR
ASSY
F/B FUSE No.5
F/B FUSE No.7
COMBINATION METER
MALFUNCTION
INDICATOR LIGHT
M
I
C
R
O

C
O
M
P
U
T
E
R
B
O
D
Y

I
N
T
E
G
R
A
T
E
D

U
N
I
T

(
C
A
N

C
O
M
M
U
N
I
C
A
T
I
O
N
)
A
B
S

C
O
N
T
R
O
L

M
O
D
U
L
E
JOINT GROUND
CONNECTOR
C
A
N
T
R
A
N
S
C
E
I
V
E
R
&

R
E
C
E
I
V
E
R
POWER
SUPPLY CIRCUIT
TACHO-
METER
ENGINE
COOLANT
TEMPER-
ATURE
GAUGE
SPEEDO-
METER
EN(H4SO)(diag)-25
EN-05036
A18
D11
D10
D9
D8
A23
A34
A29
A6
A19
D4
A28
D5
5
6
10
14
5 3
B17
C28
C17
7
FUEL INJECTOR
No. 1
FUEL INJECTOR
No. 2
FUEL INJECTOR
No. 4
FUEL INJECTOR
No. 3
DRAIN VALVE
PRESSURE CONTROL
SOLENOID VALVE
ELECTRONIC
THROTTLE
CONTROL
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
ENGINE
COOLANT
TEMPERATURE
SENSOR
OIL
TEMPERATURE
SENSOR
FUEL
TEMPERATURE
SENSOR
EN(H4SO)(diag)-26
EN-05695
A32
B9
B8
B1
B35
B26
B34
B18
C3
B4
C4
C2
A22
A12
A15
A25
A24
A14
A13
D25
D24
D31
D30
A31
4
10
5 9
7
2
11
8
12
13
MASS AIR
FLOW &
INTAKE AIR
TEMPERATURE
SENSOR
FRONT
OXYGEN
(A/F)
SENSOR
RH
REAR
OXYGEN
SENSOR
LH
VVL DIAGNOSIS
OIL PRESSURE
SWITCH LH
VVL DIAGNOSIS
OIL PRESSURE
SWITCH RH
OIL SWITCHING
SOLENOID VALVE LH
OIL SWITCHING
SOLENOID VALVE RH
CRANKSHAFT
POSITION SENSOR
CAMSHAFT
POSITION SENSOR
KNOCK SENSOR
EN(H4SO)(diag)-27
EN-05696
C24
C33
C9
D7
D3
D1
D2
A5
C15
B28
B12
B24
C35
C18
C29
C27
B20
8 13 12 6
C34
C26
2 11
MT
B11
STOP LIGHT SWITCH
BRAKE SWITCH
CRUISE CONTROL SWITCH
BODY INTEGRATED UNIT
(IMMOBILIZER)
(CAN COMMUNICATION)
SUB FAN RELAY
MAIN FAN RELAY
BLOWER FAN RELAY
ENGINE GROUND
A/C RELAY
A/C PRESSURE SWITCH
AUTO A/C CONTROL MODULE
EN(H4SO)(diag)-28
Engine Condition Data
6. Engine Condition Data
Measuring condition:
After engine is warmed-up.
Gear position is in N or P range.
Turn the A/C to OFF.
Turn all the accessory switches to OFF.
Contents Specification
Engine load
17.6 40.5 (%): Idling
14.7 29.8 (%): 2,500 rpm racing
EN(H4SO)(diag)-29
Data Link Connector
7. Data Link Connector
A: NOTE
This connector is used for Subaru Select Monitor.
CAUTION:
Do not connect any scan tools except Subaru Select Monitor or general scan tool because the circuit
for Subaru Select Monitor may be damaged.
1 2 3 4 5 7 6 8
9 10 11 12 13 15 14 16
EN-04893
Terminal No. Contents Terminal No. Contents
1 Blank 9 Blank
2 Blank 10 Blank
3 Blank 11 Blank
4 Ground 12 Blank
5 Ground 13 Blank
6 CAN (+) 14 CAN ()
7 Subaru Select Monitor signal 15 Blank
8 Blank 16 Power supply
EN(H4SO)(diag)-30
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).
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 gen-
eral scan tool instruction manual.)
NOTE:
For details concerning DTC, refer to List of Diag-
nostic Trouble Code (DTC). <Ref. to
EN(H4SO)(diag)-83, List of Diagnostic Trouble
Code (DTC).>
EN-02533
EN(H4SO)(diag)-31
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 pow-
ertrain system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.
NOTE:
Refer to general scan tool manufacturers instruction manual to access generic OBD-II PIDs (MODE $01).
PID Data Unit of measure
$01
Number of emission-related powertrain DTC, and malfunction indicator light status and diagnosis
support information

$03 Fuel system control status
$04 Calculated engine load value %
$05 Engine coolant temperature C
$06 Short term fuel trim %
$07 Long term fuel trim %
$0B Intake manifold absolute pressure kPa
$0C Engine speed rpm
$0D Vehicle speed km/h, MPH
$0E Ignition timing advance
$0F Intake air temperature C or F
$10 Air flow rate from mass air flow sensor g/sec
$11 Throttle valve absolute opening angle %
$13 Check whether oxygen sensor is installed.
$15 Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (Bank 1 Sensor 2) V and %
$1C Supporting OBD system
$1F Elapsed time after starting the engine sec
$21 Travel distance after the malfunction indicator light illuminates km
$24 A/F value and A/F sensor output voltage (Bank 1 Sensor 1) and V
$2C Target EGR %
$2D EGR deviation %
$2E Evaporative purge %
$2F Fuel level %
$30 Number of warm ups after DTC clear
$31 Travel distance after DTC clear km
$32 Fuel tank pressure Pa
$33 Barometric pressure kPa
$34 A/F value and A/F sensor current (Bank 1 Sensor 1) and mA
$3C Catalyst temperature #1 C
$41 Diagnostic monitor of each drive cycle
$42 ECM power voltage V
$43 Absolute load %
$44 A/F target lambda
$45 Relative throttle opening angle %
$46 Ambient temperature C
$47 Absolute throttle opening angle 2 %
$49 Absolute accelerator opening angle 1 %
$4A Absolute accelerator opening angle 2 %
$4C Target throttle opening angle %
$4D Engine operating time while malfunction indicator lit min
$4E Elapsed time after DTC clear min
$51 Fuel used
$5A Relative accelerator opening angle %
EN(H4SO)(diag)-32
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.
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 List of Diagnostic Trouble Code (DTC) for information about data denoting emission-related pow-
ertrain DTC. <Ref. to EN(H4SO)(diag)-83, 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 infor-
mation (MODE $04).
$02 DTC that caused the freeze frame data storage required by CARB
$06 Short term fuel trim (Bank 1 Sensor 1) %
$07 Long term fuel trim (Bank 1 Sensor 1) %
$10 Air flow rate from mass air flow sensor g/sec
$15
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (Bank 1
Sensor 2)
V and %
$2C Target EGR %
$2D EGR deviation %
$2F Fuel level %
$32 Fuel tank pressure Pa
$33 Barometric pressure kPa
$43 Absolute load %
EN(H4SO)(diag)-33
General Scan Tool
6. MODE $06
Refer to test value of troubleshooting and data of test limit indicated on the support data bit sequence table.
A list of the support data is shown in the following table.
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.).
OBDMID TID SID Diagnostic item
$01
$81 $0A
A/F sensor continuity abnormal (Bank 1 Sensor 1) $82 $8D
$83 $14
$84 $1E
A/F sensor range abnormal (Bank 1 Sensor 1)
$85 $1E
$86 $20 A/F sensor response abnormal (Bank 1 Sensor 1)
$02
$87 $0B
Oxygen sensor circuit abnormal (Bank 1 Sensor 2)
$88 $0B
$07 $0B
Oxygen sensor drop abnormal (Bank 1 Sensor 2) $08 $0B
$A5 $0B
$05 $10
Oxygen sensor response abnormal (Bank 1 Sensor 2)
$06 $10
$21 $89 $20 Catalyst deterioration diagnosis (Bank 1)
$31 $8A $FD EGR system diagnosis
$39 $93 $FE Evaporative emission control system (Cap off)
$3B
$94 $FE
Evaporative emission control system (0.04 inch leak)
$95 $FE
$3C
$96 $FE
$97 $FE
$3D $98 $FE Evaporative emission control system (Purge flow)
$41
$99 $24
A/F sensor heater abnormal (Bank 1 Sensor 1)
$9A $24
$9B $14 A/F sensor heater characteristics abnormal (Bank 1 Sensor 1)
$42
$9C $24
Oxygen sensor heater abnormal (Bank 1 Sensor 1)
$9D $24
$A1
$0B $24
Misfire monitoring (All cylinders)
$0C $24
$A2
$0B $24
Misfire monitoring (#1 cylinder)
$0C $24
$A3
$0B $24
$0C $24
$A4
$0B $24
$0C $24
$A5
$0B $24
$0C $24
EN(H4SO)(diag)-34
9. Subaru Select Monitor
A: OPERATION
1. HOW TO USE THE SUBARU SELECT
MONITOR
1) Prepare the Subaru Select Monitor kit. <Ref. to
EN(H4SO)(diag)-7, PREPARATION TOOL, Gen-
eral Description.>
2) Prepare the personal computer which has been
installed the Subaru Select Monitor.
3) Connect the USB cable between SDI (Subaru
Diagnosis Interface) and USB port on the personal
computer (dedicated port for the Subaru Select
Monitor).
NOTE:
The dedicated port for the Subaru Select Monitor
means the USB port which was used to install the
Subaru Select Monitor.
4) Connect the diagnosis cable to the SDI.
5) Connect the SDI to data link connector located in
the lower portion of the instrument panel (on the
drivers side).
CAUTION:
Do not connect the scan tools except for Suba-
ru Select Monitor and general scan tool.
6) Start up the personal computer.
7) Turn the ignition switch to ON (engine OFF), and
run the PC application help for Subaru Select
Monitor.
8) Call up DTC and data, then record them.
NOTE:
For detailed operation procedure, refer to the PC
application help for Subaru Select Monitor.
2. READ DIAGNOSTIC TROUBLE CODE
(DTC) FOR ENGINE (NORMAL MODE)
Refer to Read Diagnostic Trouble Code for informa-
tion about how to indicate DTC. <Ref. to EN(H4SO)(di-
ag)-43, Read Diagnostic Trouble Code (DTC).>
(DTC) FOR ENGINE (OBD MODE)
Refer to Read Diagnostic Trouble Code for informa-
tion about how to indicate DTC. <Ref. to EN(H4SO)(di-
ag)-43, Read Diagnostic Trouble Code (DTC).>
EN-05692
EN-02533
EN(H4SO)(diag)-35
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) Click the [OK] button 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 Current Data Display & Save display screen, select the {Normal sampling}.
6) Using the scroll key, scroll the display screen up or down until the desired data is shown.
Contents Display
Unit of
measure
Note (at idling)
Engine load Engine Load % 21.0%
Engine coolant temperature signal Coolant Temp. C or F
85C or 185F or more
(after warm-up)
A/F correction 1 A/F Correction #1 % 0.8%
A/F learning 1 A/F Learning #1 % 0.0%
Intake manifold absolute pressure Mani. Absolute Pressure
mmHg, kPa,
inHg or psig
200 300 mmHg,
26.7 40 kPa,
7.8 11.8 inHg
or 3.8 5.8 psig
Engine speed signal Engine speed rpm
700 rpm (Agree with the
tachometer indication)
Meter vehicle speed signal Vehicle Speed
km/h or
MPH
0 km/h or 0 MPH
(at parking)
Ignition timing signal Ignition Timing deg 14 16 deg
Intake air temperature signal Intake Air Temp. C or F (Ambient air temperature)
Amount of intake air Mass Air Flow g/s or lb/m 2.5 g/s or 0.33 lb/m
Throttle opening angle signal Throttle Opening Angle % 2.0%
Rear oxygen sensor voltage Rear O2 Sensor V 0.1 0.7 V
Battery voltage Battery Voltage V 12 14 V
Mass air flow voltage Air Flow Sensor Voltage V 1.26 V
Injection 1 pulse width Fuel Injection #1 Pulse ms 2.82 ms
Knock sensor compensation Knocking Correction deg 0.0 deg
Atmospheric pressure signal Atmosphere Pressure
mmHg, kPa,
inHg or psig
(Atmosphere pressure)
Intake manifold relative pressure Mani. Relative Pressure
mmHg, kPa,
inHg or psig
(Air intake absolute
pressure atmosphere
pressure)
Ignition learning value Learned Ignition
Timming
deg 0 deg
Acceleration opening angle signal Accel. Opening Angle % 0.0%
Fuel temperature signal Fuel Temp. C or F +20C or +68F
Purge control solenoid duty ratio CPC Valve Duty Ratio % 0 3%
No. of EGR steps No. of EGR Steps STEP 0 STEP
A/F sensor current value 1 A/F Sensor #1 Current mA 0.2 0.2 mA
A/F sensor resistance value 1 A/F Sensor #1 Resistance 32
A/F sensor output lambda 1
A/F sensor output
lambda 1
1.0
Throttle motor duty Throttle Motor Duty % 15%
Throttle power supply voltage Throttle Motor Voltage V (Battery voltage)
Sub throttle sensor voltage Sub-throttle Sensor V 1.52 V
Main throttle sensor voltage Main-throttle Sensor V 0.66 V
EN(H4SO)(diag)-36
Sub accelerator sensor voltage Sub-accelerator Sensor V 0.68 V
Main accelerator sensor voltage Main-accelerator Sensor V 0.68 V
Memory vehicle speed
Memorized Cruise
Speed
km/h or
MPH
0 km/h or 0 MPH
Fuel level sensor signal Fuel Level Resistance 2 96
Engine oil temperature Engine Oil Temperature C
85C (After engine is
warmed-up.)
Oil switching solenoid valve duty R OSV Duty R % 16.9%
Oil switching solenoid valve duty L OSV Duty L % 16.9%
Oil switching solenoid valve current R OSV Current R mA 192 mA
Oil switching solenoid valve current L OSV Current L mA 192 mA
Variable valve lift mode VVL Lift Mode 1
#1 cylinder roughness monitor Roughness Monitor #1 0
Knock sensor compensation Knocking Correction deg 0.0 deg
Fuel tank pressure signal Fuel Tank Pressure
mmHg, kPa,
inHg or psig
+7.7 mmHg, +1.1 kPa,
+0.31 inHg or +0.15 psig
AT/MT identification terminal AT Vehicle ID Signal AT vehicle/MT vehicle
Delivery (test) mode terminal Test Mode Terminal U check
D check request flag D Check Request OFF
Delivery (test) mode terminal Delivery Mode OFF
Neutral position switch signal Neutral Position Switch Neutral
Soft idle switch signal Idle Switch Signal At idle
Ignition switch signal Ignition Switch ON input
Power steering switch signal P/S Switch OFF input (when OFF)
Air conditioning switch signal A/C Switch OFF input (when OFF)
Starter switch signal Starter Switch OFF input
Rear oxygen monitor Rear O2 Rich Signal Rich/Lean
Knocking signal Knocking Signal None
Crankshaft position sensor signal Crankshaft Position Signal Provided
Camshaft position sensor signal Camshaft Position Signal Provided
Rear defogger switch signal Rear Defogger Switch OFF input (when OFF)
Blower fan switch signal Blower Fan Switch OFF input (when OFF)
Light switch signal Light Switch OFF input (when OFF)
A/C middle pressure switch signal A/C Mid Pressure Switch OFF input (when OFF)
Air conditioner compressor relay output signal A/C Compressor Signal OFF output (when OFF)
Radiator fan relay 1 signal Radiator Fan Relay #1 OFF output (when OFF)
Radiator fan relay 2 signal Radiator Fan Relay #2 OFF output (when OFF)
Fuel pump relay signal Fuel Pump Relay ON output
PCV hose assembly diagnosis signal
Blow-by Leak Diagnosis
Connector
Connected
Pressure control solenoid valve signal PCV Solenoid Valve OFF output
Drain valve signal Vent. Solenoid Valve OFF output
Variable valve lift diagnosis oil pressure switch signal 1 Eng. Oil Press. SW 1 ON
Variable valve lift diagnosis oil pressure switch signal 2 Eng. Oil Press. SW 2 ON
AT coordinate retard angle demand signal Retard Signal from AT None
AT coordinate fuel cut demand signal Fuel Cut Signal from AT None
Contents Display
Unit of
measure
Note (at idling)
EN(H4SO)(diag)-37
NOTE:
For detailed operation procedure, refer to the PC application help for Subaru Select Monitor.
AT coordinate permission signal
Torque Control
Permission Signal

Allowed (prohibited on
MT vehicles)
Electronic throttle control motor relay signal ETC Motor Relay ON
Clutch switch signal Clutch Switch OFF (when OFF)
Stop light switch signal Stop Light Switch OFF (when OFF)
SET/COAST switch signal SET/COAST Switch OFF (when OFF)
RES/ACC switch signal RESUME/ACCEL Switch OFF (when OFF)
Brake switch signal Brake Switch OFF input (when OFF)
Main switch signal Main Switch OFF input (when OFF)
Body integrated unit data reception Body Int. Unit Data ON
Body integrated unit counter update Body Int. Unit Count ON
Cruise control cancel switch signal Cruise Control Cancel
Switch
OFF input (when OFF)
Malfunction indicator light signal MIL Lit Flag Off (when unlit)
Contents Display
Unit of
measure
Note (at idling)
EN(H4SO)(diag)-38
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 Current Data Display & Save display screen, select the {All Data Display}.
Contents Display
Referential value
(at idling)
Unit of
measure
Number of diagnosis code Number of DTC 0
Condition of malfunction indicator light MI (MIL) OFF
Monitoring test of misfire Misfire monitoring (Supp) YES
Monitoring test of misfire Misfire monitoring (Rdy) YES
Monitoring test of fuel system
Fuel system monitoring
(Supp)
YES
(Rdy)
YES
Monitoring test of comprehensive component
Component monitoring
(Supp)
YES
(Rdy)
YES
Test of catalyst
Catalyst Diagnosis
(Supp)
YES
Test of catalyst Catalyst Diagnosis (Rdy) NO
Test of heating-type catalyst Heated catalyst (Supp) NO
Test of heating-type catalyst Heated catalyst (Rdy) N/A
Test of evaporative emission purge control system
Evaporative purge
system (Supp)
YES
Evaporative purge
system (Rdy)
NO
Secondary air system test
Secondary air system
(Supp)
NO
(Rdy)
N/A
Test of air conditioning system refrigerant
A/C system refrigerant
(Supp)
NO
(Rdy)
N/A
Test of oxygen sensor Oxygen sensor (Supp) YES
Test of oxygen sensor Oxygen sensor (Rdy) NO
Test of oxygen sensor heater
O2 Heater Diagnosis
(Supp)
YES
O2 Heater Diagnosis
(Rdy)
NO
Test of EGR system EGR system (Supp) YES
Test of EGR system EGR system (Rdy) NO
Air fuel ratio control system for bank 1 Fuel system for Bank1 Normal CLOSE
Engine load data Engine Load 23.0 %
Engine coolant temperature signal Coolant Temp. 92 C
Short term fuel trim by front oxygen (A/F) sensor (Bank 1) A/F Correction Value #1 0.8 %
Long term fuel trim by front oxygen (A/F) sensor (Bank 1) A/F Learning Value #1 0.0 %
Intake manifold absolute pressure signal Mani. Absolute Pressure 211 mmHg
EN(H4SO)(diag)-39
Engine speed signal Engine Speed 700 rpm
Vehicle speed signal Vehicle Speed 0 km/h
#1 Cylinder ignition timing Ignition timing adv.#1 16.0
Intake air temperature signal Intake Air Temp. 36 C
Amount of intake air Mass Air Flow 2.7 g/s
Throttle position signal Throttle Opening Angle 13 %
Oxygen sensor (Bank 1 Sensor 2) Oxygen sensor #12 0.7 V
A/F correction (Bank 1 Sensor 2) A/F Correction #12 0.0 %
On-board diagnostic system OBD system OBD/OBD2
Front oxygen (A/F) sensor (Bank 1 Sensor 1) Oxygen sensor #11 Support
Oxygen sensor (Bank 1 Sensor 2) Oxygen sensor #12 Support
Time elapsed after engine start Time Since Engine Start sec
Driving distance after the malfunction indicator light
illuminates
Lighted MI lamp history km
A/F lambda signal (Bank 1 Sensor 1) A/F sensor #11 1.001
A/F sensor output signal (Bank 1 Sensor 1) A/F sensor #11 2.79 V
Target EGR Target EGR %
EGR error EGR deviation %
Evaporative purge Commanded Evap Purge 0 %
Fuel level signal Fuel Level %
Number of warm ups after DTC clear Number of warm-ups
Driving distance after DTC clear Meter since DTC cleared km
Fuel tank pressure signal Fuel Tank Pressure 8.8 mmHg
Atmospheric pressure signal Atmosphere Pressure Atmospheric pressure mmHg
A/F sensor current (Bank 1 Sensor 1) A/F sensor #11 0.00 mA
Catalyst temperature #1 Catalyst Temperature #11 C
Monitoring test of misfire
Misfire monitoring
(Enable)
YES
Misfire monitoring
(Comp)
NO
(Enable)
YES
(Comp)
NO
(Enable)
YES
(Comp)
NO
Test of catalyst
Catalyst Diagnosis
(Enable)
YES
Test of catalyst
Catalyst Diagnosis
(Comp)
NO
Test of heating-type catalyst Heated catalyst (Enable) N/A
Test of heating-type catalyst Heated catalyst (Comp) N/A
Evaporative purge
system (Enable)
NO
Evaporative purge
system (Comp)
NO
(Enable)
N/A
Contents Display
Referential value
(at idling)
Unit of
measure
EN(H4SO)(diag)-40
NOTE:
(Comp)
N/A
(Enable)
N/A
(Comp)
N/A
Test of oxygen sensor Oxygen sensor (Enable) YES
Test of oxygen sensor Oxygen sensor (Comp) NO
O2 Heater Diagnosis
(Enable)
YES
O2 Heater Diagnosis
(Comp)
NO
Test of EGR system EGR system (Enable) YES
Test of EGR system EGR system (Comp) NO
ECM power voltage Control module voltage 13.789 V
Absolute load Absolute Load Value 22 %
A/F ratio target lambda Target Equivalence Ratio 0.976
Relative throttle opening angle Relative Throttle Pos. 2 %
Ambient temperature Ambient Temperature Ambient air temperature C
Absolute throttle opening angle 2 Absolute Throttle Pos.#2 32 %
Absolute accelerator opening angle 1 Accelerator Pedal Pos.#1 13 %
Target throttle opening angle Target Throt. Act. Cont. 0 %
Engine operating time while malfunction indicator lit Time while MIL lighted min
Time elapsed after DTC clear Time since DTC cleared min
Fuel used Type of fuel GAS
Relative accelerator opening angle Relative Accelera. Pos. 0 %
Contents Display
Referential value
(at idling)
Unit of
measure
EN(H4SO)(diag)-41
6. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE)
5) On the OBD Menu display screen, select the {Freeze Frame Data Display}.
NOTE:
Contents Display Unit of measure
Freeze frame data DTC code Freeze frame data DTC
Air fuel ratio control system for bank 1 Fuel system for Bank1
Normal CLOSE or OPEN
early period
Engine load data Engine Load %
Short term fuel trim by front oxygen (A/F) sensor Short term fuel trim B1 %
Long term fuel trim by front oxygen (A/F) sensor Long term fuel trim B1 %
Intake manifold absolute pressure signal Mani. Absolute Pressure mmHg, kPa, inHg or psig
Engine speed signal Engine Speed rpm
Vehicle speed signal Vehicle Speed km/h or MPH
Ignition timing advance for #1 cylinder Ignition Timing
Intake air temperature signal Intake Air Temp. C or F
Amount of intake air Mass Air Flow g/s or lb/m
Throttle position signal Throttle Opening Angle %
Oxygen sensor (Bank 1 Sensor 2) Oxygen sensor #12 V
A/F correction (Bank 1 Sensor 2) A/F Correction #12 %
On-board diagnostic system OBD system
Time elapsed after engine start Time Since Engine Start sec
EGR deviation EGR Error %
Evaporative purge Commanded Evap Purge %
Fuel tank pressure signal Fuel Tank Pressure mmHg, kPa, inHg or psig
Atmospheric pressure Atmosphere Pressure mmHg, kPa, inHg or psig
ECM power voltage Control module voltage V
Absolute load Absolute Load Value %
A/F ratio target lambda Target Equivalence Ratio
Relative throttle opening angle Relative Throttle Pos. %
Ambient temperature Ambient Temperature C or F
Absolute throttle opening angle 2 Absolute Throttle Pos.#2 %
Absolute accelerator opening angle 1 Accelerator Pedal Pos.#1 %
Target throttle opening angle Target Throt. Act. Cont. %
EN(H4SO)(diag)-42
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)-43
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) Click the [OK] button after the information of en-
gine type has been displayed.
4) On the Engine Diagnosis display screen, se-
lect the {Diagnostic Code(s) Display}.
5) On the Diagnostic Code(s) Display screen,
select the {Temporary Diagnostic Code(s)} or
{Memorized Diagnostic Code(s)}.
NOTE:
For detailed operation procedure, refer to the
PC application help for Subaru Select Monitor.
nostic Trouble Code (DTC). <Ref. to EN(H4SO)(di-
ag)-83, List of Diagnostic Trouble Code (DTC).>
2. SUBARU SELECT MONITOR (OBD
MODE)
lect the {OBD System}.
5) On the OBD Menu display screen, select the
{Diagnostic Code(s) Display}.
6) Make sure DTC is shown on the screen.
NOTE:
3. GENERAL SCAN TOOL
Refer to data denoting emission-related powertrain
DTC.
NOTE:
Refer to general scan tool manufacturers instruc-
tion manual to access powertrain DTC (MODE
$03).
EN(H4SO)(diag)-44
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(H4SO)(diag)-49, Drive Cycle.>
DTC Item Condition
P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1)
P0032 HO2S Heater Control Circuit High (Bank 1 Sensor 1)
P0077 Intake Valve Control Solenoid Circuit High (Bank 1)
P0102 Mass or Volume Air Flow Circuit Low Input
P0103 Mass or Volume Air Flow Circuit High Input
P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input
P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input
P0112 Intake Air Temperature Sensor 1 Circuit Low
P0113 Intake Air Temperature Sensor 1 Circuit High
P0117 Engine Coolant Temperature Circuit Low
P0118 Engine Coolant Temperature Circuit High
P0122 Throttle/Pedal Position Sensor/Switch A Circuit Low
P0123 Throttle/Pedal Position Sensor/Switch A Circuit High
P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
P0140 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2)
P0182 Fuel Temperature Sensor A Circuit Low Input
P0183 Fuel Temperature Sensor A Circuit High Input
P0197 Engine Oil Temperature Sensor Low
P0198 Engine Oil Temperature Sensor High
P0222 Throttle/Pedal Position Sensor/Switch B Circuit Low
P0223 Throttle/Pedal Position Sensor/Switch B Circuit High
P0327 Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor)
P0328 Knock Sensor 1 Circuit High (Bank 1 or Single Sensor)
P0335 Crankshaft Position Sensor A Circuit
P0336 Crankshaft Position Sensor A Circuit Range/Performance
P0340 Camshaft Position Sensor A Circuit (Bank 1 or Single Sensor)
P0341
Camshaft Position Sensor A Circuit Range/Performance (Bank 1 or
Single Sensor)

P0447 Evaporative Emission Control System Vent Control Circuit Open
P0448 Evaporative Emission Control System Vent Control Circuit Shorted
P0452 Evaporative Emission Control System Pressure Sensor Low Input
P0453 Evaporative Emission Control System Pressure Sensor High Input
P0458 Evaporative Emission System Purge Control Valve Circuit Low
P0462 Fuel Level Sensor A Circuit Low
P0463 Fuel Level Sensor A Circuit High
P0500 Vehicle Speed Sensor A
P0512 Starter Request Circuit
P0513 Incorrect Immobilizer Key
EN(H4SO)(diag)-45
Inspection Mode
P0600 Serial Communication Link
P0604 Internal Control Module Random Access Memory (RAM) Error
P0605 Internal Control Module Read Only Memory (ROM) Error
P0607 Control Module Performance
P0638 Throttle Actuator Control Range/Performance (Bank 1)
P0700 Transmission Control System (MIL Request)
P0851 Park/Neutral Switch Input Circuit Low
P0852 Park/Neutral Switch Input Circuit High
P1152 O2 Sensor Circuit Range/Performance (Low) (Bank 1 Sensor 1)
P1153 O2 Sensor Circuit Range/Performance (High) (Bank 1 Sensor 1)
P1160 Return Spring Failure
P1400 Fuel Tank Pressure Control Solenoid Valve Circuit Low
P1420 Fuel Tank Pressure Control Sol. Valve Circuit High
P1491 Positive Crankcase Ventilation (Blow-by) Function Problem
P1560 Backup power supply
P1570 Antenna
P1571 Reference Code Incompatibility
P1572 IMM Circuit Failure
P1574 Key Communication Failure
P1576 EGI Control Module EEPROM
P1577 IMM Control Module EEPROM
P1578 Meter Failure
P2101 Throttle Actuator Control Motor Circuit Range/Performance
P2102 Throttle Actuator Control Motor Circuit Low
P2109 Throttle/Pedal Position Sensor A Minimum Stop Performance
P2122 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
P2128 Throttle/Pedal Position Sensor/Switch E Circuit High Input
P2135 Throttle/Pedal Position Sensor/Switch A/B Voltage Correlation
P2138 Throttle/Pedal Position Sensor/Switch D/E Voltage Correlation
P2227 Barometric Pressure Circuit Range/Performance
P2228 Barometric Pressure Circuit Low
P2229 Barometric Pressure Circuit High
DTC Item Condition
EN(H4SO)(diag)-46
Inspection Mode
1. PREPARATION FOR THE INSPECTION
MODE
1) Check that the battery voltage is 12 V or more
and fuel remains approx. 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 roll-
ers.
WARNING:
Before raising the vehicle, ensure parking
brakes are applied.
Do not use a pantograph jack in place of a rig-
id rack.
Secure a rope or wire to the front or rear tow-
ing 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 remain-
ing unresolved trouble data. <Ref. to EN(H4SO)(di-
ag)-54, Clear Memory Mode.>
eral Description.>
Monitor).
NOTE:
7) Connect the delivery (test) mode connector (A)
located under the glove box.
(A) Rigid racks
(B) Free rollers
EN-00041
(A)
(B)
EN-05692
PI-00201
(A)
EN(H4SO)(diag)-47
Inspection Mode
drivers side).
CAUTION:
10) Turn the ignition switch to ON (engine OFF),
and run the PC application help for Subaru Select
Monitor.
13) Click the [OK] button after the information of
engine type has been displayed.
lect the {D Check}.
15) When the Perform Inspection (Dealer Check)
Mode is shown on the screen, click the [Next] but-
ton.
16) Perform subsequent procedures as instructed
on the display screen.
If trouble still remains in the memory, the corre-
sponding DTC appears on the display screen.
NOTE:
For details concerning DTC, refer to List of Di-
agnostic Trouble Code (DTC).
<Ref. to EN(H4SO)(diag)-83, List of Diagnostic
Trouble Code (DTC).>
Release the parking brake.
The speed difference between front and rear
wheels may illuminate the ABS warning light, but
this does not indicate a malfunction. When en-
gine control diagnosis is finished, perform the
ABS memory clearance procedure of self-diag-
nosis function. <Ref. to ABS(diag)-24, Clear
Memory Mode.>
1) After performing the diagnostics and clearing the
memory, check for any remaining unresolved trou-
ble data. <Ref. to EN(H4SO)(diag)-54, Clear Mem-
ory Mode.>
4) Connect the general scan tool to data link con-
nector located in the lower portion of the instrument
panel (on the drivers side).
CAUTION:
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-02533
PI-00201
(A)
EN-02533
EN(H4SO)(diag)-48
Inspection Mode
9) Place the select lever or shift lever in D position
(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.
this indicates no malfunctions. When engine con-
trol diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
<Ref. to ABS(diag)-24, Clear Memory Mode.>
10) Using the general scan tool, check DTC and
record the result(s).
NOTE:
nostic Trouble Code (DTC).
<Ref. to EN(H4SO)(diag)-83, List of Diagnostic
EN(H4SO)(diag)-49
Drive Cycle
12.Drive Cycle
A: PROCEDURE
For the troubleshooting, there are driving patterns described below. 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 that the battery voltage is 12 V or more and fuel remains approx. half [20 40 2 (5.3 10.6 US gal,
4.4 8.8 Imp gal)].
2) After performing the diagnostics and clearing the memory, check for any remaining unresolved trouble da-
ta. <Ref. to EN(H4SO)(diag)-54, Clear Memory Mode.>
3) Disconnect the delivery (test) mode connector.
NOTE:
Perform the diagnosis after warming up the engine except when the engine coolant temperature at starting
is specified.
Perform the diagnosis twice if the DTC marked with *. After completing the first diagnosis, stop the engine
and perform second diagnosis in same condition.
2. DRIVE CYCLE A (AFTER RUNNING 20 MINUTES AT 80 KM/H (50 MPH), IDLE THE ENGINE
FOR 1 MINUTE.)
DTC Item Condition
*P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control
Coolant temperature at start is less
than 20C (68F).
*P0128
Coolant Thermostat (Engine Coolant Temperature Below Thermostat
Regulating Temperature)

*P0133 O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)
*P0171 System Too Lean (Bank 1)
Diagnosis completes in drive cycle B
or C as well.
*P0172 System Too Rich (Bank 1)
or C as well.
P0196 Engine Oil Temperature Sensor Circuit Range/Performance
*P0301 Cylinder 1 Misfire Detected
or C as well.
or C as well.
or C as well.
or C as well.
*P0420 Catalyst System Efficiency Below Threshold (Bank 1)
*P0442 Evaporative Emission Control System Leak Detected (Small Leak)
Engine coolant temperature at
engine start is less than 30C (86F).
*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 Evaporative Emission System Purge Control Valve Circuit High
P1443 Vent Control Solenoid Valve Function Problem
*P2096 Post Catalyst Fuel Trim System Too Lean Bank 1
or C as well.
*P2097 Post Catalyst Fuel Trim System Too Rich Bank 1
or C as well.
P2103 Throttle Actuator Control Motor Circuit High
or C as well.
EN(H4SO)(diag)-50
Drive Cycle
3. DRIVE CYCLE B 10 MINUTES IDLING
NOTE:
Drive the vehicle at 10 km/h (6 MPH) or more before diagnosis.
4. DRIVE CYCLE C DRIVE THE VEHICLE WITH FOLLOWING DRIVE PATTERNS
DTC Item Condition
*P0126 Insufficient Engine Coolant Temperature for Stable Operation
Diagnosis completes in drive
cycle A or C as well.
*P0464 Fuel Level Sensor Circuit Intermittent
*P0506 Idle Air Control System RPM Lower Than Expected
*P0507 Idle Air Control System RPM Higher Than Expected
(A) Idle the engine for 10 seconds or
more.
(D) Decelerate with fully closed throt-
tle to 64 km/h (40 MPH).
(G) Stop vehicle with the throttle fully
closed.
(B) Accelerate to 97 km/h (60 MPH)
within 20 seconds.
(E) Drive the vehicle at 64 km/h (40
MPH) for 20 seconds.
(H) Vehicle speed km/h (MPH)
(I) Sec.
(C) Drive the vehicle at 97 km/h (60
(F) Accelerate to 97 km/h (60 MPH)
within 10 seconds.
EN-00842
(C)
(H)
(I)
(60) 97
64 (40)
(B)
(A)
(F) (D)
(E)
150 100 50
0
(G)
EN(H4SO)(diag)-51
Drive Cycle
DTC Item Condition
P0026 Intake Valve Control Solenoid Circuit Range/Performance (Bank 1)
*P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1)
*P0068 MAP/MAF - Throttle Position Correlation
P0076 Intake Valve Control Solenoid Circuit Low (Bank 1)
*P0101 Mass Or Volume Air Flow Circuit Range/Performance
*P0134 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)
cycle A or B as well.
*P0400 Exhaust Gas Recirculation Flow
P1492 EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input)
P1493 EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input)
EN(H4SO)(diag)-52
Drive Cycle
5. DRIVE CYCLE D
DRIFT DIAGNOSIS
1) Check that the engine coolant temperature at engine start is less than 30C (86F).
2) Make sure that fuel remains 10 2 (2.6 US gal, 2.2 Imp gal) or more and the battery voltage is 10.9 V or
more.
3) Start the engine, and check that the engine coolant temperature increases by 10C (50F) or more, and
reaches 75C (167F) or more, when the engine is warmed up.
4) Idle the engine for 120 seconds or more in the condition of step 3.
STUCK DIAGNOSIS
1) Make sure that the battery voltage is 10.9 V or more.
2) Perform the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-54, 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 battery terminals while diagnosing. (Data will be cleared by disconnecting the bat-
tery terminals.)
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:
tery terminals.)
7. DRIVE CYCLE F
2) Start the engine, and warm it up until engine coolant temperature increases over 95C (203F).
3) After the engine has reached the state of procedure 2), idle the engine for 10 minutes or more.
NOTE:
Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery
terminals.)
DTC Item Condition
P0181 Fuel Temperature Sensor A Circuit Range/Performance
DTC Item Condition
P0461 Fuel Level Sensor A Circuit Range/Performance
DTC Item Condition
P0111 Intake Air Temperature Sensor 1 Circuit Range/Performance
EN(H4SO)(diag)-53
Drive Cycle
8. DRIVE CYCLE H
2) With the ignition switch ON, read the engine coolant temperature, intake air temperature and fuel temper-
ature. <Ref. to EN(H4SO)(diag)-35, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERA-
3) If the values from step 2) satisfy the following two conditions, start the engine.
Condition:
|Engine coolant temperature intake air temperature | 5C (41F)
|Engine coolant temperature fuel temperature | 2C (36F)
NOTE:
If the conditions are not satisfied, turn the ignition switch to OFF and wait until the parameters are satisfied.
Start AT vehicles in the P range, and MT vehicles in the N position.
4) Idle the engine for 1 minute under the conditions in step 3).
DTC Item Condition
*
P1602 Control Module Programming Error
EN(H4SO)(diag)-54
Clear Memory Mode
13.Clear Memory Mode
A: OPERATION
MODE)
lect the {Clear Memory}.
5) When the Clear Memory? is shown on the
screen, click the [Yes] button.
6) When Done and Turn ignition switch to
OFF is shown on the display screen, turn the igni-
tion switch to OFF.
NOTE:
Initial diagnosis of electronic throttle control is
performed after memory clearance. Therefore,
start the engine 10 seconds or more after have
turning the ignition switch to ON.
MODE)
{Clear Diagnostic Code?}.
6) When the Clear Diagnostic Code? is shown
on the screen, click the [Yes] button.
tion switch to OFF.
NOTE:
performed after memory clearance. Therefore,
start the engine 10 seconds or more after have
turning the ignition switch to ON.
For clear memory procedures using the general
scan tool, refer to General Scan Tool Instruction
Manual.
NOTE:
Initial diagnosis of electronic throttle control is per-
formed after memory clearance. For this reason,
start the engine after 10 seconds or more have
elapsed since the ignition switch was turned to ON.
EN(H4SO)(diag)-55
Compulsory Valve Operation Check Mode
14.Compulsory Valve Operation
Check Mode
A: OPERATION
eral Description.>
Monitor).
NOTE:
drivers side).
CAUTION:
Monitor.
lect the {System Operation Check Mode}.
13) On the System operation check mode dis-
play screen, select the {Actuator ON/OFF Opera-
tion}.
14) Select the desired compulsory actuator on the
Actuator ON/OFF Operation display screen and
click the [Next] button.
EN-05692
PI-00201
(A)
EN-02533
EN(H4SO)(diag)-56
15) Clicking the [Finished] button completes the
compulsory valve operation check mode. The dis-
play will then return to the Actuator ON/OFF Op-
eration screen.
A list of the support data is shown in the following
table.
NOTE:
The following parts will be displayed but not
functional.
Description Display
Compulsory fuel pump relay
operation check
Fuel Pump
Compulsory purge control
solenoid valve operation check
CPC Solenoid
Compulsory radiator fan relay
operation check
Radiator Fan Relay
Compulsory air conditioning relay
operation check
A/C Compressor Relay
Compulsory pressure control
PCV Solenoid Valve
Compulsory drain valve opera-
tion check
Vent Control Solenoid
Valve
Display
EGR Solenoid Valve
ASV Solenoid Valve
FICD Solenoid
Pressure Switching Sol. 1
Pressure Switching Sol. 2
AAI Solenoid
Fuel Tank Sensor Control Valve
Turbocharger Wastegate Solenoid
Exhaust Bypass Valve Control Permit Flag
Secondary Air Combination Valve 1
EN(H4SO)(diag)-57
System Operation Check Mode
15.System Operation Check
Mode
A: OPERATION
eral Description.>
Monitor).
NOTE:
drivers side).
CAUTION:
Monitor.
12) The following items will be displayed on screen.
1. FUEL PUMP CONTROL (OFF DRIVE)
CAUTION:
After executing the operation check mode, execute
the Clear Memory Mode <Ref. to EN(H4SO)(diag)-
54, OPERATION, Clear Memory Mode.>.
1) On the System operation check mode display,
select the {Fuel Pump Control}.
2) On the Fuel Pump Control display screen, se-
lect the {OFF Operation}.
3) On the Start the Engine display screen, start
the engine and click the [OK] button.
4) Click the [Cancel] button to end the OFF drive.
The screen will return to the Fuel Pump Control
screen.
NOTE:
2. FUEL PUMP CONTROL (ON/OFF DRIVE)
CAUTION:
lect the {ON/OFF Operation}.
3) On the Turn Ignition Switch ON with Engine
Stalled display screen, turn the ignition switch to
ON and click the [OK] button.
4) Click the [Cancel] button to end the ON/OFF
drive. The screen will return to the Fuel Pump
Control screen.
NOTE:
EN-05692
EN-02533
Display
Actuator ON/OFF Operation
Security System
Fuel Pump Control
Idling Ignition Timing Fixed
Idle Speed Control
Injector Control
EGR Valve Control
EN(H4SO)(diag)-58
3. IDLING IGNITION TIMING FIXED
CAUTION:
1) On the System operation check mode display
screen, select the {Idling Ignition Timing Fixed}.
3) Click the [Cancel] button to end the idle ignition
timing fixed. The screen will return to the System
Operation Check Mode screen.
NOTE:
4. IDLE SPEED CONTROL
CAUTION:
screen, select the {Idle Speed Control}.
3) In the Idle Engine Speed Control screen, click
the [ ] button or the [ ] button to change the set-
ting values, then click the [OK] button.
Setting is possible in a range between 500 rpm
2,000 rpm, in increments of 50 rpm. However, the
engine speed that can actually be controlled will
vary depending on the vehicle.
4) Click the [Cancel] button to end the idle speed
control. The screen will return to the System Op-
eration Check Mode screen.
NOTE:
5. INJECTOR CONTROL. (INJECTION
STOP MODE)
CAUTION:
select the {Injector Control}.
2) On the Injector Control display screen, select
the {Injection Stop Mode}.
3) Select the desired injector number on the Injec-
tion Stop Mode screen, and click the [OK] button.
5) Click the [Cancel] button to return the Injection
Stop Mode display screen.
6) On the Injection Stop Mode display screen,
click the [Return] button to end the Injection Stop
Mode. The screen will return to the Injector Con-
trol screen.
NOTE:
QUANTITY CONTROL)
CAUTION:
the {Injection Quantity Control}.
4) In the Injection Quantity Control screen, click
Setting is possible in a range between 0 20%, in
increments of 1%.
5) Click the [Cancel] button to end the injection
quantity control. The screen will return to the In-
jector Control screen.
NOTE:
7. EGR VALVE CONTROL
CAUTION:
select the {EGR Valve Control}.
3) In the EGR Valve Control screen, click the [ ]
button or the [ ] button to change the setting val-
ues, then click the [OK] button.
Setting is possible in 1 STEP increments. However,
the number of STEPs that can actually be con-
trolled will vary depending on the vehicle.
4) Click the [Cancel] button to end the EGR valve
NOTE:
EN(H4SO)(diag)-59
Malfunction Indicator Light
16.Malfunction Indicator Light
A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4SO)(diag)-60, ACTIVATION OF MALFUNCTION INDICATOR LIGHT,
Malfunction Indicator Light.>
2. Malfunction indicator light does not come on. <Ref. to EN(H4SO)(diag)-61, MALFUNCTION INDICATOR LIGHT DOES NOT
COME ON, Malfunction Indicator Light.>
3. Malfunction indicator light does not go off. <Ref. to EN(H4SO)(diag)-63, MALFUNCTION INDICATOR LIGHT DOES NOT GO
OFF, Malfunction Indicator Light.>
4. Malfunction indicator light does not blink. <Ref. to EN(H4SO)(diag)-64, MALFUNCTION INDICATOR LIGHT DOES NOT
BLINK, Malfunction Indicator Light.>
5. Malfunction indicator light remains blinking. <Ref. to EN(H4SO)(diag)-66, MALFUNCTION INDICATOR LIGHT REMAINS
BLINKING, Malfunction Indicator Light.>
EN(H4SO)(diag)-60
B: ACTIVATION OF MALFUNCTION
INDICATOR LIGHT
1) When the ignition switch is turned to ON (engine
OFF), the malfunction indicator light (A) in the com-
bination meter illuminates.
NOTE:
If the engine malfunction indicator light does not il-
luminate, perform diagnostics of malfunction indi-
cator light circuit or the combination meter circuit.
<Ref. to EN(H4SO)(diag)-61, MALFUNCTION IN-
DICATOR LIGHT DOES NOT COME ON, Malfunc-
tion Indicator Light.>
2) After starting the engine, the malfunction indica-
tor light goes out. If it does not go off, either the en-
gine or emission control system has malfunction.
3) If the diagnostic system detects a misfire which
could damage the catalyst, the malfunction indica-
tor light will blink at a cycle of 1 Hz.
4) Turn the ignition switch to OFF and connect the
delivery (test) mode connector.
(1) When the ignition switch is turned to ON
(engine OFF), the malfunction indicator light il-
luminates.
(2) After the engine starts, malfunction indicator
light blinks in a cycle of 0.5 Hz. (During diagno-
sis)
(3) Malfunction indicator light blinks at a cycle of
3 Hz after diagnosis if there is no trouble. Mal-
function indicator light illuminates if faulty.
(1) No faulty
(2) Trouble occurs
(3) ON
(4) OFF
(5) Ignition switch ON
(6) Engine start
CHECK
ENGINE
(A)
EN-05736
EN-01679
(1)
(2)
(5)
(6)
(3)
(4)
(3)
(4)
(1) ON
(2) OFF
(4) Engine start
(5) Misfire start
(6) 1 second
(1) ON
(2) OFF
(4) 1 second
EN-01680
(2)
(1)
(3)
(4)
(5)
(6)
EN-01681
(2)
(1)
(4)
(3)
EN(H4SO)(diag)-61
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:
EN-05697
3
B72
i3
B38
B136
i10
SBF-6
1
1
1
3
B72
8
MAIN SBF No.5
1
6
E
1 3
4 5 6
2
B136 i10
B38
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
ECM
COMBINATION
METER
IGNITION
SWITCH
BATTERY
EN(H4SO)(diag)-62
Step Check Yes No
1 CHECK OUTPUT SIGNAL OF ECM.
2) Measure the voltage between ECM connec-
tor and chassis ground.
(B136) No. 11 (+) Chassis ground ():
Is the voltage less than 1 V? Go to step 4. Go to step 2.
Check for poor connection by shaking or pulling
ECM connector and harness.
light illuminate?
Repair poor con-
tact of the ECM
connector.
Go to step 3.
3 CHECK ECM CONNECTOR.
Check the connection of ECM connector.
Is the ECM connector correctly
connected?
Replace the ECM.
<Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
Repair the connec-
tion of ECM con-
nector.
4 CHECK HARNESS BETWEEN COMBINA-
TION METER AND ECM CONNECTOR.
2) Remove the combination meter. <Ref. to
IDI-19, Combination Meter.>
3) Disconnect the connector from ECM and
combination meter.
ECM and combination meter connector.
(B136) No. 11 (i10) No. 16:
Is the resistance less than 1 ? Go to step 5. Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and combi-
nation meter con-
nector
Poor contact of
coupling connector
Check poor contact of combination meter con-
nector.
Is there poor contact in combi-
nation meter connector?
Repair the poor
contact of combi-
nation meter con-
nector.
Go to step 6.
TION METER AND IGNITION SWITCH CON-
NECTOR.
2) Measure the voltage between combination
meter connector and chassis ground.
(i10) No. 3 (+) Chassis ground ():
Is the voltage 10 V or more? Replace the com-
bination meter cir-
cuit board. <Ref. to
IDI-19, Combina-
tion Meter.>
Check the follow-
ing item and repair
if necessary.
NOTE:
Blown out of fuse
(No. 5)
Open or short
circuit in harness
between fuse (No.
5) and battery ter-
minal
Poor contact of
ignition switch con-
nector
EN(H4SO)(diag)-63
D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF
DIAGNOSIS:
The malfunction indicator light circuit is shorted.
TROUBLE SYMPTOM:
Although malfunction indicator light illuminates when the engine runs, DTC is not shown on the Subaru Se-
lect Monitor display.
WIRING DIAGRAM:
Step Check Yes No
light illuminate?
Repair the short
circuit of harness
between combina-
tion meter and
ECM connector.
Replace the ECM.
<Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
EN-05697
3
B72
i3
B38
B136
i10
SBF-6
1
1
1
3
B72
8
MAIN SBF No.5
1
6
E
1 3
4 5 6
2
B136 i10
B38
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
ECM
COMBINATION
METER
IGNITION
SWITCH
BATTERY
EN(H4SO)(diag)-64
E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK
DIAGNOSIS:
The delivery (test) mode connector circuit is open.
TROUBLE SYMPTOM:
Malfunction indicator light does not blink during Inspection Mode.
WIRING DIAGRAM:
EN-05698
i10
1
6
3
B135 B:
8
i3
B38
B75 B76
1 1
B136 C:
E
3
B72
SBF-6
1
MAIN SBF No.5
B135
B136
B:
C:
B72 B75
2
1 3
4 6
2
i10 B38
1 2 3 4 5 6 7 8 9
10 11 12 13 15 16 17 19 20
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5 1 2 3 4
5 6 8
B122
14 18 7
1
5
C
1
1
C
6
B122
B
2
7
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
IGNITION
SWITCH BATTERY
COMBINATION
METER
ECM
: TERMINAL No. OPTIONAL
ARRANGEMENT
DELIVERY (TEST)
MODE CONNECTOR
EN(H4SO)(diag)-65
Step Check Yes No
1 CHECK STATUS OF MALFUNCTION INDI-
CATOR LIGHT.
2) Disconnect the delivery (test) mode connec-
tor.
3) Turn the ignition switch to ON. (engine OFF)
light illuminate?
Go to step 2. Repair the malfunc-
tion indicator light
circuit. <Ref. to
EN(H4SO)(diag)-
61, MALFUNC-
TION INDICATOR
LIGHT DOES NOT
COME ON, Mal-
function Indicator
Light.>
light illuminate?
Repair the short
circuit of harness
between combina-
tion meter and
ECM connector.
Go to step 3.
3 CHECK HARNESS BETWEEN DELIVERY
(TEST) MODE CONNECTOR AND ECM.
delivery (test) mode connector and ECM.
(B76) No. 1 (B136) No. 6:
and connector.
NOTE:
the following item:
Open circuit of har-
ness between deliv-
ery (test) mode
connector and chas-
sis ground
connector?
Repair poor con-
tact of the ECM
connector.
Go to step 5.
5 CHECK HARNESS BETWEEN ECM AND DE-
LIVERY (TEST) MODE CONNECTOR.
1) Connect the delivery (test) mode connector.
ECM and delivery (test) mode connector.
(B135) No. 27 (B136) No. 6:
circuit of harness
between ECM and
delivery (test)
mode connector.
connector?
Repair poor con-
tact of the ECM
connector.
Replace the ECM.
<Ref. to FU(H4SO)-
37, Engine Control
Module (ECM).>
EN(H4SO)(diag)-66
F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING
DIAGNOSIS:
The delivery (test) mode connector circuit is shorted.
TROUBLE SYMPTOM:
Malfunction indicator light blinks when delivery (test) mode connector is not connected.
WIRING DIAGRAM:
EN-05698
i10
1
6
3
B135 B:
8
i3
B38
B75 B76
1 1
B136 C:
E
3
B72
SBF-6
1
MAIN SBF No.5
B135
B136
B:
C:
B72 B75
2
1 3
4 6
2
i10 B38
1 2 3 4 5 6 7 8 9
10 11 12 13 15 16 17 19 20
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5 1 2 3 4
5 6 8
B122
14 18 7
1
5
C
1
1
C
6
B122
B
2
7
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
IGNITION
SWITCH BATTERY
COMBINATION
METER
ECM
ARRANGEMENT
DELIVERY (TEST)
MODE CONNECTOR
EN(H4SO)(diag)-67
Step Check Yes No
1 CHECK DELIVERY (TEST) MODE CONNEC-
TOR.
tor.
light blink?
Go to step 2. System is normal.
NOTE:
Malfunction indica-
tor light blinks
when delivery
(test) mode con-
nector is connect-
ed.
2 CHECK HARNESS BETWEEN ECM CON-
NECTOR AND DELIVERY (TEST) MODE
CONNECTOR.
ECM connector and chassis ground.
(B135) No. 27 Chassis ground:
Is the resistance less than 5 ? Repair the short
circuit of harness
between ECM and
delivery (test)
mode connector.
Replace the ECM.
<Ref. to FU(H4SO)-
37, Engine Control
Module (ECM).>
EN(H4SO)(diag)-68
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)-69, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
3. Inspection of ECM power supply and ground line <Ref. to EN(H4SO)(diag)-73, 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)-75, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
5. Inspection of fuel pump circuit <Ref. to EN(H4SO)(diag)-78, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
6. Inspection of fuel indicator circuit <Ref. to EN(H4SO)(diag)-81, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
EN(H4SO)(diag)-69
B: STARTER MOTOR CIRCUIT
CAUTION:
After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-54,
Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)(diag)-44, Inspection Mode.>.
WIRING DIAGRAM:
Step Check Yes No
1 CHECK BATTERY.
Check the battery voltage.
Is the voltage 12 V or more? Go to step 2. Charge or replace
the battery.
2 CHECK OPERATION OF STARTER MOTOR.
NOTE:
Check the security alarm is not sounding.
Does the starter motor oper-
ate?
EN-06894
No.21
B225
MAIN SBF SBF-6
E
B136
B106
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
2
0
3
2
B72
B14
3 2
1
2
M
B106
1
2
1
2
B72
1 3
4 5 6
2
B12
1 2 3 4
5 6 7 8
9 10 11 12
AT
AT
M
T
AT
M
T
AT
M
T
B12 T3 T7
P R N D
7
12
11
12
9
6
OT NT
OT
NT
:
1 2 3 4 5 6
7 8 9 10 11 12
T7 OT
:
1 2 3 4 5
7 6 9 8
NT
: T7
1
3
1
4
1
6
1
5
B225
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
CLUTCH
SWITCH
ECM
STARTER MOTOR
STARTER RELAY
IGNITION
SWITCH
INHIBITOR
SWITCH
BATTERY
: TRANSMISSION SERIAL NO. 4078112
OR EARLIER
OR LATER
EN(H4SO)(diag)-70
3 CHECK DTC. Is DTC displayed? <Ref. to
EN(H4SO)(diag)-43, OPERA-
TION, Read Diagnostic Trouble
Code (DTC).>
Check the appro-
priate DTC using
the List of Diagnos-
tic Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Repair poor con-
tact of the ECM
connector.
4 CHECK INPUT SIGNAL FOR STARTER MO-
TOR.
2) Disconnect the connector from starter
motor.
3) Turn the ignition switch to START.
4) Measure the power supply voltage between
starter motor connector terminal and engine
ground.
(B14) No. 1 (+) Engine ground ():
NOTE:
For AT model, place the select lever in P range
or N range. For MT model, depress the clutch
pedal.
Is the voltage 10 V or more? Check the starter
motor. <Ref. to
SC(H4SO)-6,
Starter.>
Go to step 5.
5 CHECK HARNESS BETWEEN BATTERY
AND IGNITION SWITCH CONNECTOR.
1) Disconnect the connector from ignition
switch.
ignition switch connector and chassis ground.
Is the voltage 10 V or more? Go to step 6. Repair the open
circuit or ground
short of harness
between ignition
switch and battery,
and check fuse
SBF No. 6 and
MAIN SBF.
6 CHECK IGNITION SWITCH.
switch.
2) Measure the resistance between ignition
switch terminals after turning the ignition switch
to START position.
Terminals
No. 2 No. 3:
Is the resistance less than 5 ? Go to step 7. Replace the igni-
tion switch.
7 CHECK INPUT VOLTAGE OF STARTER RE-
LAY.
2) Disconnect the connector from starter relay.
3) Connect the connector to ignition switch.
4) Measure the input voltage between starter
relay connector and chassis ground after turn-
ing the ignition switch to START position.
Is the voltage 10 V or more? Go to step 8. Repair open or
ground short circuit
of harness
between starter
relay and ignition
switch.
8 CHECK STARTER RELAY.
1) Connect the battery to starter relay termi-
nals No. 15 and No. 16.
2) Measure the resistance between starter
relay terminals.
Terminals
No. 13 No. 14:
Is the resistance less than 1 ? Go to step 9. Replace the starter
relay.
Step Check Yes No
EN(H4SO)(diag)-71
9 CHECK HARNESS BETWEEN STARTER RE-
LAY AND ECM.
starter relay and ECM.
(B225) No. 16 (B136) No. 20:
Is the resistance less than 1 ? Go to step 10. Repair the open or
of harness
between starter
relay and ECM.
10 CHECK TRANSMISSION TYPE. Is the transmission type AT? Go to step 11. Go to step 15.
11 CHECK ECM INPUT VOLTAGE.
2) Measure the input voltage between ECM
connector and chassis ground.
Is the voltage 10 V or more? Go to step 12. Repair the open or
of harness
between ECM and
ignition switch.
12 CHECK HARNESS BETWEEN STARTER RE-
LAY AND INHIBITOR SWITCH.
2) Disconnect the connector from inhibitor
switch.
the starter relay and inhibitor switch.
Transmission serial No. 4078112 or earlier
(B225) No. 14 (T7) No. 7:
Transmission serial No. 4078113 or later
(B225) No. 14 (T7) No. 9:
Is the resistance less than 1 ? Go to step 13. Repair open circuit
of harness
between starter
relay and inhibitor
switch.
13 CHECK HARNESS BETWEEN INHIBITOR
SWITCH AND STARTER MOTOR.
Measure the resistance of harness between the
inhibitor switch and starter motor.
(T7) No. 12 (B14) No. 1:
(T7) No. 6 (B14) No. 1:
Is the resistance less than 5 ? Go to step 14. Repair open circuit
of harness
between inhibitor
switch and starter
motor.
14 CHECK INHIBITOR SWITCH.
1) Place the select lever other than P range
and N range.
2) Measure the resistance between inhibitor
switch connector terminals.
Terminals
No. 7 No. 12:
No. 6 No. 9:
more?
Check the ECM
power supply and
ground line.
<Ref. to
EN(H4SO)(diag)-
73, CHECK
POWER SUPPLY
AND GROUND
LINE OF ENGINE
CONTROL MOD-
ULE (ECM), Diag-
nostics for Engine
Starting Failure.>
Replace the inhibi-
tor switch. <Ref. to
4AT-47, Inhibitor
Switch.>
15 CHECK HARNESS BETWEEN IGNITION
SWITCH AND CLUTCH SWITCH.
2) Disconnect the connector from clutch
switch.
4) Measure the voltage between the clutch
switch and chassis ground.
of harness
between clutch
switch and ignition
switch.
Step Check Yes No
EN(H4SO)(diag)-72
16 CHECK CLUTCH SWITCH.
Measure the resistance between clutch switch
terminals while depressing the clutch.
Terminals
No. 1 No. 2:
Is the resistance less than 1 ? Go to step 17. Replace the clutch
switch.
17 CHECK HARNESS BETWEEN ECM AND
CLUTCH SWITCH.
Measure the resistance of harness between
ECM and clutch switch.
(B136) No. 32 (B106) No. 2:
Is the resistance less than 1 ? Contact your SOA
service center.
Repair the open
circuit of harness
between the ECM
and clutch switch.
Step Check Yes No
EN(H4SO)(diag)-73
C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL
MODULE (ECM)
CAUTION:
After repairing or replacing the defective part, perform the Clear Memory Mode <Ref. to EN(H4SO)(di-
ag)-54, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)(diag)-44, PRO-
CEDURE, Inspection Mode.>.
WIRING DIAGRAM:
EN-05700
SBF-6 MAIN SBF
SBF-7
B72
No.12
B47
E2
B21
2
1
4
6
5
3
E
3 1
B134
B135
A:
D: B137
C: B136
B:
3 4
1 2
5 6
B47
No.13
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B72
1 3
4 5 6
2
A: B:
D:
A
7
B
2
C
2
3
B
1
9
D
7
D
1
D
3
A
5
B
5
5
2
3
7
3
6
3
4
D
2
3
5
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
E
MAIN RELAY
ECM
IGNITION
SWITCH
BATTERY
TO IGNITION COIL & IGNITOR ASSY
EN(H4SO)(diag)-74
Step Check Yes No
1 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:
Is the resistance less than 10
?
relay.
2 CHECK GROUND CIRCUIT FOR ECM.
ECM and chassis ground.
circuit of harness
between ECM con-
nector and engine
grounding termi-
nal.
3 CHECK INPUT VOLTAGE OF ECM.
of power supply
circuit.
4 CHECK INPUT VOLTAGE OF MAIN RELAY.
Measure the voltage between main relay con-
nector and chassis ground.
of harness of
power supply cir-
cuit.
Is the voltage 10 V or more? Check ignition con-
trol system. <Ref. to
EN(H4SO)(diag)-
75, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Starting
Failure.>
Repair the open or
of harness
between ECM con-
nector and main
relay connector.
EN(H4SO)(diag)-75
D: IGNITION CONTROL SYSTEM
CAUTION:
After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-54,
Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)(diag)-44, Inspection Mode.>.
WIRING DIAGRAM:
EN-05701
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
5 3
1
9
B21
E2
E12
SBF-7 15A
3
2
4
9
3
3
4
7
12 34
B137
1
8
2
6
6
3 4
1 2
B47
E
1 2
B225
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
3 4
1 2
5 6
B47
1 2 3 4
E12
9
10
1 2
3 4
5 6
7 8
11 12
14
15 16
13
18
19 20
17
22
23 24
21
38
39 40
37
34
35 36
33
30
31 32
29
26
27 28
25
B225
ECM
RELAY BLOCK MAIN RELAY
BATTERY
IGNITION COIL
&
IGNITOR ASSY
EN(H4SO)(diag)-76
Step Check Yes No
1 CHECK IGNITION SYSTEM FOR SPARKS.
1) Remove the plug cord cap from each spark
plug.
2) Install a new spark plug on plug cord cap.
CAUTION:
Do not remove the spark plug from engine.
3) Contact the spark plug thread portion to
engine.
4) While opening the throttle valve fully, crank
the engine to check that spark occurs at each
cylinder.
Does spark occur at each cylin-
der?
Check fuel pump
system. <Ref. to
EN(H4SO)(diag)-
78, FUEL PUMP
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
Go to step 2.
2 CHECK POWER SUPPLY CIRCUIT FOR IG-
NITION COIL AND IGNITOR ASSEMBLY.
2) Disconnect the connector from the ignition
ignition coil and ignitor assembly connector and
engine ground.
(E12) No. 2 (+) Engine ground ():
Is the voltage 10 V or more? Go to step 3. Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between the
ignition coil and igni-
tor assembly, and
main relay connector
Poor contact of
coupling connector
Blown out of fuse
3 CHECK HARNESS BETWEEN IGNITION
COIL AND IGNITOR ASSEMBLY, AND ECM.
2) Measure the resistance between the igni-
tion coil and ignitor assembly connector, and
ECM.
(E12) No. 3 (B137) No. 6:
(E12) No. 3 (B137) No. 26:
and connector.
NOTE:
the following item:
Open circuit in har-
ness between igni-
tion coil and ignitor
assembly connec-
tor, and ECM
4 CHECK IGNITION COIL AND IGNITOR AS-
SEMBLY.
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:
Is the resistance between 10
and 15 k?
Go to step 5. Replace the igni-
assembly. <Ref. to
IG(H4SO)-6, Igni-
tion Coil and Ignitor
Assembly.>
5 CHECK INPUT SIGNAL FOR IGNITION COIL
AND IGNITOR ASSEMBLY.
1) Connect the connector to the Ignition coil
and ignitor assembly.
2) Check if voltage varies synchronously with
engine speed when cranking, while monitoring
voltage between ignition coil and ignitor assem-
bly connector and engine ground.
Does the voltage vary 10 V or
more?
Go to step 6. Replace the igni-
assembly. <Ref. to
IG(H4SO)-6, Igni-
tion Coil and Ignitor
Assembly.>
EN(H4SO)(diag)-77
6 CHECK HARNESS BETWEEN ECM AND IG-
NITION COIL AND IGNITOR ASSEMBLY
CONNECTOR.
ECM and ignition coil and ignitor assembly con-
nector.
(B137) No. 18 (E12) No. 1:
(B137) No. 19 (E12) No. 4:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and ignition
coil and ignitor as-
sembly connector
Poor contact of
coupling connector
CONNECTOR.
ECM and engine ground.
Connector & terminal:
(B137) No. 18 Engine ground:
more?
Go to step 8. Repair the ground
short circuit of har-
ness between
ECM and ignition
coil and ignitor
assembly connec-
tor.
connector?
Repair poor con-
tact of the ECM
connector.
Check fuel pump
circuit. <Ref. to
EN(H4SO)(diag)-
78, FUEL PUMP
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
Step Check Yes No
EN(H4SO)(diag)-78
E: FUEL PUMP CIRCUIT
CAUTION:
WIRING DIAGRAM:
EN-05702
5
3
B97
MAIN SBF No.12 SBF-6
E
3 1
B72
B362
B136
No.11
B136 B72
1 3
4 5 6
2
R142 R58
5
6
7 8
3
4
1 2
B362
1
2
1
2
R58
M
6
5
E
R142
2
1
B97
R1
2
0
R67 R46
12
R67
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
1
4
3
2
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
1 2
3 4
5 6
BATTERY
ECM
IGNITION
SWITCH
FUEL PUMP
RELAY
FUEL PUMP
FUEL PUMP
CONDENSER
EN(H4SO)(diag)-79
Step Check Yes No
1 CHECK OPERATING SOUND OF FUEL
PUMP.
Make sure that the fuel pump operates for two
seconds when turning the ignition switch to ON.
NOTE:
Fuel pump operation can be executed using the
Regarding the procedures, refer to Compulso-
ry Valve Operation Check Mode. <Ref. to
tion Check Mode.>
Does the fuel pump emit oper-
ating sound?
Check the fuel
injector circuit.
<Ref. to
EN(H4SO)(diag)-
81, FUEL INJEC-
TOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
Go to step 2.
2 CHECK GROUND CIRCUIT OF FUEL PUMP.
2) Remove the fuel pump access hole lid.
4) Measure the resistance of harness connec-
tor between fuel pump and chassis ground.
(R58) No. 6 Chassis ground:
and connector.
NOTE:
the following item:
Open circuit in har-
ness between fuel
pump connector
and chassis
grounding terminal
3 CHECK POWER SUPPLY TO FUEL PUMP.
2) Measure the voltage of power supply circuit
between fuel pump connector and chassis
ground.
(R58) No. 5 (+) Chassis ground ():
Is the voltage 10 V or more? Replace the fuel
pump. <Ref. to
FU(H4SO)-53,
Fuel Pump.>
Go to step 4.
4 CHECK HARNESS BETWEEN FUEL PUMP
AND FUEL PUMP RELAY CONNECTOR.
2) Measure the resistance of harness connec-
tor between fuel pump and fuel pump relay.
(R58) No. 5 (B362) No. 2:
and connector.
NOTE:
the following item:
Open circuit in
harness between
fuel pump connec-
tor and chassis
grounding terminal
Poor contact of
coupling connector
AND FUEL PUMP RELAY CONNECTOR.
fuel pump and fuel pump relay connector.
more?
Go to step 6. Repair the short
circuit of harness
between fuel pump
and fuel pump
relay connector.
6 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 con-
nector terminals No. 3 and No. 4.
4) Measure the resistance between connector
terminals of fuel pump relay.
Terminals
No. 1 No. 2:
?
Go to step 7. Replace the fuel
pump relay. <Ref.
to FU(H4SO)-39,
Fuel Pump Relay.>
EN(H4SO)(diag)-80
FUEL PUMP RELAY CONNECTOR.
ECM and fuel pump relay connector.
(B136) No. 12 (B362) No. 3:
circuit of harness
between ECM and
fuel pump relay
connector.
connector?
Repair poor con-
tact of the ECM
connector.
Check the fuel
injector circuit.
<Ref. to
EN(H4SO)(diag)-
81, FUEL INJEC-
TOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
Step Check Yes No
EN(H4SO)(diag)-81
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)-54, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)(di-
ag)-44, PROCEDURE, Inspection Mode.>.
WIRING DIAGRAM:
EN-05703
E6 E17
E5 E16
1 2
1 21 21 21 2
1
0
9 8
1
1
4
2
4
8
4
3
4
4
4
5
B137
E5 E16 E6 E17
B21
E2
SBF-7
B47
1
2
4
6
3
5
B47
3 4
1 2
5 6
E
B137 B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
MAIN RELAY
BATTERY
ECM
FUEL INJECTOR
No.1
FUEL INJECTOR
No.2
FUEL INJECTOR
No.3
FUEL INJECTOR
No.4
EN(H4SO)(diag)-82
Step Check Yes No
1 CHECK OPERATION OF EACH FUEL INJEC-
TOR.
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.
ating sound?
Check the fuel
pressure. <Ref. to
ME(H4SO)-26,
INSPECTION,
Fuel Pressure.>
Go to step 2.
2 CHECK POWER SUPPLY TO EACH FUEL IN-
JECTOR.
2) Disconnect the connector from fuel injector.
fuel injector terminal and engine ground.
#1 (E5) No. 2 (+) Engine ground ():
and connector.
NOTE:
the following item:
Open circuit of
harness between
main relay and fuel
injector connector
Poor contact of
main relay connec-
tor
Poor contact of
coupling connector
Poor contact of
fuel injector con-
nector
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:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel in-
jector connector
Poor contact of
coupling connector
#1 (B137) No. 8 Chassis ground:
more?
ness between
ECM and fuel
injector connector.
5 CHECK EACH FUEL INJECTOR.
2) Measure the resistance between each fuel
injector terminals.
Terminals
No. 1 No. 2:
20 ?
Go to step 6. Replace the faulty
fuel injector.
connector?
Repair poor con-
tact of the ECM
connector.
Inspection using
General Diagnos-
tic Table <Ref. to
EN(H4SO)(diag)-
307, INSPEC-
TION, General
Diagnostic Table.>
EN(H4SO)(diag)-83
List of Diagnostic Trouble Code (DTC)
18.List of Diagnostic Trouble Code (DTC)
A: LIST
DTC Item Reference
P0026 Intake Valve Control Solenoid Circuit
Range/Performance (Bank 1)
<Ref. to EN(H4SO)(diag)-90, DTC P0026 INTAKE VALVE CONTROL SOLE-
NOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
P0030 HO2S Heater Control Circuit
(Bank 1 Sensor 1)
<Ref. to EN(H4SO)(diag)-94, DTC P0030 HO2S HEATER CONTROL CIR-
CUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0031 HO2S Heater Control Circuit Low
(Bank 1 Sensor 1)
CUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0032 HO2S Heater Control Circuit High
(Bank 1 Sensor 1)
CUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
(Bank 1 Sensor 2)
CUIT LOW (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
(Bank 1 Sensor 2)
CUIT HIGH (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0068 MAP/MAF - Throttle Position
Correlation
<Ref. to EN(H4SO)(diag)-104, DTC P0068 MAP/MAF - THROTTLE POSI-
TION CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Low (Bank 1)
NOID CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
High (Bank 1)
NOID CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
Low (Bank 2)
NOID CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
High (Bank 2)
NOID CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0101 Mass or Volume Air Flow Circuit
Range/Performance
<Ref. to EN(H4SO)(diag)-114, 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
CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0107 Manifold Absolute Pressure/Barometric
Pressure Circuit Low Input
<Ref. to EN(H4SO)(diag)-120, DTC P0107 MANIFOLD ABSOLUTE PRES-
SURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
P0108 Manifold Absolute Pressure/Barometric
Pressure Circuit High Input
<Ref. to EN(H4SO)(diag)-122, DTC P0108 MANIFOLD ABSOLUTE PRES-
SURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Proce-
EN(H4SO)(diag)-84
P0111 Intake Air Temperature Sensor 1
Circuit Range/Performance
<Ref. to EN(H4SO)(diag)-124, DTC P0111 INTAKE AIR TEMPERATURE
SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
Circuit Low
SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Circuit High
SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0117 Engine Coolant Temperature Circuit
Low
<Ref. to EN(H4SO)(diag)-130, DTC P0117 ENGINE COOLANT TEMPERA-
TURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
High
<Ref. to EN(H4SO)(diag)-132, DTC P0118 ENGINE COOLANT TEMPERA-
TURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0122 Throttle/Pedal Position Sensor/Switch
A Circuit Low
<Ref. to EN(H4SO)(diag)-134, DTC P0122 THROTTLE/PEDAL POSITION
SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Procedure with Diagnostic
A Circuit High
SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic
P0125 Insufficient Coolant Temperature for
Closed Loop Fuel Control
<Ref. to EN(H4SO)(diag)-138, DTC P0125 INSUFFICIENT COOLANT TEM-
PERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Procedure
P0126 Insufficient Engine Coolant
Temperature for Stable Operation
<Ref. to EN(H4SO)(diag)-139, DTC P0126 INSUFFICIENT ENGINE COOL-
ANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Procedure with
P0128 Coolant Thermostat (Engine Coolant
Temperature Below Thermostat
<Ref. to EN(H4SO)(diag)-140, DTC P0128 COOLANT THERMOSTAT
(ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING
TEMPERATURE), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0131 O2 Sensor Circuit Low Voltage
(Bank 1 Sensor 1)
<Ref. to EN(H4SO)(diag)-141, DTC P0131 O2 SENSOR CIRCUIT LOW
VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0132 O2 Sensor Circuit High Voltage
(Bank 1 Sensor 1)
<Ref. to EN(H4SO)(diag)-143, DTC P0132 O2 SENSOR CIRCUIT HIGH
ble Code (DTC).>
P0133 O2 Sensor Circuit Slow Response
(Bank 1 Sensor 1)
<Ref. to EN(H4SO)(diag)-145, DTC P0133 O2 SENSOR CIRCUIT SLOW
RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
P0134 O2 Sensor Circuit No Activity
Detected (Bank 1 Sensor 1)
<Ref. to EN(H4SO)(diag)-147, DTC P0134 O2 SENSOR CIRCUIT NO ACTIV-
ITY DETECTED (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
(Bank 1 Sensor 2)
<Ref. to EN(H4SO)(diag)-149, DTC P0137 O2 SENSOR CIRCUIT LOW
ble Code (DTC).>
(Bank 1 Sensor 2)
<Ref. to EN(H4SO)(diag)-151, DTC P0138 O2 SENSOR CIRCUIT HIGH
ble Code (DTC).>
(Bank 1 Sensor 2)
<Ref. to EN(H4SO)(diag)-153, DTC P0139 O2 SENSOR CIRCUIT SLOW
Detected (Bank1 Sensor2)
<Ref. to EN(H4SO)(diag)-155, DTC P0140 O2 SENSOR CIRCUIT NO ACTIV-
ITY DETECTED (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic
P0171 System Too Lean (Bank 1) <Ref. to EN(H4SO)(diag)-158, DTC P0171 SYSTEM TOO LEAN (BANK 1),
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
DTC Item Reference
EN(H4SO)(diag)-85
P0172 System Too Rich (Bank 1) <Ref. to EN(H4SO)(diag)-158, DTC P0172 SYSTEM TOO RICH (BANK 1),
P0181 Fuel Temperature Sensor A Circuit
Range/Performance
<Ref. to EN(H4SO)(diag)-160, DTC P0181 FUEL TEMPERATURE SENSOR
A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
Low Input
A CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
High Input
A CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0196 Engine Oil Temperature Sensor
<Ref. to EN(H4SO)(diag)-166, DTC P0196 ENGINE OIL TEMPERATURE
SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with
P0197 Engine Oil Temperature Sensor Low <Ref. to EN(H4SO)(diag)-168, DTC P0197 ENGINE OIL TEMPERATURE
SENSOR LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0198 Engine Oil Temperature Sensor High <Ref. to EN(H4SO)(diag)-170, DTC P0198 ENGINE OIL TEMPERATURE
SENSOR HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
B Circuit Low
SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Procedure with Diagnostic
B Circuit High
SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Procedure with Diagnostic
P0301 Cylinder 1 Misfire Detected <Ref. to EN(H4SO)(diag)-175, DTC P0301 CYLINDER 1 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)-182, DTC P0327 KNOCK SENSOR 1 CIRCUIT
LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic
P0328 Knock Sensor 1 Circuit High
<Ref. to EN(H4SO)(diag)-184, DTC P0328 KNOCK SENSOR 1 CIRCUIT
HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic
P0335 Crankshaft Position Sensor A Circuit <Ref. to EN(H4SO)(diag)-186, DTC P0335 CRANKSHAFT POSITION SEN-
SOR A CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Range/Performance
<Ref. to EN(H4SO)(diag)-188, DTC P0336 CRANKSHAFT POSITION SEN-
SOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with
P0340 Camshaft Position Sensor A Circuit
<Ref. to EN(H4SO)(diag)-190, DTC P0340 CAMSHAFT POSITION SENSOR
A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with
Range/Performance (Bank 1 or Sin-
gle Sensor)
<Ref. to EN(H4SO)(diag)-192, DTC P0341 CAMSHAFT POSITION SENSOR
A CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR),
P0400 Exhaust Gas Recirculation Flow <Ref. to EN(H4SO)(diag)-194, 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)-196, DTC P0420 CATALYST SYSTEM EFFICIENCY
BELOW THRESHOLD (BANK 1), Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
DTC Item Reference
EN(H4SO)(diag)-86
P0442 Evaporative Emission Control
System Leak Detected (Small Leak)
<Ref. to EN(H4SO)(diag)-200, DTC P0442 EVAPORATIVE EMISSION CON-
TROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Procedure
System Vent Control Circuit Open
TROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Procedure
System Vent Control Circuit Shorted
TROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Proce-
System Pressure Sensor
TROL SYSTEM PRESSURE SENSOR, Diagnostic Procedure with Diagnostic
System Pressure Sensor Low Input
TROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Procedure
System Pressure Sensor High Input
TROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Procedure
System Leak Detected
(Very Small Leak)
TROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Proce-
System Leak Detected
(Fuel Cap Loose/Off)
TROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P0458 Evaporative Emission System Purge
Control Valve Circuit Low
<Ref. to EN(H4SO)(diag)-219, DTC P0458 EVAPORATIVE EMISSION SYS-
TEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Procedure with
Control Valve Circuit High
<Ref. to EN(H4SO)(diag)-221, DTC P0459 EVAPORATIVE EMISSION SYS-
TEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Procedure with
P0461 Fuel Level Sensor A Circuit Range
/Performance
<Ref. to EN(H4SO)(diag)-222, DTC P0461 FUEL LEVEL SENSOR A CIR-
CUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0462 Fuel Level Sensor A Circuit Low <Ref. to EN(H4SO)(diag)-222, DTC P0462 FUEL LEVEL SENSOR A CIR-
CUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0463 Fuel Level Sensor A Circuit High <Ref. to EN(H4SO)(diag)-223, DTC P0463 FUEL LEVEL SENSOR A CIR-
CUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0464 Fuel Level Sensor Circuit Intermittent <Ref. to EN(H4SO)(diag)-223, DTC P0464 FUEL LEVEL SENSOR CIRCUIT
INTERMITTENT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0500 Vehicle Speed Sensor A <Ref. to EN(H4SO)(diag)-224, DTC P0500 VEHICLE SPEED SENSOR A,
P0506 Idle Air Control System RPM Lower
Than Expected
<Ref. to EN(H4SO)(diag)-225, DTC P0506 IDLE AIR CONTROL SYSTEM
RPM LOWER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0507 Idle Air Control System RPM Higher
Than Expected
<Ref. to EN(H4SO)(diag)-227, DTC P0507 IDLE AIR CONTROL SYSTEM
RPM HIGHER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0512 Starter Request Circuit <Ref. to EN(H4SO)(diag)-229, DTC P0512 STARTER REQUEST CIRCUIT,
P0513 Incorrect Immobilizer Key <Ref. to IM(diag)-16, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
P0600 Serial Communication Link <Ref. to EN(H4SO)(diag)-230, DTC P0600 SERIAL COMMUNICATION LINK,
P0604 Internal Control Module Random
Access Memory (RAM) Error
<Ref. to EN(H4SO)(diag)-231, DTC P0604 INTERNAL CONTROL MODULE
RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with
DTC Item Reference
EN(H4SO)(diag)-87
P0605 Internal Control Module Read Only
Memory (ROM) Error
<Ref. to EN(H4SO)(diag)-232, DTC P0605 INTERNAL CONTROL MODULE
READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with Diagnostic
P0607 Control Module Performance <Ref. to EN(H4SO)(diag)-233, DTC P0607 CONTROL MODULE PERFOR-
MANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0638 Throttle Actuator Control Range
/Performance (Bank 1)
<Ref. to EN(H4SO)(diag)-234, DTC P0638 THROTTLE ACTUATOR CON-
TROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P0700 Transmission Control System
(MIL Request)
<Ref. to EN(H4SO)(diag)-234, DTC P0700 TRANSMISSION CONTROL SYS-
TEM (MIL REQUEST), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
(AT Model)
<Ref. to EN(H4SO)(diag)-235, DTC P0851 PARK/NEUTRAL SWITCH INPUT
CIRCUIT LOW (AT MODEL), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
(MT Model)
<Ref. to EN(H4SO)(diag)-237, DTC P0851 NEUTRAL SWITCH INPUT CIR-
CUIT LOW (MT MODEL), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
(AT Model)
<Ref. to EN(H4SO)(diag)-239, DTC P0852 PARK/NEUTRAL SWITCH INPUT
CIRCUIT HIGH (AT MODEL), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0852 Neutral Switch Input Circuit High
(MT Model)
<Ref. to EN(H4SO)(diag)-241, DTC P0852 NEUTRAL SWITCH INPUT CIR-
CUIT HIGH (MT MODEL), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1152 O2 Sensor Circuit Range
/Performance (Low) (Bank1 Sensor1)
<Ref. to EN(H4SO)(diag)-243, DTC P1152 O2 SENSOR CIRCUIT RANGE/
PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Procedure with
P1153 O2 Sensor Circuit Range
/Performance (High) (Bank1 Sensor1)
<Ref. to EN(H4SO)(diag)-245, DTC P1153 O2 SENSOR CIRCUIT RANGE/
PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Procedure with
P1160 Return Spring Failure <Ref. to EN(H4SO)(diag)-246, DTC P1160 RETURN SPRING FAILURE,
P1400 Fuel Tank Pressure Control Solenoid
Valve Circuit Low
<Ref. to EN(H4SO)(diag)-247, DTC P1400 FUEL TANK PRESSURE CON-
TROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Procedure with Diagnos-
P1420 Fuel Tank Pressure Control Sol. Valve
Circuit High
<Ref. to EN(H4SO)(diag)-249, DTC P1420 FUEL TANK PRESSURE CON-
TROL SOL. VALVE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic
P1443 Vent Control Solenoid Valve Function
Problem
<Ref. to EN(H4SO)(diag)-251, DTC P1443 VENT CONTROL SOLENOID
VALVE FUNCTION PROBLEM, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1491 Positive Crankcase Ventilation
(Blow-by) Function Problem
<Ref. to EN(H4SO)(diag)-253, DTC P1491 POSITIVE CRANKCASE VENTI-
LATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Procedure with Diag-
P1492 EGR Solenoid Valve Signal #1 Circuit
Malfunction (Low Input)
<Ref. to EN(H4SO)(diag)-255, DTC P1492 EGR SOLENOID VALVE SIGNAL
#1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diag-
Malfunction (High Input)
#1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diag-
DTC Item Reference
EN(H4SO)(diag)-88
P1560 Back-up Voltage Circuit Malfunction <Ref. to EN(H4SO)(diag)-261, DTC P1560 BACK-UP VOLTAGE CIRCUIT
MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1570 Antenna <Ref. to IM(diag)-17, DTC P1570 ANTENNA, Diagnostic Procedure with Diag-
P1571 Reference Code Incompatibility <Ref. to IM(diag)-19, DTC P1571 REFERENCE CODE INCOMPATIBILITY,
P1572 IMM Circuit Failure (Except Antenna
Circuit)
<Ref. to IM(diag)-20, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
ANTENNA CIRCUIT), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1574 KEY Communication Failure <Ref. to IM(diag)-22, DTC P1574 KEY COMMUNICATION FAILURE, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC).>
P1576 EGI Control Module EEPROM <Ref. to IM(diag)-23, DTC P1576 EGI CONTROL MODULE EEPROM, Diag-
P1577 IMM Control Module EEPROM <Ref. to IM(diag)-23, DTC P1577 IMM CONTROL MODULE EEPROM, Diag-
P1578 Meter Failure <Ref. to IM(diag)-24, DTC P1578 METER FAILURE, Diagnostic Procedure
P1602 Control Module Programming Error <Ref. to EN(H4SO)(diag)-263, DTC P1602 CONTROL MODULE PROGRAM-
MING ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2096 Post Catalyst Fuel Trim System Too
Lean Bank 1
<Ref. to EN(H4SO)(diag)-273, DTC P2096 POST CATALYST FUEL TRIM
SYSTEM TOO LEAN BANK 1, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Rich Bank 1
<Ref. to EN(H4SO)(diag)-278, DTC P2097 POST CATALYST FUEL TRIM
SYSTEM TOO RICH BANK 1, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P2101 Throttle Actuator Control Motor Circuit
Range/Performance
TROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure
Low
TROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
High
TROL 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
D Circuit Low Input
SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Procedure with
D Circuit High Input
SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Procedure with
DTC Item Reference
EN(H4SO)(diag)-89
E Circuit Low Input
SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Procedure with
E Circuit High Input
SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Procedure with
A/B Voltage Correlation
SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Procedure
D/E Voltage Correlation
SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Procedure
P2227 Barometric Pressure Circuit Range
/Performance
<Ref. to EN(H4SO)(diag)-305, DTC P2227 BAROMETRIC PRESSURE CIR-
ble Code (DTC).>
P2228 Barometric Pressure Circuit Low <Ref. to EN(H4SO)(diag)-305, DTC P2228 BAROMETRIC PRESSURE CIR-
P2229 Barometric Pressure Circuit High <Ref. to EN(H4SO)(diag)-306, DTC P2229 BAROMETRIC PRESSURE CIR-
DTC Item Reference
EN(H4SO)(diag)-90
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:
EN-04025
B134
3
1
B21
E2
2
1
ECM
B21
1
VVL DIAGNOSIS
OIL PRESSURE SWITCH RH
E71
B134
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
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
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
EN(H4SO)(diag)-91
Step Check Yes No
VARIABLE VALVE LIFT DIAGNOSIS OIL
PRESSURE SWITCH.
3) Disconnect the connectors from the ECM
and variable valve lift diagnosis oil pressure
switch.
ECM and variable valve lift diagnosis oil pres-
sure switch connector.
(B134) No. 31 (E71) No. 1:
circuit of harness
between ECM and
variable valve lift
diagnosis oil pres-
sure switch con-
nector.
PRESSURE SWITCH.
Measure the resistance between the variable
valve lift diagnosis oil pressure switch connec-
tor and engine ground.
(E71) No. 1 Engine ground:
more?
ness between
ECM and variable
valve lift diagnosis
oil pressure switch
connector.
PRESSURE SWITCH.
2) Measure the voltage between the variable
Is the voltage 10 V or more? Repair the short
circuit to power of
the harness
between the ECM
and variable valve
lift diagnosis oil
pressure switch
connector.
Go to step 4.
4 CHECK DTC.
1) Perform the Clear Memory Mode.
2) After idling the engine, check the DTC.
NOTE:
For detailed procedures, refer to Clear Memory
Mode. <Ref. to EN(H4SO)(diag)-54, Clear
Memory Mode.>
Is DTC displayed? Replace the oil
switching solenoid
valve. <Ref. to
ME(H4SO)-87, Oil
Switching Solenoid
Valve.> Go to step
5.
END.
5 CHECK DTC.
NOTE:
Memory Mode.>
Is DTC displayed? Check for oil rout-
ing.
END.
EN(H4SO)(diag)-92
B: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE
/PERFORMANCE (BANK 2)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-04026
1
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
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
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
B21
E2
2
2
B134
3
2
ECM
VVL DIAGNOSIS
OIL PRESSURE SWITCH LH
E72
B21
B134
EN(H4SO)(diag)-93
Step Check Yes No
PRESSURE SWITCH.
switch.
(B134) No. 32 (E72) No. 1:
circuit of harness
between ECM and
variable valve lift
diagnosis oil pres-
sure switch con-
nector.
PRESSURE SWITCH.
more?
ness between
ECM and variable
oil pressure switch
connector.
PRESSURE SWITCH.
circuit to power of
the harness
between the ECM
and variable valve
lift diagnosis oil
pressure switch
connector.
Go to step 4.
4 CHECK DTC.
NOTE:
Memory Mode.>
switching solenoid
valve. <Ref. to
ME(H4SO)-87, Oil
Switching Solenoid
Valve.> Go to step 5.
END.
5 CHECK DTC.
NOTE:
Memory Mode.>
ing.
END.
EN(H4SO)(diag)-94
C: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
Detected when two consecutive driving cycles with fault occur.
GENERAL DESCRIPTION <Ref. to GD(H4SO)-12, DTC P0030 HO2S HEATER CONTROL CIRCUIT
(BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05042
B137
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
31 26 27
3 4
1 2
5 6
B327
SBF-5
E
E
B327
E22
6
4
5
3
2
1
6
41 3
B
1
B
9
B
8
C
3
C
2
A
5
D
7
D
1
D
2
D
3
3
6
5
2
3
4
3
5
3
7
B134 A:
B135 B:
B136 C:
B137 D:
B21
E2
ECM
B21 E2
50
5
1
3 4
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E22 B138
B134
B135
A:
B:
B136 C:
D:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B138
*
*
*
3 1
6 5 4
2
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
3 4
5 6
1 2
7 8
OXYGEN SENSOR RELAY
FRONT
OXYGEN (A/F)
SENSOR
BATTERY
ARRANGEMENT
EN(H4SO)(diag)-95
Step Check Yes No
FRONT OXYGEN (A/F) SENSOR CONNEC-
TOR.
and front oxygen (A/F) sensor.
ECM and front oxygen (A/F) sensor connector.
(B136) No. 2 (E22) No. 4:
(B136) No. 3 (E22) No. 4:
circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
TOR.
(B135) No. 9 (E22) No. 1:
(B135) No. 8 (E22) No. 3:
circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
3 CHECK FRONT OXYGEN (A/F) SENSOR.
Measure the resistance between front oxygen
(A/F) sensor connector terminals.
Terminals
No. 6 No. 4:
Is the resistance less than 5 ? Go to step 4. Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4SO)-33,
Front Oxygen (A/F)
Sensor.>
Check poor contact of ECM and front oxygen
(A/F) sensor connector.
Is there poor contact in ECM or
front oxygen (A/F) sensor con-
nector?
Repair the poor
contact of ECM or
front oxygen (A/F)
sensor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4SO)-33,
Front Oxygen (A/F)
Sensor.>
EN(H4SO)(diag)-96
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:
EN-05042
B137
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
31 26 27
3 4
1 2
5 6
B327
SBF-5
E
E
B327
E22
6
4
5
3
2
1
6
41 3
B
1
B
9
B
8
C
3
C
2
A
5
D
7
D
1
D
2
D
3
3
6
5
2
3
4
3
5
3
7
B134 A:
B135 B:
B136 C:
B137 D:
B21
E2
ECM
B21 E2
50
5
1
3 4
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E22 B138
B134
B135
A:
B:
B136 C:
D:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B138
*
*
*
3 1
6 5 4
2
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
3 4
5 6
1 2
7 8
OXYGEN SENSOR RELAY
FRONT
OXYGEN (A/F)
SENSOR
BATTERY
ARRANGEMENT
EN(H4SO)(diag)-97
Step Check Yes No
1 CHECK POWER SUPPLY TO FRONT OXY-
GEN (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.
supply line or
replace the main
relay.
NOTE:
the following item:
Open circuit in
harness between
A/F, oxygen sen-
sor relay and front
oxygen (A/F) sen-
sor connector
Poor contact in
A/F, oxygen sen-
sor relay connector
Poor contact in
coupling connector
FRONT OXYGEN (A/F) SENSOR.
3) Measure the resistance between ECM and
front oxygen (A/F) sensor connector.
(B136) No. 2 (E22) No. 4:
(B136) No. 3 (E22) No. 4:
circuit of harness
between ECM and
front oxygen (A/F)
sensor.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
Terminals
No. 6 No. 4:
Is the resistance between
2 3 ?
Repair poor con-
tact of the ECM
connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4SO)-33,
Front Oxygen (A/F)
Sensor.>
EN(H4SO)(diag)-98
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:
EN-05042
B137
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
31 26 27
3 4
1 2
5 6
B327
SBF-5
E
E
B327
E22
6
4
5
3
2
1
6
41 3
B
1
B
9
B
8
C
3
C
2
A
5
D
7
D
1
D
2
D
3
3
6
5
2
3
4
3
5
3
7
B134 A:
B135 B:
B136 C:
B137 D:
B21
E2
ECM
B21 E2
50
5
1
3 4
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E22 B138
B134
B135
A:
B:
B136 C:
D:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B138
*
*
*
3 1
6 5 4
2
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
3 4
5 6
1 2
7 8
OXYGEN SENSOR RELAY
FRONT
OXYGEN (A/F)
SENSOR
BATTERY
ARRANGEMENT
EN(H4SO)(diag)-99
Step Check Yes No
2) Measure the voltage between ECM and
chassis ground.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
nector.
Go to step 2.
chassis ground.
Is the resistance less than 5 ? Repair the poor
contact of the ECM
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact of
coupling connector
EN(H4SO)(diag)-100
F: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)
CAUTION:
WIRING DIAGRAM:
EN-05043
A
5
D
1
D
2
D
3
D
7
3
6
3
4
3
5
3
7
5
2
ECM
B21
B138
E2
B135 B:
D: B137
C: B136
E
A: B134
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
A:
B:
C:
D:
*
*
*
3 4
1 2
5 6
B327
SBF-5
E
B327
E23
6
4
5
3
2
1
1
B21 E2
50
5
3
1
1
9
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E23
REAR OXYGEN
SENSOR
1
3 4
2
2
3 4
B
1
B
4
A
2
9
C
4
B138
3 4
5 6
1 2
7 8
OXYGEN SENSOR RELAY BATTERY
: TERMINAL No. OPTIONAL ARRANGEMENT
AMONG 3, 4, 7 AND 8
EN(H4SO)(diag)-101
Step Check Yes No
1 CHECK POWER SUPPLY TO REAR OXY-
GEN SENSOR.
2) Disconnect the connector from the rear oxy-
gen sensor.
4) Measure the voltage between rear oxygen
sensor connector and engine ground.
supply line or
replace the main
relay.
NOTE:
the following item:
Open circuit in
harness between
A/F, oxygen sen-
sor relay and rear
oxygen sensor
Poor contact in
A/F, oxygen sen-
sor relay connector
Poor contact in
coupling connector
REAR OXYGEN SENSOR.
oxygen sensor connector.
(B136) No. 4 (E23) No. 1:
circuit of the har-
ness between
ECM and rear oxy-
gen sensor.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
4 CHECK REAR OXYGEN SENSOR.
Measure the resistance between rear oxygen
sensor connector terminals.
Terminals
No. 2 No. 1:
7 ?
Repair poor con-
tact of the ECM
connector.
Replace the rear
oxygen sensor.
<Ref. to
FU(H4SO)-35,
Rear Oxygen Sen-
sor.>
EN(H4SO)(diag)-102
G: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
CAUTION:
WIRING DIAGRAM:
EN-05043
A
5
D
1
D
2
D
3
D
7
3
6
3
4
3
5
3
7
5
2
ECM
B21
B138
E2
B135 B:
D: B137
C: B136
E
A: B134
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
A:
B:
C:
D:
*
*
*
3 4
1 2
5 6
B327
SBF-5
E
B327
E23
6
4
5
3
2
1
1
B21 E2
50
5
3
1
1
9
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E23
REAR OXYGEN
SENSOR
1
3 4
2
2
3 4
B
1
B
4
A
2
9
C
4
B138
3 4
5 6
1 2
7 8
AMONG 3, 4, 7 AND 8
EN(H4SO)(diag)-103
Step Check Yes No
REAR OXYGEN SENSOR.
chassis ground.
circuit to power in
the harness
between ECM and
rear oxygen sen-
sor connector.
Go to step 2.
chassis ground.
contact of the ECM
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact of
coupling connector
EN(H4SO)(diag)-104
H: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
GENERAL DESCRIPTION <Ref. to GD(H4SO)-22, DTC P0068 MAP/MAF - THROTTLE POSITION
CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-04029
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1
9
2
0
7
B21
E2
23 1
E21
E21
ECM
B21
B134
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
1 2 3
2
9
6
1
9
EN(H4SO)(diag)-105
Step Check Yes No
1 CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or
disconnection of hose on air
intake system?
Repair the air
intake system.
Go to step 2.
2 CHECK MANIFOLD ABSOLUTE PRESSURE
SENSOR.
1) Start the engine and warm-up engine until
coolant temperature is higher than 75C
(167F).
2) For AT models, set the select lever to the P
or N range, and for MT models, place the shift
lever in the neutral position.
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:
For detailed operation procedures, refer to
READ CURRENT DATA FOR ENGINE. <Ref.
to EN(H4SO)(diag)-34, Subaru Select Moni-
tor.>
General scan tool
General Scan Tool Instruction Manual.
Is the measured value 73.3
106.6 kPa (550 800 mmHg,
21.65 31.50 inHg) when the
ignition is turned ON, and 20.0
46.7 kPa (150 350 mmHg,
5.91 13.78 inHg) during
idling?
Go to step 3. Replace the mani-
fold absolute pres-
sure sensor. <Ref.
to FU(H4SO)-25,
Manifold Absolute
Pressure Sensor.>
3 CHECK THROTTLE OPENING ANGLE.
Read the data of throttle position signal using
NOTE:
tor.>
General scan tool
Is the measured value less than
5% when throttle is fully
closed?
Go to step 4. Replace the elec-
tronic throttle con-
trol. <Ref. to
FU(H4SO)-11,
Throttle Body.>
4 CHECK THROTTLE OPENING ANGLE. Is the measured value 85% or
more when throttle is fully
open?
Replace the mani-
fold absolute pres-
sure sensor. <Ref.
to FU(H4SO)-25,
Manifold Absolute
Pressure Sensor.>
Replace the elec-
trol. <Ref. to
FU(H4SO)-11,
Throttle Body.>
EN(H4SO)(diag)-106
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:
EN-05704
B21
E2
B137
E67
2
4
2 1
2
4
2
3E67
B21
1 2
2
5
B137
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
ECM
OIL SWITCHING SOLENOID VALVE RH
EN(H4SO)(diag)-107
Step Check Yes No
1 CHECK HARNESS BETWEEN ECM AND OIL
SWITCHING SOLENOID VALVE.
and oil switching solenoid valve.
ECM and oil switching solenoid valve.
(B137) No. 25 (E67) No. 1:
(B137) No. 24 (E67) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and oil
switching solenoid
valve connector
Poor contact of
coupling connector
Measure the resistance between ECM and
chassis ground.
more?
ness between
ECM and oil
switching solenoid
valve connector.
3 CHECK OIL SWITCHING SOLENOID VALVE.
Measure the resistance between oil switching
solenoid valve terminals.
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of ECM
and oil switching
solenoid valve
connector.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H4SO)-87, Oil
Switching Solenoid
Valve.>
EN(H4SO)(diag)-108
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:
EN-05704
B21
E2
B137
E67
2
4
2 1
2
4
2
3E67
B21
1 2
2
5
B137
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
ECM
OIL SWITCHING SOLENOID VALVE RH
EN(H4SO)(diag)-109
Step Check Yes No
chassis ground.
Is the voltage less than 1 V? Go to step 2. Repair the short
circuit to power in
the harness
between ECM and
oil switching sole-
noid valve connec-
tor.
ECM and oil switching solenoid valve connec-
tor.
(B137) No. 25 (E67) No. 1:
(B137) No. 24 (E67) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and oil
switching solenoid
valve connector
Poor contact of
coupling connector
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of ECM
and oil switching
solenoid valve
connector.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H4SO)-87, Oil
Switching Solenoid
Valve.>
EN(H4SO)(diag)-110
K: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)
GENERAL DESCRIPTION<Ref. to GD(H4SO)-27, DTC P0082 INTAKE VALVE CONTROL SOLENOID
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05705
B21
E2
B137
E68
3
0
2 1
2
8
2
7E68
B21
1 2
3
1
B137
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
ECM
OIL SWITCHING SOLENOID VALVE LH
EN(H4SO)(diag)-111
Step Check Yes No
oil switching solenoid valve.
(B137) No. 31 (E68) No. 1:
(B137) No. 30 (E68) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and oil
switching solenoid
valve connector
Poor contact of
coupling connector
chassis ground.
more?
ness between
ECM and oil
switching solenoid
valve connector.
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of ECM
and oil switching
solenoid valve
connector.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H4SO)-87, Oil
Switching Solenoid
Valve.>
EN(H4SO)(diag)-112
L: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)
GENERAL DESCRIPTION<Ref. to GD(H4SO)-27, DTC P0083 INTAKE VALVE CONTROL SOLENOID
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05705
B21
E2
B137
E68
3
0
2 1
2
8
2
7E68
B21
1 2
3
1
B137
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
ECM
OIL SWITCHING SOLENOID VALVE LH
EN(H4SO)(diag)-113
Step Check Yes No
chassis ground.
circuit to power in
the harness
between ECM and
oil switching sole-
noid valve connec-
tor.
Measure the resistance between the ECM and
oil switching solenoid valve connector.
(B137) No. 31 (E68) No. 1:
(B137) No. 30 (E68) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and oil
switching solenoid
valve connector
Poor contact of
coupling connector
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of ECM
and oil switching
solenoid valve
connector.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H4SO)-87, Oil
Switching Solenoid
Valve.>
EN(H4SO)(diag)-114
M: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE
/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4SO)-28, 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:
EN-05706
E
B83
3
B3
B135
SBF-7
*
*
4 1 5 2
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
*
B3
1 2 3 4 5
3 4
1 2
5 6
B47
1 2 3 4
5 6 7 8
B83 B135
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
MAIN RELAY
BATTERY
MASS AIR FLOW & INTAKE AIR
TEMPERATURE SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
EN(H4SO)(diag)-115
Step Check Yes No
1 CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check the appro-
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
EN(H4SO)(diag)-116
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:
EN-05706
E
B83
3
B3
B135
SBF-7
*
*
4 1 5 2
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
*
B3
1 2 3 4 5
3 4
1 2
5 6
B47
1 2 3 4
5 6 7 8
B83 B135
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
MAIN RELAY
BATTERY
TEMPERATURE SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
EN(H4SO)(diag)-117
Step Check Yes No
1 CHECK CURRENT DATA.
2) Read the data of air flow sensor signal using
the Subaru Select Monitor or general scan tool.
NOTE:
tor.>
General scan tool
Is the voltage less than 0.2 V? Go to step 2. Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the failure,
and then reperform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector
may be the cause.
2 CHECK POWER SUPPLY OF MASS AIR
FLOW AND INTAKE AIR TEMPERATURE
SENSOR.
2) Disconnect the connector from the mass air
4) Measure the voltage between mass air flow
and intake air temperature sensor connector
and engine ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
the main relay and
the mass air flow
and intake air tem
perature sensor
connector.
Poor contact of
main relay connec-
tor
3 CHECK HARNESS BETWEEN ECM, MASS
AIR FLOW AND INTAKE AIR TEMPERA-
TURE SENSOR CONNECTORS.
ECM and the mass air flow and intake air tem-
perature sensor connector.
(B135) No. 26 (B3) No. 5:
circuit of harness
between the ECM
and the mass air
flow and intake air
temperature sen-
sor connector.
chassis ground.
more?
ness between the
ECM and the mass
air flow and intake
air temperature
sensor connector.
Check for any poor contact in the ECM or the
mass air flow or intake air temperature sensor
connector.
ECM or the mass air flow and
intake air temperature sensor
connector?
Repair any poor
contact in the ECM
or the mass air flow
and intake air tem-
perature sensor
connector.
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
EN(H4SO)(diag)-118
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:
EN-05706
E
B83
3
B3
B135
SBF-7
*
*
4 1 5 2
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
*
B3
1 2 3 4 5
3 4
1 2
5 6
B47
1 2 3 4
5 6 7 8
B83 B135
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
MAIN RELAY
BATTERY
TEMPERATURE SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
EN(H4SO)(diag)-119
Step Check Yes No
NOTE:
tor.>
General scan tool
Is the voltage 5 V or more? Go to step 2. Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failute.
NOTE:
tor.>
General scan tool
circuit to power in
the harness
between the ECM
and the mass air
flow & intake air
temperature sen-
sor connectors.
Go to step 3.
mass air flow and intake air temperature sensor
connector and engine ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM, mass air flow
and intake air tem-
perature sensor
connectors.
Poor contact in
ECM connector
Check for any poor contact between the mass
air flow and intake air temperature sensor con-
nectors.
mass air flow and intake air
temperature sensor connec-
tors?
Repair any poor
contact of the
mass air flow and
intake air tempera-
ture sensor con-
nectors.
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
EN(H4SO)(diag)-120
P: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT LOW INPUT
GENERAL DESCRIPTION <Ref. to GD(H4SO)-35, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/
BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-04029
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1
9
2
0
7
B21
E2
23 1
E21
E21
ECM
B21
B134
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
1 2 3
2
9
6
1
9
EN(H4SO)(diag)-121
Step Check Yes No
2) Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor or
general scan tool.
NOTE:
tor.>
General scan tool
13.3 kPa (100 mmHg, 3.94
inHg) ?
Go to step 2. Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failute.
2 CHECK POWER SUPPLY OF THE MANI-
FOLD ABSOLUTE PRESSURE SENSOR.
2) Disconnect the connector from manifold
absolute pressure sensor.
4) Measure the voltage between manifold
absolute pressure sensor connector and
engine ground.
Is the voltage 4.5 V or more? Go to step 3. Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and manifold
absolute pressure
sensor connector.
Poor contact in
ECM connector
Poor contact of
coupling connector
MANIFOLD ABSOLUTE PRESSURE SEN-
SOR CONNECTOR.
ECM and manifold absolute pressure sensor
connector.
(B134) No. 6 (E21) No. 1:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and manifold
absolute pressure
sensor connector.
Poor contact of
coupling connector
SOR CONNECTOR.
chassis ground.
more?
Go to step 5. Repair ground
ness between
ECM and manifold
absolute pressure
sensor connector.
Check for poor contact between the ECM and
manifold pressure sensor connector.
ECM or manifold absolute pres-
sure sensor connector?
Repair the poor
contact in the ECM
or manifold abso-
lute pressure sen-
sor connector.
Replace the mani-
fold absolute pres-
sure sensor. <Ref.
to FU(H4SO)-25,
Manifold Absolute
Pressure Sensor.>
EN(H4SO)(diag)-122
Q: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT HIGH INPUT
GENERAL DESCRIPTION <Ref. to GD(H4SO)-37, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/
BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-04029
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1
9
2
0
7
B21
E2
23 1
E21
E21
ECM
B21
B134
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
1 2 3
2
9
6
1
9
EN(H4SO)(diag)-123
Step Check Yes No
general scan tool.
NOTE:
tor.>
General scan tool
kPa (896.5 mmHg, 35.29 inHg)
or more?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failute.
SOR CONNECTOR.
general scan tool.
NOTE:
tor.>
General scan tool
kPa (896.5 mmHg, 35.29 inHg)
or more?
Repair the short
circuit to power in
the harness
between ECM and
manifold absolute
pressure sensor
connector.
Go to step 3.
SOR CONNECTOR.
manifold absolute pressure sensor connector
and engine ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and manifold
absolute pressure
sensor connector.
Poor contact in
ECM connector
Poor contact of
coupling connector
Check for poor contact of the manifold absolute
pressure sensor connector.
Is there poor contact in mani-
fold absolute pressure sensor
connector?
Repair the poor
contact of mani-
fold absolute pres-
sure sensor
connector.
Replace the mani-
fold absolute pres-
sure sensor. <Ref.
to FU(H4SO)-25,
Manifold Absolute
Pressure Sensor.>
EN(H4SO)(diag)-124
R: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE
/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4SO)-39, DTC P0111 INTAKE AIR TEMPERATURE SENSOR
1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05706
E
B83
3
B3
B135
SBF-7
*
*
4 1 5 2
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
*
B3
1 2 3 4 5
3 4
1 2
5 6
B47
1 2 3 4
5 6 7 8
B83 B135
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
MAIN RELAY
BATTERY
TEMPERATURE SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
EN(H4SO)(diag)-125
Step Check Yes No
1 CHECK ENGINE COOLANT TEMPERA-
TURE.
1) Start the engine and warm-up completely.
2) Measure the engine coolant temperature
using the Subaru Select Monitor or general
scan tool.
NOTE:
tor.>
General scan tool
Is the engine coolant tempera-
ture 75C (167F) or higher?
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Check DTC P0125
using List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
EN(H4SO)(diag)-126
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:
EN-05706
E
B83
3
B3
B135
SBF-7
*
*
4 1 5 2
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
*
B3
1 2 3 4 5
3 4
1 2
5 6
B47
1 2 3 4
5 6 7 8
B83 B135
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
MAIN RELAY
BATTERY
TEMPERATURE SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
EN(H4SO)(diag)-127
Step Check Yes No
2) Read the data of intake air temperature sen-
sor signal using Subaru Select Monitor or gen-
eral scan tool.
NOTE:
tor.>
General scan tool
Is the intake air temperature
120C (248F) or higher?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failute.
2) Disconnect the connector from the ECM
and the mass air flow & intake air temperature
sensor.
chassis ground.
more?
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Repair the ground
ness between the
ECM and the mass
air flow & intake air
temperature sen-
sor connectors.
EN(H4SO)(diag)-128
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:
EN-05706
E
B83
3
B3
B135
SBF-7
*
*
4 1 5 2
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
*
B3
1 2 3 4 5
3 4
1 2
5 6
B47
1 2 3 4
5 6 7 8
B83 B135
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
MAIN RELAY
BATTERY
TEMPERATURE SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
EN(H4SO)(diag)-129
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
less than 40C (40F) ?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failute.
Repair any poor contact between the ECM and
the mass air flow & intake air temperature sen-
sor connectors.
ECM or the mass air flow &
connectors?
Repair any poor
contact between
the ECM and the
mass air flow &
intake air tempera-
ture sensor con-
nectors.
Go to step 3.
sensor.
ECM and mass air flow & intake air temperature
sensor connectors.
(B135) No. 18 (B3) No. 1:
(B135) No. 30 (B3) No. 2:
circuit of harness
between the ECM
and mass air flow
& intake air tem-
perature sensor
connectors.
1) Connect all connectors.
chassis ground.
circuit to power in
the harness
between the ECM
and the mass air
flow & intake air
temperature sen-
sor connectors.
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
EN(H4SO)(diag)-130
U: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
GENERAL DESCRIPTION <Ref. to GD(H4SO)-45, DTC P0117 ENGINE COOLANT TEMPERATURE
CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-04033
2
9
3
4
1
9
8
B134 ECM
1 2
E2
B21
E8
E8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
ENGINE
COOLANT
TEMPERATURE
SENSOR
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H4SO)(diag)-131
Step Check Yes No
2) Read the data of engine coolant tempera-
ture sensor signal using Subaru Select Monitor
or general scan tool.
NOTE:
tor.>
General scan tool
ture 150C (302F) or higher ?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failute.
2 CHECK HARNESS BETWEEN ECM AND EN-
GINE COOLANT TEMPERATURE SENSOR
CONNECTOR.
and engine coolant temperature sensor.
chassis ground.
more?
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H4SO)-20,
Engine Coolant
Temperature Sen-
sor.>
Repair the ground
short circuit of the
harness between
the ECM and
engine coolant
temperature sen-
sor.
EN(H4SO)(diag)-132
V: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4SO)-47, DTC P0118 ENGINE COOLANT TEMPERATURE
CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-04033
2
9
3
4
1
9
8
B134 ECM
1 2
E2
B21
E8
E8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
ENGINE
COOLANT
TEMPERATURE
SENSOR
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H4SO)(diag)-133
Step Check Yes No
NOTE:
tor.>
General scan tool
ture less than 40C (40F) ?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failute.
engine coolant temperature sensor connectors.
ECM or engine coolant temper-
ature sensor connectors?
Repair any poor
contact between
the ECM and
engine coolant
temperature sen-
sor connectors.
Go to step 3.
CONNECTOR.
between the ECM and engine coolant tempera-
ture sensor connector.
(B134) No. 34 (E8) No. 2:
(B134) No. 29 (E8) No. 1:
circuit of the har-
ness between the
ECM and engine
coolant tempera-
ture sensor con-
nector.
CONNECTOR.
chassis ground.
circuit to power in
the harness
between the ECM
and engine coolant
temperature sen-
sor connector.
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H4SO)-20,
Engine Coolant
Temperature Sen-
sor.>
EN(H4SO)(diag)-134
W: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT
LOW
GENERAL DESCRIPTION <Ref. to GD(H4SO)-49, DTC P0122 THROTTLE/PEDAL POSITION SEN-
SOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05044
SBF-7
B134 A: B137 B136 D:
B362
C:
E
C
1
C
2
1
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
D
3
A
2
8
A
1
8
C
6
ECM
5
8
7
6
B362 B21 E57 B122
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B134 A:
B136 C: B137 D:
1 2 3 4 5 6
E2
B21
B122
E
E
3
9
2
0
E57
46 123 5
3
6
3
5
3
7
3
4
5
2
*
*
*
1
8
1
7
3
8
1
9
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ELECTRONIC THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC
THROTTLE CONTROL
ARRANGEMENT
EN(H4SO)(diag)-135
Step Check Yes No
ELECTRONIC THROTTLE CONTROL.
2) Disconnect the connectors from ECM and
electronic throttle control.
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
2 CHECK SHORT CIRCUIT INSIDE THE ECM.
1) Connect the ECM.
2) Measure the resistance between electronic
throttle control connector and engine ground.
more?
Replace the elec-
trol. <Ref. to
FU(H4SO)-11,
Throttle Body.>
Repair the ground
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
EN(H4SO)(diag)-136
X: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT
HIGH
SOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05044
SBF-7
B134 A: B137 B136 D:
B362
C:
E
C
1
C
2
1
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
D
3
A
2
8
A
1
8
C
6
ECM
5
8
7
6
B362 B21 E57 B122
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B134 A:
B136 C: B137 D:
1 2 3 4 5 6
E2
B21
B122
E
E
3
9
2
0
E57
46 123 5
3
6
3
5
3
7
3
4
5
2
*
*
*
1
8
1
7
3
8
1
9
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ELECTRONIC THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC
THROTTLE CONTROL
ARRANGEMENT
EN(H4SO)(diag)-137
Step Check Yes No
ECM and electronic throttle control connector.
(B134) No. 18 (E57) No. 6:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
1) Connect the ECM.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
2) Measure the voltage between electronic
Is the voltage 4.85 V or more? Repair the short
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 4.
3) Measure the resistance between ECM con-
nectors.
(B134) No. 19 (B134) No. 18:
more?
Repair poor con-
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4SO)-11,
Throttle Body.>
Repair the short
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
EN(H4SO)(diag)-138
Y: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP
FUEL CONTROL
GENERAL DESCRIPTION <Ref. to GD(H4SO)-53, DTC P0125 INSUFFICIENT COOLANT TEMPERA-
TURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine does not return to idle.
CAUTION:
Step Check Yes No
1 CHECK TIRE SIZE. Is the tire size as specified? and
the same size as other three
wheels?
Go to step 2. Replace the tire.
2 CHECK ENGINE COOLANT.
Check the following items:
Amount of engine coolant
Engine coolant freeze
Contamination of engine coolant
Is the engine coolant normal? Go to step 3. Fill or replace the
engine coolant.
<Ref. to
CO(H4SO)-12,
REPLACEMENT,
Engine Coolant.>
3 CHECK THERMOSTAT. Does the thermostat remain
opened?
Replace the ther-
mostat. <Ref. to
CO(H4SO)-16,
Thermostat.>
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H4SO)-20,
Engine Coolant
Temperature Sen-
sor.>
EN(H4SO)(diag)-139
Z: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR
STABLE OPERATION
GENERAL DESCRIPTION <Ref. to GD(H4SO)-56, DTC P0126 INSUFFICIENT ENGINE COOLANT
TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-04033
2
9
3
4
1
9
8
B134 ECM
1 2
E2
B21
E8
E8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
ENGINE
COOLANT
TEMPERATURE
SENSOR
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H4SO)(diag)-140
AA:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE
BELOW THERMOSTAT REGULATING TEMPERATURE)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-58, DTC P0128 COOLANT THERMOSTAT (ENGINE
COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Trouble
Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Thermostat remains open.
CAUTION:
Step Check Yes No
1 CHECK ENGINE COOLANT TEMPERATURE
SENSOR.
Measure the resistance between engine cool-
ant temperature sensor terminals when the
engine coolant is cold and after warmed-up.
Terminals
No. 1 No. 2:
Is the resistance of engine cool-
ant temperature sensor differ-
ent between when engine
coolant is cold and after
warmed-up?
Repair the poor
contact of the ECM
connector.
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H4SO)-20,
Engine Coolant
Temperature Sen-
sor.>
Step Check Yes No
1 CHECK ENGINE COOLANT. Are the coolant level and mix-
ture ratio of engine coolant to
anti-freeze solution correct?
Go to step 2. Replace the
engine coolant.
<Ref. to
CO(H4SO)-12,
REPLACEMENT,
Engine Coolant.>
2 CHECK RADIATOR FAN.
2) Check the radiator fan operation.
Does the radiator fan continu-
ously rotate for 3 minutes or
more during idling?
Repair radiator fan
circuit. <Ref. to
CO(H4SO)-23,
Radiator Main Fan
and Fan
Motor.>and <Ref.
to CO(H4SO)-25,
Radiator Sub Fan
and Fan Motor.>
Replace the ther-
mostat. <Ref. to
CO(H4SO)-16,
Thermostat.>
EN(H4SO)(diag)-141
AB:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-60, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE
CAUTION:
WIRING DIAGRAM:
EN-05042
B137
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
31 26 27
3 4
1 2
5 6
B327
SBF-5
E
E
B327
E22
6
4
5
3
2
1
6
41 3
B
1
B
9
B
8
C
3
C
2
A
5
D
7
D
1
D
2
D
3
3
6
5
2
3
4
3
5
3
7
B134 A:
B135 B:
B136 C:
B137 D:
B21
E2
ECM
B21 E2
50
5
1
3 4
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E22 B138
B134
B135
A:
B:
B136 C:
D:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B138
*
*
*
3 1
6 5 4
2
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
3 4
5 6
1 2
7 8
OXYGEN SENSOR RELAY
FRONT
OXYGEN (A/F)
SENSOR
BATTERY
ARRANGEMENT
EN(H4SO)(diag)-142
Step Check Yes No
1 CHECK FRONT OXYGEN (A/F) SENSOR
CONNECTOR AND COUPLING CONNEC-
TOR.
Has water entered the connec-
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
Check poor contact of front oxygen (A/F) sen-
sor connector.
Is there poor contact in front
oxygen (A/F) sensor connec-
tor?
Repair the poor
contact of the front
oxygen (A/F) sen-
sor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4SO)-33,
Front Oxygen (A/F)
Sensor.>
EN(H4SO)(diag)-143
AC:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-62, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE
CAUTION:
WIRING DIAGRAM:
EN-05042
B137
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
31 26 27
3 4
1 2
5 6
B327
SBF-5
E
E
B327
E22
6
4
5
3
2
1
6
41 3
B
1
B
9
B
8
C
3
C
2
A
5
D
7
D
1
D
2
D
3
3
6
5
2
3
4
3
5
3
7
B134 A:
B135 B:
B136 C:
B137 D:
B21
E2
ECM
B21 E2
50
5
1
3 4
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E22 B138
B134
B135
A:
B:
B136 C:
D:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B138
*
*
*
3 1
6 5 4
2
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
3 4
5 6
1 2
7 8
OXYGEN SENSOR RELAY
FRONT
OXYGEN (A/F)
SENSOR
BATTERY
ARRANGEMENT
EN(H4SO)(diag)-144
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
(A/F) sensor.
chassis ground.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
nector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4SO)-33,
Front Oxygen (A/F)
Sensor.>
EN(H4SO)(diag)-145
AD:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-64, DTC P0133 O2 SENSOR CIRCUIT SLOW RE-
SPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05042
B137
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
31 26 27
3 4
1 2
5 6
B327
SBF-5
E
E
B327
E22
6
4
5
3
2
1
6
41 3
B
1
B
9
B
8
C
3
C
2
A
5
D
7
D
1
D
2
D
3
3
6
5
2
3
4
3
5
3
7
B134 A:
B135 B:
B136 C:
B137 D:
B21
E2
ECM
B21 E2
50
5
1
3 4
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E22 B138
B134
B135
A:
B:
B136 C:
D:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B138
*
*
*
3 1
6 5 4
2
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
3 4
5 6
1 2
7 8
OXYGEN SENSOR RELAY
FRONT
OXYGEN (A/F)
SENSOR
BATTERY
ARRANGEMENT
EN(H4SO)(diag)-146
Step Check Yes No
1 CHECK 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
Is there any fault in exhaust
system?
Repair the exhaust
system.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4SO)-33,
Front Oxygen (A/F)
Sensor.>
EN(H4SO)(diag)-147
AE:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-67, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY
DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05042
B137
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
31 26 27
3 4
1 2
5 6
B327
SBF-5
E
E
B327
E22
6
4
5
3
2
1
6
41 3
B
1
B
9
B
8
C
3
C
2
A
5
D
7
D
1
D
2
D
3
3
6
5
2
3
4
3
5
3
7
B134 A:
B135 B:
B136 C:
B137 D:
B21
E2
ECM
B21 E2
50
5
1
3 4
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E22 B138
B134
B135
A:
B:
B136 C:
D:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B138
*
*
*
3 1
6 5 4
2
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
3 4
5 6
1 2
7 8
OXYGEN SENSOR RELAY
FRONT
OXYGEN (A/F)
SENSOR
BATTERY
ARRANGEMENT
EN(H4SO)(diag)-148
Step Check Yes No
TOR.
(B135) No. 9 (E22) No. 1:
(B135) No. 8 (E22) No. 3:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact of
coupling connector
nector?
Repair the poor
contact of ECM or
front oxygen (A/F)
sensor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4SO)-33,
Front Oxygen (A/F)
Sensor.>
EN(H4SO)(diag)-149
AF:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-69, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE
CAUTION:
WIRING DIAGRAM:
EN-05043
A
5
D
1
D
2
D
3
D
7
3
6
3
4
3
5
3
7
5
2
ECM
B21
B138
E2
B135 B:
D: B137
C: B136
E
A: B134
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
A:
B:
C:
D:
*
*
*
3 4
1 2
5 6
B327
SBF-5
E
B327
E23
6
4
5
3
2
1
1
B21 E2
50
5
3
1
1
9
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E23
REAR OXYGEN
SENSOR
1
3 4
2
2
3 4
B
1
B
4
A
2
9
C
4
B138
3 4
5 6
1 2
7 8
AMONG 3, 4, 7 AND 8
EN(H4SO)(diag)-150
Step Check Yes No
1 CHECK REAR OXYGEN SENSOR DATA.
1) Warm-up the engine until engine coolant
temperature is higher than 75C (167F), and
keep the engine speed at 3,000 rpm. (2 minutes
maximum)
2) Read the data of rear oxygen sensor signal
using Subaru Select Monitor or general scan
tool.
NOTE:
tor.>
General scan tool
Is the voltage 490 mV or more? Go to step 5. Go to step 2.
2 CHECK REAR OXYGEN SENSOR CONNEC-
TOR AND COUPLING CONNECTOR.
tor?
Completely
remove any water
inside.
Go to step 3.
REAR OXYGEN SENSOR CONNECTOR.
rear oxygen sensor.
ECM and rear oxygen sensor connector.
(B135) No. 4 (E23) No. 3:
(B134) No. 29 (E23) No. 4:
circuit of harness
between ECM and
rear oxygen sen-
sor connector.
REAR OXYGEN SENSOR.
gen sensor.
sensor connector and chassis ground.
Is the voltage 0.2 0.5 V? Replace the rear
oxygen sensor.
<Ref. to
FU(H4SO)-35,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
Check exhaust system parts.
NOTE:
Loose part and incomplete installation of ex-
haust system
Damage (crack, hole etc.) of parts
Loose part and improper installation between
front oxygen (A/F) sensor and rear oxygen sen-
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to FU(H4SO)-
35, Rear Oxygen
Sensor.>
EN(H4SO)(diag)-151
AG:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-72, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE
CAUTION:
WIRING DIAGRAM:
EN-05043
A
5
D
1
D
2
D
3
D
7
3
6
3
4
3
5
3
7
5
2
ECM
B21
B138
E2
B135 B:
D: B137
C: B136
E
A: B134
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
A:
B:
C:
D:
*
*
*
3 4
1 2
5 6
B327
SBF-5
E
B327
E23
6
4
5
3
2
1
1
B21 E2
50
5
3
1
1
9
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E23
REAR OXYGEN
SENSOR
1
3 4
2
2
3 4
B
1
B
4
A
2
9
C
4
B138
3 4
5 6
1 2
7 8
AMONG 3, 4, 7 AND 8
EN(H4SO)(diag)-152
Step Check Yes No
rapidly reduce the engine speed from 3,000
rpm.
tool.
NOTE:
tor.>
General scan tool
Is the voltage 250 mV or less? Go to step 5. Go to step 2.
tor?
Completely
remove any water
inside.
Go to step 3.
rear oxygen sensor.
(B135) No. 4 (E23) No. 3:
(B134) No. 29 (E23) No. 4:
circuit of harness
between ECM and
rear oxygen sen-
sor connector.
REAR OXYGEN SENSOR.
gen sensor.
oxygen sensor.
<Ref. to FU(H4SO)-
35, Rear Oxygen
Sensor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
NOTE:
haust system
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to FU(H4SO)-
35, Rear Oxygen
Sensor.>
EN(H4SO)(diag)-153
AH:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-73, DTC P0139 O2 SENSOR CIRCUIT SLOW RE-
CAUTION:
WIRING DIAGRAM:
EN-05043
A
5
D
1
D
2
D
3
D
7
3
6
3
4
3
5
3
7
5
2
ECM
B21
B138
E2
B135 B:
D: B137
C: B136
E
A: B134
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
A:
B:
C:
D:
*
*
*
3 4
1 2
5 6
B327
SBF-5
E
B327
E23
6
4
5
3
2
1
1
B21 E2
50
5
3
1
1
9
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E23
REAR OXYGEN
SENSOR
1
3 4
2
2
3 4
B
1
B
4
A
2
9
C
4
B138
3 4
5 6
1 2
7 8
AMONG 3, 4, 7 AND 8
EN(H4SO)(diag)-154
Step Check Yes No
rear oxygen sensor.
(B135) No. 4 (E23) No. 3:
circuit of harness
between ECM and
rear oxygen sen-
sor connector.
(E23) No. 3 Chassis ground:
more?
ness between
ECM and rear oxy-
gen sensor con-
nector.
sensor terminals.
Terminals
No. 3 No. 4
Is the resistance less than 1 ? Replace the rear
oxygen sensor.
<Ref. to FU(H4SO)-
35, Rear Oxygen
Sensor.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
EN(H4SO)(diag)-155
AI: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SEN-
SOR 2)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-80, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY
CAUTION:
WIRING DIAGRAM:
EN-05043
A
5
D
1
D
2
D
3
D
7
3
6
3
4
3
5
3
7
5
2
ECM
B21
B138
E2
B135 B:
D: B137
C: B136
E
A: B134
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
A:
B:
C:
D:
*
*
*
3 4
1 2
5 6
B327
SBF-5
E
B327
E23
6
4
5
3
2
1
1
B21 E2
50
5
3
1
1
9
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E23
REAR OXYGEN
SENSOR
1
3 4
2
2
3 4
B
1
B
4
A
2
9
C
4
B138
3 4
5 6
1 2
7 8
AMONG 3, 4, 7 AND 8
EN(H4SO)(diag)-156
Step Check Yes No
maximum)
tool.
NOTE:
tor.>
General scan tool
rpm.
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 4.
rear oxygen sensor.
(B135) No. 4 (E23) No. 3:
(B134) No. 29 (E23) No. 4:
circuit of harness
between ECM and
rear oxygen sen-
sor connector.
EN(H4SO)(diag)-157
REAR OXYGEN SENSOR.
gen sensor.
oxygen sensor.
<Ref. to FU(H4SO)-
35, Rear Oxygen
Sensor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
NOTE:
haust system
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to FU(H4SO)-
35, Rear Oxygen
Sensor.>
Step Check Yes No
EN(H4SO)(diag)-158
AJ:DTC P0171 SYSTEM TOO LEAN (BANK 1)
Refer to DTC P0172 for diagnostic procedure. <Ref. to EN(H4SO)(diag)-158, DTC P0172 SYSTEM TOO
RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AK:DTC P0172 SYSTEM TOO RICH (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-83, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnos-
tic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Step Check Yes No
1 CHECK EXHAUST SYSTEM. Are there holes or loose bolts
on exhaust system?
Repair the exhaust
system.
Go to step 2.
intake system?
Repair the air
intake system.
Go to step 3.
3 CHECK FUEL PRESSURE.
WARNING:
working area.
CAUTION:
Measure the fuel pressure. <Ref. to ME(H4SO)-
26, INSPECTION, Fuel Pressure.>
CAUTION:
Release fuel pressure before removing the
fuel pressure gauge.
360.5 kPa (3.5 3.7 kg/cm
2
,
49 52 psi)?
Go to step 4. Repair the follow-
ing item.
Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
SENSOR.
NOTE:
tor.>
General scan tool
Go to step 5. Replace the engine
coolant tempera-
ture sensor. <Ref.
to FU(H4SO)-20,
Engine Coolant
Temperature Sen-
sor.>
EN(H4SO)(diag)-159
5 CHECK MASS AIR FLOW AND INTAKE AIR
TEMPERATURE SENSOR.
(167F).
5) Read the data of mass air flow and intake air
temperature sensor signal using Subaru Select
Monitor or general scan tool.
NOTE:
tor.>
General scan tool
5.0 g/s (0.26 0.66 lb/m)?
Go to step 6. Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
TEMPERATURE SENSOR.
(158F).
5) Open the front hood.
6) Measure the ambient temperature.
NOTE:
tor.>
General scan tool
Subtract ambient temperature
from intake air temperature. Is
the obtained value 10 50C
(18 90F)?
Repair the poor
contact of the ECM
connector.
Check the mass air
flow and intake air
temperature sen-
sor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Step Check Yes No
EN(H4SO)(diag)-160
AL:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE
/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4SO)-85, DTC P0181 FUEL TEMPERATURE SENSOR A
CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05707
R46
R67
B97
R1
R58
B83
3
0
1
7
*
*
23
4
1
8
B135
14
R58 R67
1 2
3 4 5 6
*
1 2 3 4
5 6 7 8
B83 B135 B97
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
1 2
3 4
5 6
FUEL TEMPERATURE
SENSOR
ECM
ARRANGEMENT
EN(H4SO)(diag)-161
Step Check Yes No
1 CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check the appropri-
ate DTC using the
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Replace the fuel
temperature sensor.
<Ref. to EC(H4SO)-
9, Fuel Temperature
Sensor.>
EN(H4SO)(diag)-162
AM:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT
CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05707
R46
R67
B97
R1
R58
B83
3
0
1
7
*
*
23
4
1
8
B135
14
R58 R67
1 2
3 4 5 6
*
1 2 3 4
5 6 7 8
B83 B135 B97
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
1 2
3 4
5 6
FUEL TEMPERATURE
SENSOR
ECM
ARRANGEMENT
EN(H4SO)(diag)-163
Step Check Yes No
2) Read the data of fuel temperature sensor
signal using Subaru Select Monitor.
NOTE:
tor.>
Is the temperature 120C
(248F) or higher?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
FUEL TEMPERATURE SENSOR CONNEC-
TOR.
and fuel temperature sensor.
chassis ground.
more?
Replace the fuel
temperature sensor.
<Ref. to EC(H4SO)-
9, Fuel Temperature
Sensor.>
Repair the ground
ness between
ECM and fuel
pump.
EN(H4SO)(diag)-164
AN:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT
CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05707
R46
R67
B97
R1
R58
B83
3
0
1
7
*
*
23
4
1
8
B135
14
R58 R67
1 2
3 4 5 6
*
1 2 3 4
5 6 7 8
B83 B135 B97
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
1 2
3 4
5 6
FUEL TEMPERATURE
SENSOR
ECM
ARRANGEMENT
EN(H4SO)(diag)-165
Step Check Yes No
NOTE:
tor.>
Is the temperature less than
40C (40F)?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
fuel temperature sensor connectors.
ECM or fuel temperature sen-
sor connectors?
Repair any poor
contact between
the ECM and fuel
temperature sen-
sor connectors.
Go to step 3.
TOR.
between the ECM and fuel temperature sensor
connector.
(B135) No. 17 (R58) No. 2:
(B135) No. 30 (R58) No. 3:
circuit of the har-
ness between the
ECM and fuel tem-
perature sensor
connector.
TOR.
chassis ground.
circuit to power in
the harness
between the ECM
and fuel tempera-
ture sensor con-
nector.
Replace the fuel
temperature sensor.
<Ref. to EC(H4SO)-
9, Fuel Temperature
Sensor.>
EN(H4SO)(diag)-166
AO:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE
/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4SO)-92, DTC P0196 ENGINE OIL TEMPERATURE SENSOR
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-04036
E75
E2
B21
B134 ECM
1
2
9
2
2
3
E75
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
OIL
TEMPERATURE
SENSOR
1
9
6
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H4SO)(diag)-167
Step Check Yes No
ate DTC using the
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Replace the oil tem-
perature sensor.
<Ref. to FU(H4SO)-
32, Oil Tempera-
ture Sensor.>
EN(H4SO)(diag)-168
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:
EN-04036
E75
E2
B21
B134 ECM
1
2
9
2
2
3
E75
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
OIL
TEMPERATURE
SENSOR
1
9
6
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H4SO)(diag)-169
Step Check Yes No
2) Read the data of the oil temperature sensor
signal using the Subaru Select Monitor or gen-
eral scan tool.
NOTE:
tor.>
General scan tool
Is the oil temperature 215C
(419F) or more?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
TEMPERATURE SENSOR CONNECTOR.
and oil temperature sensor.
chassis ground.
more?
perature sensor.
<Ref. to FU(H4SO)-
32, Oil Tempera-
ture Sensor.>
Repair the ground
ness between
ECM and oil tem-
perature sensor.
EN(H4SO)(diag)-170
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:
EN-04036
E75
E2
B21
B134 ECM
1
2
9
2
2
3
E75
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
OIL
TEMPERATURE
SENSOR
1
9
6
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H4SO)(diag)-171
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
Is the oil temperature less than
40C (40F)?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Check for poor contact of the ECM and oil tem-
ECM or oil temperature sensor
connector?
Repair the poor
contact in the ECM
or the oil tempera-
ture sensor con-
nector.
Go to step 3.
between the ECM and oil temperature sensor
connector.
(B134) No. 23 (E75) No. 2:
(B134) No. 29 (E75) No. 1:
circuit of harness
between ECM and
oil temperature
sensor connector.
chassis ground.
circuit to power
supply in the har-
ness between the
ECM and oil tem-
perature sensor
connector.
perature sensor.
<Ref. to FU(H4SO)-
32, Oil Tempera-
ture Sensor.>
EN(H4SO)(diag)-172
AR:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
LOW
SOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05044
SBF-7
B134 A: B137 B136 D:
B362
C:
E
C
1
C
2
1
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
D
3
A
2
8
A
1
8
C
6
ECM
5
8
7
6
B362 B21 E57 B122
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B134 A:
B136 C: B137 D:
1 2 3 4 5 6
E2
B21
B122
E
E
3
9
2
0
E57
46 123 5
3
6
3
5
3
7
3
4
5
2
*
*
*
1
8
1
7
3
8
1
9
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ELECTRONIC THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC
THROTTLE CONTROL
ARRANGEMENT
EN(H4SO)(diag)-173
Step Check Yes No
chassis ground.
more?
ness between
ECM and elec-
trol connector.
1) Connect the ECM.
more?
Replace the elec-
trol. <Ref. to
FU(H4SO)-11,
Throttle Body.>
Repair the ground
ness between ECM
and electronic
throttle control con-
nector. Replace the
ECM if defective.
<Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
EN(H4SO)(diag)-174
AS:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
HIGH
SOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05044
SBF-7
B134 A: B137 B136 D:
B362
C:
E
C
1
C
2
1
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
D
3
A
2
8
A
1
8
C
6
ECM
5
8
7
6
B362 B21 E57 B122
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B134 A:
B136 C: B137 D:
1 2 3 4 5 6
E2
B21
B122
E
E
3
9
2
0
E57
46 123 5
3
6
3
5
3
7
3
4
5
2
*
*
*
1
8
1
7
3
8
1
9
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ELECTRONIC THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC
THROTTLE CONTROL
ARRANGEMENT
EN(H4SO)(diag)-175
AT:DTC P0301 CYLINDER 1 MISFIRE DETECTED
NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4SO)(diag)-176, 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:
Step Check Yes No
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
1) Connect the ECM.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 4.
nectors.
(B134) No. 19 (B134) No. 28:
more?
Repair poor contact
of the electronic
nector. Replace the
electronic throttle
control if defective.
<Ref. to
FU(H4SO)-11,
Throttle Body.>
Repair the short
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
EN(H4SO)(diag)-176
AW:DTC P0304 CYLINDER 4 MISFIRE DETECTED
Immediately at fault recognition (A misfire which could damage catalyst occurs.)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-107, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Di-
agnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
Rough driving
CAUTION:
WIRING DIAGRAM:
EN-05703
E6 E17
E5 E16
1 2
1 21 21 21 2
1
0
9 8
1
1
4
2
4
8
4
3
4
4
4
5
B137
E5 E16 E6 E17
B21
E2
SBF-7
B47
1
2
4
6
3
5
B47
3 4
1 2
5 6
E
B137 B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
MAIN RELAY
BATTERY
ECM
FUEL INJECTOR
No.1
FUEL INJECTOR
No.2
FUEL INJECTOR
No.3
FUEL INJECTOR
No.4
EN(H4SO)(diag)-177
Step Check Yes No
2) Measure the voltage between the ECM and
chassis ground for faulty cylinders.
#1 (B137) No. 8 (+) Chassis ground ():
FUEL INJECTOR.
2) Disconnect the connector from fuel injector
on faulty cylinders.
3) Measure the resistance between the fuel
injector connector and engine ground on faulty
cylinders.
#1 (E5) No. 1 Engine ground:
more?
ness between
ECM and fuel
injector.
FUEL INJECTOR.
ECM 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:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel in-
jector connector
Poor contact of
coupling connector
4 CHECK FUEL INJECTOR.
Measure the resistance between fuel injector
terminals on faulty cylinder.
Terminals
No. 1 No. 2:
20 ?
fuel injector. <Ref.
to FU(H4SO)-28,
Fuel Injector.>
5 CHECK POWER SUPPLY LINE.
2) Measure the voltage between fuel injector
and engine ground on faulty cylinders.
Is the voltage 10 V or more? Repair the poor
contact of all con-
nectors in fuel
injector circuit.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the main relay and
fuel injector con-
nector on faulty
cylinders
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
Poor contact of
fuel injector con-
nector on faulty
cylinders
EN(H4SO)(diag)-178
FUEL INJECTOR.
circuit to power in
the harness
between the ECM
and fuel injector.
Go to step 7.
2) Measure the resistance between fuel injec-
tor terminals on faulty cylinder.
Terminals
No. 1 No. 2:
Is the resistance less than 1 ? Replace the faulty
to FU(H4SO)-28,
Fuel Injector.>
Go to step 8.
8 CHECK INSTALLATION CONDITION OF
CAMSHAFT POSITION SENSOR/CRANK-
SHAFT POSITION SENSOR.
Is the camshaft position sensor
or crankshaft position sensor
loosely installed?
Tighten the cam-
shaft position sen-
sor or crankshaft
position sensor.
Go to step 9.
9 CHECK CRANK SPROCKET.
Remove the timing belt cover. <Ref. to
Is the crank sprocket rusted or
does it have damaged teeth?
Replace the crank
sprocket. <Ref. to
ME(H4SO)-48,
Crank Sprocket.>
Go to step 10.
TIMING BELT.
Turn the crankshaft using ST, and align align-
ment mark on crank sprocket with alignment
mark on cylinder block.
ST 499987500 CRANKSHAFT
SOCKET
Is the timing belt dislocated
from its proper position?
Repair the installa-
tion condition of
timing belt. <Ref.
to ME(H4SO)-42,
Timing Belt.>
Go to step 11.
11 CHECK FUEL LEVEL. Is the fuel meter indication
higher than the Lower level?
Go to step 12. Replenish fuel so
that fuel meter indi-
cation is higher
than the Lower
level. After replen-
ishing fuel, Go to
step 12.
CATOR LIGHT.
1) Clear the memory using the Subaru Select
<Ref. to EN(H4SO)(diag)-54, Clear Memory
Mode.>
NOTE:
<Ref. to EN(H4SO)(diag)-34, Subaru Select
Monitor.>
General scan tool
Refer to operating manuals for the general scan
tool.
2) Start the engine, and drive the vehicle 10
minutes or more.
light illuminate or blink?
Step Check Yes No
EN(H4SO)(diag)-179
13 CHECK CAUSE OF MISFIRE. Has the cause of misfire been
detected while running the
engine?
Finish diagnostics
operation, if the
engine has no
abnormality.
Repair the poor
contact of connec-
tor.
NOTE:
the following item:
Poor contact of
ignition coil con-
nector
Poor contact of
fuel injector con-
nector on faulty
cylinders
Poor contact in
ECM connector
Poor contact of
coupling connector
14 CHECK AIR INTAKE SYSTEM. Is there any fault in air intake
system?
Repair the air
intake system.
NOTE:
Check the follow-
ing items.
Are there air
leaks or air suction
caused by loose or
dislocated nuts
and bolts?
Are there cracks
or any disconnec-
tion of hoses?
Go to step 15.
15 CHECK MISFIRE SYMPTOM.
2) Read DTC.
NOTE:
tor.>
General scan tool
Does the Subaru Select Moni-
tor or general scan tool indicate
only one DTC?
16 CHECK DTC. Are DTCs P0301 and P0302
displayed on the Subaru Select
Monitor or general scan tool?
Step Check Yes No
EN(H4SO)(diag)-180
20 ONLY ONE CYLINDER. Is there any fault in the cylin-
der?
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Spark plug cord
Fuel injector
Compression ra-
tio
Go to DTC P0171.
<Ref. to
EN(H4SO)(diag)-
158, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
21 GROUP OF #1 AND #2 CYLINDERS. Are there any faults in #1 and
#2 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the fol-
lowing items.
Spark plug
Fuel injector
Ignition coil
Compression
ratio
If any fault are
not found, check
the IGNITION
CONTROL SYS-
TEM of #1 and #2
cylinders side.
<Ref. to
EN(H4SO)(diag)-
75, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Starting
Failure.>
Go to DTC P0171.
<Ref. to
EN(H4SO)(diag)-
158, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
#4 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the fol-
lowing items.
Spark plug
Fuel injector
Ignition coil
Compression
ratio
If any fault are
not found, check
the IGNITION
CONTROL SYS-
TEM of #3 and #4
cylinders side.
<Ref. to
EN(H4SO)(diag)-
75, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Starting
Failure.>
Go to DTC P0171.
<Ref. to
EN(H4SO)(diag)-
158, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
Step Check Yes No
EN(H4SO)(diag)-181
#3 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Compression ra-
tio
Skipping timing
belt teeth
Go to DTC P0171.
<Ref. to
EN(H4SO)(diag)-
158, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
#4 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Compression ra-
tio
Skipping timing
belt teeth
Go to DTC P0171.
<Ref. to
EN(H4SO)(diag)-
158, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
25 CYLINDER AT RANDOM. Is the engine idle rough? Go to DTC P0171.
<Ref. to
EN(H4SO)(diag)-
158, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Compression ra-
tio
Step Check Yes No
EN(H4SO)(diag)-182
AX:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE
SENSOR)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-108, 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:
EN-04038
1
5
2
5
2
9
1 2
1
6
1
9
ECM B134
B21
E2
E14
E
KNOCK SENSOR
E14
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H4SO)(diag)-183
Step Check Yes No
KNOCK SENSOR.
nectors.
(B134) No. 15 (B134) No. 29:
Is the resistance 600 k or
more?
Go to step 2. Repair poor con-
tact of the ECM
connector.
2 CHECK KNOCK SENSOR.
1) Disconnect the connector from knock sen-
sor.
2) Measure the resistance between knock
sensor terminals.
Terminals
No. 1 No. 2:
more?
Replace the knock
sensor. <Ref. to
FU(H4SO)-23,
Knock Sensor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and knock
sensor
Poor contact of
the knock sensor
connector
Poor contact of
coupling connector
EN(H4SO)(diag)-184
AY:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE
SENSOR)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-110, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH
TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
EN-04038
1
5
2
5
2
9
1 2
1
6
1
9
ECM B134
B21
E2
E14
E
KNOCK SENSOR
E14
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H4SO)(diag)-185
Step Check Yes No
KNOCK SENSOR.
nectors.
(B134) No. 15 (B134) No. 29:
k?
sor.
sensor terminals.
Terminals
No. 1 No. 2:
k?
Replace the knock
sensor. <Ref. to
FU(H4SO)-23,
Knock Sensor.>
Repair the ground
ness between the
ECM and knock
sensor connector.
NOTE:
The harness be-
tween both con-
nectors are
shielded. Remove
the shield and re-
pair the short cir-
cuit of the harness
circuit.
3 CHECK INPUT SIGNAL OF ECM.
1) Connect the ECM.
chassis ground.
Is the voltage 2 V or more? Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Repair poor con-
tact of the ECM
connector.
EN(H4SO)(diag)-186
AZ:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT
GENERAL DESCRIPTION <Ref. to GD(H4SO)-112, 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:
EN-04039
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
1
5
1
4
1
4
2
4
B21
E2
E10
E10
1 2
B134 ECM
1
3
E
CRANKSHAFT
POSITION
SENSOR
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
EN(H4SO)(diag)-187
Step Check Yes No
CRANKSHAFT POSITION SENSOR.
Is the crankshaft position sen-
sor installation bolt tightened
securely?
Go to step 2. Tighten the crank-
shaft position sen-
sor installation bolt
securely.
2 CHECK CRANKSHAFT POSITION SENSOR.
terminals of crankshaft position sensor.
Terminals
No. 1 No. 2:
Is the resistance between 1 and
4 k?
Go to step 3. Replace the crank-
shaft position sen-
sor. <Ref. to
FU(H4SO)-21,
Crankshaft Posi-
tion Sensor.>
CRANK SHAFT POSITION SENSOR.
the ECM and crankshaft position sensor con-
nector.
(B134) No. 13 (E10) No. 1:
(B134) No. 14 (E10) No. 2:
contact of the ECM
and crankshaft
position sensor
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and crank-
shaft position sen-
sor connector
Poor contact of
coupling connector
EN(H4SO)(diag)-188
BA:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE
/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4SO)-114, DTC P0336 CRANKSHAFT POSITION SENSOR A
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-04039
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
1
5
1
4
1
4
2
4
B21
E2
E10
E10
1 2
B134 ECM
1
3
E
CRANKSHAFT
POSITION
SENSOR
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
EN(H4SO)(diag)-189
Step Check Yes No
1 CHECK CONDITION OF CRANKSHAFT PO-
SITION SENSOR.
Turn the ignition switch to OFF.
securely?
shaft position sen-
securely.
Remove the timing belt cover.
Are crank sprocket teeth
cracked or damaged?
Replace the crank
sprocket. <Ref. to
ME(H4SO)-48,
Crank Sprocket.>
Go to step 3.
TIMING BELT.
Turn the crankshaft, and align alignment mark
on crank sprocket with alignment mark on cylin-
der block.
tion condition of
timing belt. <Ref.
to ME(H4SO)-42,
Timing Belt.>
Replace the crank-
shaft position sen-
sor. <Ref. to
FU(H4SO)-21,
Crankshaft Posi-
tion Sensor.>
EN(H4SO)(diag)-190
BB:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR
SINGLE SENSOR)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-116, 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:
EN-04040
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
E15
1 2
1
3
1
2
2
2
2
4
B21
E2
E15
B134 ECM
1
2
E
CAMSHAFT
POSITION
SENSOR
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
EN(H4SO)(diag)-191
Step Check Yes No
CAMSHAFT POSITION SENSOR.
and camshaft position sensor.
the ECM and camshaft position sensor connec-
tor.
(B134) No. 12 (E15) No. 1:
(B134) No. 22 (E15) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
the harness be-
tween the ECM
and camshaft posi-
tion sensor
Poor contact in
ECM connector
Poor contact of
coupling connector
Measure the resistance between camshaft
position sensor connector and engine ground.
more?
circuit to ground of
harness between
the ECM and cam-
shaft position sen-
sor.
NOTE:
The harness be-
tween both con-
nectors are
shielded. Remove
the shield and re-
pair the ground
harness circuit.
installation bolt tightened
securely?
Go to step 4. Tighten the cam-
shaft position sen-
securely.
4 CHECK CAMSHAFT POSITION SENSOR.
1) Remove the camshaft position sensor.
terminals of camshaft position sensor.
Terminals
No. 1 No. 2:
4 k?
Repair the poor
contact of the ECM
or camshaft posi-
tion sensor con-
nector.
Replace the cam-
shaft position sen-
sor. <Ref. to
FU(H4SO)-22,
Camshaft Position
Sensor.>
EN(H4SO)(diag)-192
BC:DTC P0341 CAMSHAFT POSITION SENSOR A CIRCUIT RANGE
/PERFORMANCE (BANK 1 OR SINGLE SENSOR)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-118, DTC P0341 CAMSHAFT POSITION SENSOR A
CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) De-
tecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-04040
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
E15
1 2
1
3
1
2
2
2
2
4
B21
E2
E15
B134 ECM
1
2
E
CAMSHAFT
POSITION
SENSOR
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
EN(H4SO)(diag)-193
Step Check Yes No
and camshaft position sensor.
the ECM and camshaft position sensor connec-
tor.
(B134) No. 12 (E15) No. 1:
(B134) No. 22 (E15) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
the harness be-
tween the ECM
and camshaft posi-
tion sensor
Poor contact in
ECM connector
Poor contact of
coupling connector
more?
harness between
the ECM and cam-
shaft position sen-
sor.
NOTE:
The harness be-
tween both con-
nectors are
shielded. Remove
the shield and re-
pair the ground
harness circuit.
securely?
shaft position sen-
securely.
1) Remove the camshaft position sensor.
terminals of camshaft position sensor.
Terminals
No. 1 No. 2:
4 k?
Go to step 5. Replace the cam-
shaft position sen-
sor. <Ref. to
FU(H4SO)-22,
Camshaft Position
Sensor.>
5 CHECK CAM SPROCKET.
ME(H4SO)-41, Timing Belt Cover.>
Are cam sprocket teeth cracked
or damaged?
Replace the cam
sprocket. <Ref. to
ME(H4SO)-47,
Cam Sprocket.>
Go to step 6.
TIMING BELT.
Turn the crankshaft using the ST, and align the
alignment mark on the cam sprocket with the
alignment mark on the timing belt cover LH.
SOCKET
tion condition of
timing belt. <Ref.
to ME(H4SO)-42,
Timing Belt.>
Replace the cam-
shaft position sen-
sor. <Ref. to
FU(H4SO)-22,
Camshaft Position
Sensor.>
EN(H4SO)(diag)-194
BD:DTC P0400 EXHAUST GAS RECIRCULATION FLOW
GENERAL DESCRIPTION <Ref. to GD(H4SO)-120, DTC P0400 EXHAUST GAS RECIRCULATION
FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Movement performance problem when engine is low speed.
Improper idling
Movement performance problem
CAUTION:
WIRING DIAGRAM:
EN-05708
E
B47
E18
2 5
6 4 3 1
B21
E2
E2
B21
5
3
6
4
2
1
4
8
3
0
2
5
2
9
2
6
SBF-7
B134
B47
E18
3 4
1 2
5 6
1 3
4 5 6
2
B134
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
2
0
1
0
8 9
MAIN RELAY
EGR
VALVE
ECM
BATTERY
EN(H4SO)(diag)-195
Step Check Yes No
2) Read data of intake manifold absolute pres-
sure signal using Subaru Select Monitor or gen-
eral scan tool.
NOTE:
tor.>
General scan tool
Is the measured value 53.3 kPa
(400 mmHg, 15.75 inHg) or
more?
Make sure that the
EGR valve, mani-
fold absolute pres-
sure sensor and
throttle body are
installed securely.
Go to step 2.
2 CHECK EGR SOLENOID VALVE.
Remove the EGR valve.
Are there holes, plugged piping
or foreign objects caught in the
EGR system?
Repair the EGR
system.
Replace the EGR
valve. <Ref. to
FU(H4SO)-27,
EGR Valve.>
EN(H4SO)(diag)-196
BE:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD
(BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-124, DTC P0420 CATALYST SYSTEM EFFICIENCY BE-
LOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Idle mixture is out of specifications.
CAUTION:
WIRING DIAGRAM:
EN-05043
A
5
D
1
D
2
D
3
D
7
3
6
3
4
3
5
3
7
5
2
ECM
B21
B138
E2
B135 B:
D: B137
C: B136
E
A: B134
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
A:
B:
C:
D:
*
*
*
3 4
1 2
5 6
B327
SBF-5
E
B327
E23
6
4
5
3
2
1
1
B21 E2
50
5
3
1
1
9
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E23
REAR OXYGEN
SENSOR
1
3 4
2
2
3 4
B
1
B
4
A
2
9
C
4
B138
3 4
5 6
1 2
7 8
AMONG 3, 4, 7 AND 8
EN(H4SO)(diag)-197
Step Check Yes No
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
Loose or improperly attached front oxygen
(A/F) sensor or rear oxygen sensor
system?
Repair or replace
the exhaust sys-
tem. <Ref. to
EX(H4SO)-2, Gen-
eral Description.>
Go to step 2.
2 CHECK WAVEFORM DATA ON THE SUBA-
RU SELECT MONITOR (WHILE DRIVING).
1) Drive at a constant speed between 80
112 km/h (50 70 MPH).
2) After 5 minutes have elapsed in the condi-
tion of step 1), use the Subaru Select Monitor
while still driving to read the waveform data.
Is a normal waveform dis-
played?
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the failure,
and then perform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector
may be the cause.
Go to step 3.
RrO2 SENSOR
RrO2 SENSOR
A/F LAMBDA 1
A/F LAMBDA 1
EN-04895
EN(H4SO)(diag)-198
RU SELECT MONITOR (WHILE IDLING).
1) Run the engine at idle.
2) In the condition of step 1), use the Subaru
Select Monitor to read the waveform data.
played?
4 CHECK CATALYTIC CONVERTER. Is the catalytic converter dam-
aged?
Replace the cata-
lytic converter.
<Ref. to EC(H4SO)-
3, Front Catalytic
Converter.>
Go to step 5.
tor?
Completely
remove any water
inside.
Go to step 6.
rear oxygen sensor.
(B135) No. 4 (E23) No. 3:
(B134) No. 29 (E23) No. 4:
circuit of harness
between ECM and
rear oxygen sen-
sor connector.
Step Check Yes No
RrO2 SENSOR
RrO2 SENSOR
EN-04896
EN(H4SO)(diag)-199
Is the voltage 0.2 0.5 V? Go to step 8. Repair the harness
and connector.
NOTE:
Repair the follow-
ing locations.
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the ECM and rear
oxygen sensor
Poor contact in
ECM connector
8 CHECK REAR OXYGEN SENSOR SHIELD.
2) Expose the rear oxygen sensor connector
body side harness sensor shield.
3) Measure the resistance between the sensor
shield and chassis ground.
oxygen sensor.
<Ref. to FU(H4SO)-
35, Rear Oxygen
Sensor.>
Repair the open
circuit in the rear
oxygen sensor
harness.
Step Check Yes No
EN(H4SO)(diag)-200
BF:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK
DETECTED (SMALL LEAK)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-127, 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:
EN-05709
5
3
6
4
2
1
B47
SBF-7
E4
12
E2
B21
4
1
4
8
D
2
9
R68
12
R213
R15
15
R1
B97
1
4
1
5
R67
R46
7
6
C
1
7
C
2
8
R144
12
B136 C: B137 D:
3
1 2
4
5 6
B47 R213
E
B21
E4
1 2
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 2 3
4 5 6 7 8
1 2
R68
1 2
B97 R144 R67
1 2
3 4 5 6
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
MAIN RELAY
ECM
BATTERY
DRAIN VALVE PRESSURE CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE
EN(H4SO)(diag)-201
Step Check Yes No
1 CHECK FUEL FILLER CAP.
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 has caught while
tightening.
Is the fuel filler cap tightened
securely?
Go to step 2. Tighten fuel filler
cap securely.
2 CHECK FUEL FILLER CAP. Is the fuel filler cap genuine? Go to step 3. Replace with a
genuine fuel filler
cap.
3 CHECK FUEL FILLER PIPE GASKET. Is there any damage to the seal
between fuel filler cap and fuel
filler pipe?
Repair or replace
the fuel filler cap
and fuel filler pipe.
<Ref. to FU(H4SO)-
50, Fuel Filler
Pipe.>
Go to step 4.
4 CHECK DRAIN VALVE.
3) Operate the drain valve using the Subaru
Select Monitor.
NOTE:
Drain valve operation can be executed using
Subaru Select Monitor. Regarding the proce-
dures, refer to Compulsory Valve Operation
Check Mode. <Ref. to EN(H4SO)(diag)-55,
Compulsory Valve Operation Check Mode.>
Does the drain valve operate? Go to step 5. Replace the drain
valve. <Ref. to
EC(H4SO)-15,
Drain Valve.>
5 CHECK PURGE CONTROL SOLENOID
VALVE.
Operate the purge control solenoid valve using
the Subaru Select Monitor.
NOTE:
Purge control solenoid valve operation can be
executed using Subaru Select Monitor. Regard-
ing the procedures, refer to Compulsory Valve
Operation Check Mode. <Ref. to
tion Check Mode.>
Does the purge control sole-
noid valve operate?
Go to step 6. Replace the purge
control solenoid
valve. <Ref. to
EC(H4SO)-6,
Purge Control
Solenoid Valve.>
6 CHECK PRESSURE CONTROL SOLENOID
VALVE.
Operate the pressure control solenoid valve
using the Subaru Select Monitor.
NOTE:
The pressure control solenoid valve operation
can be executed using the Subaru Select Mon-
itor. Regarding the procedures, refer to Com-
pulsory Valve Operation Check Mode. <Ref. to
tion Check Mode.>
Does the pressure control sole-
noid valve operate?
Go to step 7. Replace the pres-
sure control sole-
noid valve. <Ref. to
EC(H4SO)-12,
Pressure Control
Solenoid Valve.>
7 CHECK EVAPORATIVE EMISSION CON-
TROL SYSTEM LINE.
tor.
Is there any hole of more than
1.0 mm (0.04 in) dia. on evapo-
ration line?
Repair or replace
the evaporation line.
<Ref. to FU(H4SO)-
59, Fuel Delivery
and Evaporation
Lines.>
Go to step 8.
8 CHECK CANISTER. Is the canister damaged or is
there a hole of more than 1.0
mm (0.04 in) dia. in it?
Repair or replace
the canister. <Ref.
to EC(H4SO)-5,
Canister.>
Go to step 9.
EN(H4SO)(diag)-202
9 CHECK FUEL TANK.
Remove the fuel tank. <Ref. to FU(H4SO)-43,
Fuel Tank.>
Is the fuel tank damaged or is
there any hole of more than 1.0
Repair or replace
the fuel tank. <Ref.
to FU(H4SO)-43,
Fuel Tank.>
Go to step 10.
10 CHECK ANY OTHER MECHANICAL TROU-
BLE IN EVAPORATIVE EMISSION CON-
TROL SYSTEM.
1.0 mm (0.04 in) dia., crack,
clogging, or disconnections,
bend, misconnection of hoses
or pipes in evaporative emis-
sion control system?
Repair or replace
the hoses or pipes.
Repair the poor
contact of the ECM
connector.
Step Check Yes No
EN(H4SO)(diag)-203
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:
EN-05710
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
7
B97 R1
1
2
7
R144 R15 R213
R46 R67
B136
SBF-7
5
3
6
4
2
1
B47
6
1
E
B47
3 4
1 2
5 6
1 2 3
4 5 6 7 8
1 2
3 4 5 6
R67 R213 B97
14
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2
R144
MAIN RELAY
BATTERY
DRAIN
VALVE
ECM
EN(H4SO)(diag)-204
Step Check Yes No
chassis ground.
contact of the ECM
connector.
Go to step 2.
DRAIN VALVE.
and drain valve.
3) Measure the resistance between the drain
valve connector and chassis ground.
more?
ness between
ECM and drain
valve connector.
DRAIN VALVE.
ECM and drain valve connector.
(B136) No. 17 (R144) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and drain
valve connector
Poor contact of
coupling connector
Measure the resistance between drain valve
terminals.
Terminals
No. 1 No. 2:
100 ?
Go to step 5. Replace the drain
valve. <Ref. to
EC(H4SO)-15,
Drain Valve.>
5 CHECK POWER SUPPLY TO DRAIN VALVE.
2) Measure the voltage between drain valve
and chassis ground.
Is the voltage 10 V or more? Repair poor con-
tact of the drain
valve connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
main relay and
drain valve
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
EN(H4SO)(diag)-205
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:
EN-05710
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
7
B97 R1
1
2
7
R144 R15 R213
R46 R67
B136
SBF-7
5
3
6
4
2
1
B47
6
1
E
B47
3 4
1 2
5 6
1 2 3
4 5 6 7 8
1 2
3 4 5 6
R67 R213 B97
14
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2
R144
MAIN RELAY
BATTERY
DRAIN
VALVE
ECM
EN(H4SO)(diag)-206
Step Check Yes No
DRAIN VALVE.
and drain valve.
chassis ground.
circuit to power in
the harness
between ECM and
drain valve con-
nector.
Go to step 2.
2) Measure the resistance between drain
valve terminals.
Terminals
No. 1 No. 2:
Is the resistance less than 1 ? Replace the drain
valve. <Ref. to
EC(H4SO)-15,
Drain Valve.>
Repair the poor
contact of the ECM
connector.
EN(H4SO)(diag)-207
BI: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR
SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05047
6
1
7
1
3
B97
R1
764
R15
R213
321
R47
B83
B135 ECM
B97
B83
3 4
5 6
1 2
7 8
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
*
*
*
R47
1 2 3
R213
1 2 3
4 5 6 7 8
2
2
3
2
3
0
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
FUEL TANK
PRESSURE
SENSOR
ARRANGEMENT
EN(H4SO)(diag)-208
Step Check Yes No
2) Open the fuel flap.
securely?
cap securely.
2 CHECK PRESSURE VACUUM LINE.
NOTE:
Disconnection, leakage and clogging of the
vacuum hoses and pipes between fuel tank
pressure sensor and fuel tank
Disconnection, leakage and clogging of air
ventilation hoses and pipes between fuel filler
pipe and fuel tank
Is there any fault in pressure/
vacuum line?
Repair or replace
the hoses and
pipes.
Replace the fuel tank
pressure sensor.
<Ref. to EC(H4SO)-
11, Fuel Tank Pres-
sure Sensor.>
EN(H4SO)(diag)-209
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:
EN-05047
6
1
7
1
3
B97
R1
764
R15
R213
321
R47
B83
B135 ECM
B97
B83
3 4
5 6
1 2
7 8
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
*
*
*
R47
1 2 3
R213
1 2 3
4 5 6 7 8
2
2
3
2
3
0
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
FUEL TANK
PRESSURE
SENSOR
ARRANGEMENT
EN(H4SO)(diag)-210
Step Check Yes No
2) Read the data of fuel tank pressure sensor
eral scan tool.
NOTE:
tor.>
General scan tool
7.41 kPa (55.6 mmHg, 2.19
inHg)?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
2 CHECK FUEL TANK PRESSURE SENSOR
POWER SOURCE.
pressure sensor.
4) Measure the voltage between the fuel tank
pressure sensor connector and chassis ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel tank
pressure sensor
connector
Poor contact in
ECM connector
Poor contact of
coupling connector
FUEL TANK PRESSURE SENSOR CONNEC-
TOR.
the ECM and fuel tank pressure sensor connec-
tor.
(B135) No. 32 (R47) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel tank
pressure sensor
connector
Poor contact of
coupling connector
TOR.
chassis ground.
more?
ness between
ECM and fuel tank
pressure sensor
connector.
fuel tank pressure sensor connector.
ECM or fuel tank pressure sen-
sor connector?
Repair the poor
contact in the ECM
or fuel tank pres-
sure sensor con-
nector.
pressure sensor.
<Ref. to EC(H4SO)-
11, Fuel Tank Pres-
sure Sensor.>
EN(H4SO)(diag)-211
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:
EN-05047
6
1
7
1
3
B97
R1
764
R15
R213
321
R47
B83
B135 ECM
B97
B83
3 4
5 6
1 2
7 8
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
*
*
*
R47
1 2 3
R213
1 2 3
4 5 6 7 8
2
2
3
2
3
0
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
FUEL TANK
PRESSURE
SENSOR
ARRANGEMENT
EN(H4SO)(diag)-212
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
(59.6 mmHg, 2.35 inHg) or
more?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
TOR.
pressure sensor.
eral scan tool.
NOTE:
tor.>
General scan tool
(59.6 mmHg, 2.35 inHg) or
more?
Repair the short
circuit to power in
the harness
between ECM and
fuel tank pressure
sensor connector.
Go to step 3.
TOR.
fuel tank pressure sensor connector and engine
ground.
(R47) No. 1 Engine ground:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel tank
pressure sensor
connector
Poor contact in
ECM connector
Poor contact of
coupling connector
Check for poor contact of the fuel tank pressure
sensor connector.
Is there poor contact in fuel tank
pressure sensor connector?
Repair the poor
contact in the fuel
tank pressure sen-
sor connector.
pressure sensor.
<Ref. to EC(H4SO)-
11, Fuel Tank Pres-
sure Sensor.>
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:
EN-05709
5
3
6
4
2
1
B47
SBF-7
E4
12
E2
B21
4
1
4
8
D
2
9
R68
12
R213
R15
15
R1
B97
1
4
1
5
R67
R46
7
6
C
1
7
C
2
8
R144
12
B136 C: B137 D:
3
1 2
4
5 6
B47 R213
E
B21
E4
1 2
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 2 3
4 5 6 7 8
1 2
R68
1 2
B97 R144 R67
1 2
3 4 5 6
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
MAIN RELAY
ECM
BATTERY
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE
EN(H4SO)(diag)-214
Step Check Yes No
NOTE:
tightening.
securely?
cap securely.
genuine fuel filler
cap.
filler pipe?
Repair or replace
the fuel filler cap
<Ref. to FU(H4SO)-
50, Fuel Filler
Pipe.>
Go to step 4.
Select Monitor.
NOTE:
the Subaru Select Monitor. Regarding the pro-
cedures, refer to Compulsory Valve Operation
valve. <Ref. to
EC(H4SO)-15,
Drain Valve.>
VALVE.
NOTE:
tion Check Mode.>
noid valve operate?
control solenoid
valve. <Ref. to
EC(H4SO)-6,
Purge Control
Solenoid Valve.>
VALVE.
NOTE:
tion Check Mode.>
noid valve operate?
sure control sole-
EC(H4SO)-12,
Pressure Control
Solenoid Valve.>
TROL SYSTEM LINE.
tor.
0.5 mm (0.020 in) dia. on evap-
oration line?
Repair or replace
<Ref. to FU(H4SO)-
59, Fuel Delivery
and Evaporation
Lines.>
Go to step 8.
Repair or replace
the canister. <Ref.
to EC(H4SO)-5,
Canister.>
Go to step 9.
EN(H4SO)(diag)-215
9 CHECK FUEL TANK.
Fuel Tank.>
Repair or replace
to FU(H4SO)-43,
Fuel Tank.>
Go to step 10.
TROL SYSTEM.
Repair or replace
the hoses or pipes.
Repair the poor
contact of the ECM
connector.
Step Check Yes No
EN(H4SO)(diag)-216
BM:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK
DETECTED (FUEL CAP LOOSE/OFF)
SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Fuel odor
Fuel filler cap loose or lost
CAUTION:
WIRING DIAGRAM:
EN-05709
5
3
6
4
2
1
B47
SBF-7
E4
12
E2
B21
4
1
4
8
D
2
9
R68
12
R213
R15
15
R1
B97
1
4
1
5
R67
R46
7
6
C
1
7
C
2
8
R144
12
B136 C: B137 D:
3
1 2
4
5 6
B47 R213
E
B21
E4
1 2
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 2 3
4 5 6 7 8
1 2
R68
1 2
B97 R144 R67
1 2
3 4 5 6
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
MAIN RELAY
ECM
BATTERY
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE
EN(H4SO)(diag)-217
Step Check Yes No
NOTE:
tightening.
securely?
cap securely.
genuine fuel filler
cap.
filler pipe?
Repair or replace
the fuel filler cap
<Ref. to FU(H4SO)-
50, Fuel Filler
Pipe.>
Go to step 4.
Select Monitor.
NOTE:
valve. <Ref. to
EC(H4SO)-15,
Drain Valve.>
VALVE.
NOTE:
tion Check Mode.>
noid valve operate?
control solenoid
valve. <Ref. to
EC(H4SO)-6,
Purge Control
Solenoid Valve.>
VALVE.
NOTE:
tion Check Mode.>
noid valve operate?
sure control sole-
EC(H4SO)-12,
Pressure Control
Solenoid Valve.>
TROL SYSTEM LINE.
tor.
Are there any disconnected,
broken or clogged evaporation
lines?
Repair or replace
<Ref. to FU(H4SO)-
59, Fuel Delivery
and Evaporation
Lines.>
Go to step 8.
8 CHECK CANISTER. Is the canister damaged? Repair or replace
the canister. <Ref.
to EC(H4SO)-5,
Canister.>
Go to step 9.
EN(H4SO)(diag)-218
9 CHECK FUEL TANK.
Fuel Tank.>
Is the fuel tank damaged? Repair or replace
to FU(H4SO)-43,
Fuel Tank.>
Go to step 10.
TROL SYSTEM.
Are there holes, cracks, clog-
ging, or disconnections, mis-
connection of hoses or pipes in
evaporative emission control
system?
Repair or replace
the hoses or pipes.
Repair the poor
contact of the ECM
connector.
Step Check Yes No
EN(H4SO)(diag)-219
BN:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT LOW
GENERAL DESCRIPTION <Ref. to GD(H4SO)-154, DTC P0458 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-04046
PURGE CONTROL
SOLENOID VALVE
E4
B21
E2
B47
B47
3 4
1 2
5 6
SBF-7
MAIN RELAY
1
2
4
6
3
5
2
9
1 2
4
8
4
1
B137 ECM
E4
B137
E
1 2
BATTERY
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H4SO)(diag)-220
Step Check Yes No
chassis ground.
contact of the ECM
connector.
Go to step 2.
PURGE CONTROL SOLENOID VALVE.
purge control solenoid valve.
3) Measure the resistance between the purge
control solenoid valve connector and engine
ground.
more?
ness between
ECM and purge
control solenoid
valve connector.
ECM and purge control solenoid valve.
(B137) No. 29 (E4) No. 1:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and purge
control solenoid
valve connector
Poor contact of
coupling connector
VALVE.
2) Measure the resistance between purge con-
trol solenoid valve terminals.
Terminals
No. 1 No. 2:
100 ?
control solenoid
valve. <Ref. to
EC(H4SO)-6,
Purge Control
Solenoid Valve.>
5 CHECK POWER SUPPLY TO PURGE CON-
TROL SOLENOID VALVE.
2) Measure the voltage between purge control
solenoid valve and engine ground.
contact of purge
control solenoid
valve connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the main relay and
purge control sole-
noid valve
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
EN(H4SO)(diag)-221
BO:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4SO)-156, DTC P0459 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-04046
PURGE CONTROL
SOLENOID VALVE
E4
B21
E2
B47
B47
3 4
1 2
5 6
SBF-7
MAIN RELAY
1
2
4
6
3
5
2
9
1 2
4
8
4
1
B137 ECM
E4
B137
E
1 2
BATTERY
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H4SO)(diag)-222
BP:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4SO)-158, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT
CAUTION:
BQ:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW
NOTE:
For the diagnostic procedure, refer to DTC P0463. <Ref. to EN(H4SO)(diag)-223, DTC P0463 FUEL LEVEL
SENSOR A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Step Check Yes No
chassis ground.
circuit to power in
the harness
between the ECM
and purge control
solenoid valve
connector.
Go to step 2.
VALVE.
Terminals
No. 1 No. 2:
Is the resistance less than 1 ? Replace the purge
control solenoid
valve. <Ref. to
EC(H4SO)-6,
Purge Control
Solenoid Valve.>
Repair the poor
contact of the ECM
connector.
Step Check Yes No
ate DTC using the
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Replace the fuel
level sensor and
fuel sub level sen-
sor. <Ref. to
FU(H4SO)-55, Fuel
Level Sensor.>
<Ref. to FU(H4SO)-
56, Fuel Sub Level
Sensor.>
EN(H4SO)(diag)-223
BR:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4SO)-162, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT
CAUTION:
BS:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
GENERAL DESCRIPTION <Ref. to GD(H4SO)-164, DTC P0464 FUEL LEVEL SENSOR CIRCUIT IN-
TERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Step Check Yes No
1 CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0462 or P0463 dis-
played on the Subaru Select
Monitor?
Check the combi-
nation meter. <Ref.
to IDI-13, CHECK
FUEL LEVEL
SENSOR,
INSPECTION,
Combination Meter
System.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Step Check Yes No
1 CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0464 displayed on the
display?
Check the combi-
nation meter. <Ref.
to IDI-13, CHECK
FUEL LEVEL
SENSOR,
INSPECTION,
Combination Meter
System.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
EN(H4SO)(diag)-224
BT:DTC P0500 VEHICLE SPEED SENSOR A
GENERAL DESCRIPTION <Ref. to GD(H4SO)-168, DTC P0500 VEHICLE SPEED SENSOR A, Diag-
nostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Step Check Yes No
1 CHECK DTC OF ABS.
Check DTC of ABS.
Is DTC of ABS displayed? Perform the diag-
nosis according to
DTC. <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Repair poor con-
tact of the ECM
connector.
EN(H4SO)(diag)-225
BU:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
GENERAL DESCRIPTION <Ref. to GD(H4SO)-170, DTC P0506 IDLE AIR CONTROL SYSTEM RPM
LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Hard to start the engine.
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05044
SBF-7
B134 A: B137 B136 D:
B362
C:
E
C
1
C
2
1
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
D
3
A
2
8
A
1
8
C
6
ECM
5
8
7
6
B362 B21 E57 B122
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B134 A:
B136 C: B137 D:
1 2 3 4 5 6
E2
B21
B122
E
E
3
9
2
0
E57
46 123 5
3
6
3
5
3
7
3
4
5
2
*
*
*
1
8
1
7
3
8
1
9
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ELECTRONIC THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC
THROTTLE CONTROL
ARRANGEMENT
EN(H4SO)(diag)-226
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
2 CHECK AIR CLEANER ELEMENT.
2) Check the air cleaner element.
Is there excessive clogging on
air cleaner element?
Replace the air
cleaner element.
<Ref. to IN(H4SO)-
4, Air Cleaner Ele-
ment.>
Go to step 3.
3 CHECK ELECTRONIC THROTTLE CON-
TROL.
1) Remove the electronic throttle control.
2) Check the electronic throttle control.
Are foreign matter found inside
electronic throttle control?
Remove foreign
matter from elec-
trol.
Perform the diag-
nosis of DTC
P2101. <Ref. to
EN(H4SO)(diag)-
283, DTC P2101
THROTTLE
ACTUATOR CON-
TROL MOTOR
CIRCUIT RANGE/
PERFORMANCE,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
EN(H4SO)(diag)-227
BV:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
GENERAL DESCRIPTION <Ref. to GD(H4SO)-172, 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:
EN-05044
SBF-7
B134 A: B137 B136 D:
B362
C:
E
C
1
C
2
1
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
D
3
A
2
8
A
1
8
C
6
ECM
5
8
7
6
B362 B21 E57 B122
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B134 A:
B136 C: B137 D:
1 2 3 4 5 6
E2
B21
B122
E
E
3
9
2
0
E57
46 123 5
3
6
3
5
3
7
3
4
5
2
*
*
*
1
8
1
7
3
8
1
9
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ELECTRONIC THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC
THROTTLE CONTROL
ARRANGEMENT
EN(H4SO)(diag)-228
Step Check Yes No
ate DTC using the
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
2 CHECK AIR INTAKE SYSTEM.
1) Start and idle the engine.
2) 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
Is there any fault in air intake
system?
Repair air suction
and leaks.
Go to step 3.
TROL.
Remove foreign
matter from elec-
trol.
Perform the diag-
nosis of DTC
P2101. <Ref. to
EN(H4SO)(diag)-
283, DTC P2101
THROTTLE
ACTUATOR CON-
TROL MOTOR
CIRCUIT RANGE/
PERFORMANCE,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
EN(H4SO)(diag)-229
BW:DTC P0512 STARTER REQUEST CIRCUIT
GENERAL DESCRIPTION <Ref. to GD(H4SO)-174, DTC P0512 STARTER REQUEST CIRCUIT, Diag-
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
EN-05699
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
No.21
B225
B225 B106
MAIN SBF SBF-6
E
1
5
1
3
1
6
1
4
B136
B106
B72 B136
2
0
3
2
B72
B14
3 2
1
2
M
1 3
4 5 6
2
B12 T3 T7
P R N D 3 2 1
7
12
11
12
AT
AT
AT
AT
B12 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
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
M
T
M
T
M
T
M
T
1
2
BATTERY
IGNITION
SWITCH
STARTER RELAY
CLUTCH
SWITCH
ECM
STARTER MOTOR
(MAGNET)
INHIBITOR SWITCH
EN(H4SO)(diag)-230
BX:DTC P0600 SERIAL COMMUNICATION LINK
NOTE:
For the diagnostic procedure, refer to LAN section. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
Step Check Yes No
ate DTC using the
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
NITION SWITCH.
chassis ground.
circuit to power in
the harness
between the ECM
and ignition switch.
Repair the poor
contact of the ECM
connector.
EN(H4SO)(diag)-231
BY:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY
(RAM) ERROR
GENERAL DESCRIPTION <Ref. to GD(H4SO)-178, DTC P0604 INTERNAL CONTROL MODULE RAN-
DOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05700
SBF-6 MAIN SBF
SBF-7
B72
No.12
B47
E2
B21
2
1
4
6
5
3
E
3 1
B134
B135
A:
D: B137
C: B136
B:
3 4
1 2
5 6
B47
No.13
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B72
1 3
4 5 6
2
A: B:
D:
A
7
B
2
C
2
3
B
1
9
D
7
D
1
D
3
A
5
B
5
5
2
3
7
3
6
3
4
D
2
3
5
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
E
MAIN RELAY
ECM
IGNITION
SWITCH
BATTERY
EN(H4SO)(diag)-232
BZ:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)
ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4SO)(diag)-233, DTC P0607 CONTROL
MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Step Check Yes No
ate DTC using the
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
EN(H4SO)(diag)-233
CA:DTC P0607 CONTROL MODULE PERFORMANCE
Depending on the content of malfunction, adapt either of the followings.
GENERAL DESCRIPTION <Ref. to GD(H4SO)-181, DTC P0607 CONTROL MODULE PERFORMANCE,
Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05711
SBF-6 MAIN SBF
SBF-7
B72
B
2
A
7
C
2
4
A
5
D
3
D
2
D
7
D
1
B
5
B
2
7
No.12
B47
E2
B21
2
1
4
6
5
3
E
3 4
B134 B135 A:
D: B137
B:
3
6
3
7
3
4
5
2
3
5
3 4
1 2
5 6
B47
No.13
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B72
1 3
4 5 6
2
A:
B:
E
*
*
E
C: B136
B122
E57
A
1
9
D
4
D
5
A
2
9
A
2
8
A
1
8
C
6
2
0
3
9
3
8
1
9
5123
1
8
1
7
46
B122
3 4
5 6
1 2
7 8
B136 C:
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
*
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
E57
1 2 3 4 5 6
MAIN RELAY
IGNITION
SWITCH
ECM
BATTERY
ARRANGEMENT
ELECTRONIC
THROTTLE CONTROL
EN(H4SO)(diag)-234
CB:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE
(BANK 1)
NOTE:
For the diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4SO)(diag)-283, DTC P2101 THROTTLE
ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnos-
CC:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
NOTE:
For the diagnostic procedure, refer to AT section. <Ref. to 4AT(diag)-2, Basic Diagnostic Procedure.>
Step Check Yes No
chassis ground.
Is the voltage 10 13 V? Go to step 2. Repair the open or
of power supply
circuit.
chassis ground.
of power supply
circuit.
(B134) No. 19 (E57) No. 5:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
4 CHECK ECM GROUND HARNESS.
Measure the voltage between ECM and chassis
ground.
Is the voltage less than 1 V? Repair the poor
contact of the ECM
connector.
Repair the follow-
ing item.
Open circuit of
ground circuit
Retightening of
engine ground ter-
minals
Poor contact in
ECM connector
Poor contact of
coupling connector
EN(H4SO)(diag)-235
CD:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-188, DTC P0851 PARK/NEUTRAL SWITCH INPUT CIR-
CUIT LOW (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-06895
B14
B136
3
1
6
B12
1 2 3 4
5 6 7 8
9 10 11 12
1
B25 T2 T2 B25
2
M
B25
2 1
B122
*
*
B136
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B122
3 4
5 6
1 2
7 8
A
T
MT
MT
1 2 3 4 5 6
7 8 9 10 11 12
T7 OT
:
1 2 3 4 5
7 6 9 8
NT
: T7
B12 T3 T7
P R N D
7
12
11
12
9
6
OT NT
OT
:
NT
:
*
:
ECM
NEUTRAL
POSITION
SWITCH
INHIBITOR
SWITCH
STARTER MOTOR
OR EARLIER
OR LATER
EN(H4SO)(diag)-236
Step Check Yes No
1 CHECK SELECT CABLE. Are there any faults in the
select cable?
Repair or adjust
the select cable.
<Ref. to CS-27,
Select Cable.>
Go to step 2.
2) Place the select lever other than P range
and N range.
chassis ground.
contact of the ECM
connector.
Go to step 3.
TRANSMISSION HARNESS CONNECTOR.
transmission harness connector (T3).
chassis ground.
more?
ness between
ECM and trans-
mission harness
connector.
4 CHECK TRANSMISSION HARNESS CON-
NECTOR.
switch.
2) Measure the resistance between the trans-
mission harness connector and engine ground.
(T3) No. 11 Engine ground:
more?
Replace the inhibi-
4AT-47, Inhibitor
Switch.>
Repair the ground
ness between
transmission har-
ness connector
and inhibitor switch
connector.
EN(H4SO)(diag)-237
CE:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-189, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT
LOW (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-06895
B14
B136
3
1
6
B12
1 2 3 4
5 6 7 8
9 10 11 12
1
B25 T2 T2 B25
2
M
B25
2 1
B122
*
*
B136
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B122
3 4
5 6
1 2
7 8
A
T
MT
MT
1 2 3 4 5 6
7 8 9 10 11 12
T7 OT
:
1 2 3 4 5
7 6 9 8
NT
: T7
B12 T3 T7
P R N D
7
12
11
12
9
6
OT NT
OT
:
NT
:
*
:
ECM
NEUTRAL
POSITION
SWITCH
INHIBITOR
SWITCH
STARTER MOTOR
OR EARLIER
OR LATER
EN(H4SO)(diag)-238
Step Check Yes No
2) Place the shift lever in a position except for
neutral.
chassis ground.
contact of the ECM
connector.
Go to step 2.
NEUTRAL POSITION SWITCH CONNEC-
TOR.
chassis ground.
more?
Repair the short
circuit of transmis-
sion harness, or
replace the neutral
position switch.
Repair the ground
ness between
ECM and trans-
mission harness
connector.
EN(H4SO)(diag)-239
CF:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-191, DTC P0852 PARK/NEUTRAL SWITCH INPUT CIR-
CUIT HIGH (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-06895
B14
B136
3
1
6
B12
1 2 3 4
5 6 7 8
9 10 11 12
1
B25 T2 T2 B25
2
M
B25
2 1
B122
*
*
B136
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B122
3 4
5 6
1 2
7 8
A
T
MT
MT
1 2 3 4 5 6
7 8 9 10 11 12
T7 OT
:
1 2 3 4 5
7 6 9 8
NT
: T7
B12 T3 T7
P R N D
7
12
11
12
9
6
OT NT
OT
:
NT
:
*
:
ECM
NEUTRAL
POSITION
SWITCH
INHIBITOR
SWITCH
STARTER MOTOR
OR EARLIER
OR LATER
EN(H4SO)(diag)-240
Step Check Yes No
1 CHECK SELECT CABLE. Are there any faults in the
select cable?
Repair or adjust
the select cable.
<Ref. to CS-27,
Select Cable.>
Go to step 2.
chassis ground with select lever at P range
and N range.
contact of the ECM
connector.
Go to step 3.
3 CHECK HARNESS BETWEEN ECM AND IN-
HIBITOR SWITCH CONNECTOR.
inhibitor switch.
ECM and inhibitor switch connector.
(B136) No. 31 (T7) No. 7:
(B136) No. 31 (T7) No. 9:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and inhibitor
switch connector
Poor contact of
coupling connector
4 CHECK INHIBITOR SWITCH GROUND LINE.
inhibitor switch connector and engine ground.
Is the resistance less than 5 ? Replace the inhibi-
4AT-47, Inhibitor
Switch.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
inhibitor switch
connector and
starter motor
ground line
Poor contact of
coupling connector
Poor contact in
starter motor con-
nector
Poor contact in
starter motor
ground
Starter motor
EN(H4SO)(diag)-241
CG:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-192, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT
HIGH (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-06895
B14
B136
3
1
6
B12
1 2 3 4
5 6 7 8
9 10 11 12
1
B25 T2 T2 B25
2
M
B25
2 1
B122
*
*
B136
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B122
3 4
5 6
1 2
7 8
A
T
MT
MT
1 2 3 4 5 6
7 8 9 10 11 12
T7 OT
:
1 2 3 4 5
7 6 9 8
NT
: T7
B12 T3 T7
P R N D
7
12
11
12
9
6
OT NT
OT
:
NT
:
*
:
ECM
NEUTRAL
POSITION
SWITCH
INHIBITOR
SWITCH
STARTER MOTOR
OR EARLIER
OR LATER
EN(H4SO)(diag)-242
Step Check Yes No
2) Place the shift lever in neutral.
chassis ground.
contact of the ECM
connector.
Go to step 2.
NEUTRAL SWITCH CONNECTOR.
2) Disconnect connectors from the ECM and
transmission harness.
ECM and transmission harness connector.
(B136) No. 31 (T2) No. 2:
circuit of harness
between ECM and
transmission har-
ness connector.
(B136) No. 6 (T2) No. 1:
and connector.
NOTE:
the following item:
Open circuit of
harness between
transmission har-
ness connector
and engine ground
Poor contact of
coupling connector
4 CHECK NEUTRAL SWITCH.
2) Measure the resistance between transmis-
sion harness connector terminals.
(T2) No. 1 No. 2:
contact of trans-
mission harness
connector.
Repair the open
sion harness, or
replace the neutral
switch.
EN(H4SO)(diag)-243
CH:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1
SENSOR1)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-194, DTC P1152 O2 SENSOR CIRCUIT RANGE/PER-
FORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05042
B137
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
31 26 27
3 4
1 2
5 6
B327
SBF-5
E
E
B327
E22
6
4
5
3
2
1
6
41 3
B
1
B
9
B
8
C
3
C
2
A
5
D
7
D
1
D
2
D
3
3
6
5
2
3
4
3
5
3
7
B134 A:
B135 B:
B136 C:
B137 D:
B21
E2
ECM
B21 E2
50
5
1
3 4
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E22 B138
B134
B135
A:
B:
B136 C:
D:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B138
*
*
*
3 1
6 5 4
2
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
3 4
5 6
1 2
7 8
OXYGEN SENSOR RELAY
FRONT
OXYGEN (A/F)
SENSOR
BATTERY
ARRANGEMENT
EN(H4SO)(diag)-244
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
(B135) No. 9 (E22) No. 1:
(B135) No. 8 (E22) No. 3:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Poor contact of
coupling connector
Check poor contact of front oxygen (A/F) sen-
sor connector.
tor?
Repair the poor
oxygen (A/F) sen-
sor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4SO)-33,
Front Oxygen (A/F)
Sensor.>
EN(H4SO)(diag)-245
CI: DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1
SENSOR1)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-197, DTC P1153 O2 SENSOR CIRCUIT RANGE/PER-
FORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05042
B137
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
31 26 27
3 4
1 2
5 6
B327
SBF-5
E
E
B327
E22
6
4
5
3
2
1
6
41 3
B
1
B
9
B
8
C
3
C
2
A
5
D
7
D
1
D
2
D
3
3
6
5
2
3
4
3
5
3
7
B134 A:
B135 B:
B136 C:
B137 D:
B21
E2
ECM
B21 E2
50
5
1
3 4
E2
B21
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
E22 B138
B134
B135
A:
B:
B136 C:
D:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B138
*
*
*
3 1
6 5 4
2
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
3 4
5 6
1 2
7 8
OXYGEN SENSOR RELAY
FRONT
OXYGEN (A/F)
SENSOR
BATTERY
ARRANGEMENT
EN(H4SO)(diag)-246
CJ:DTC P1160 RETURN SPRING FAILURE
NOTE:
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
3 CHECK OUTPUT SIGNAL FOR ECM.
1) Connect the ECM.
chassis ground.
Is the voltage 4.5 V or more? Go to step 5. Go to step 4.
ground.
Is the voltage 4.95 V or more? Go to step 5. Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4SO)-33,
Front Oxygen (A/F)
Sensor.>
ground.
Is the voltage 8 V or more? Repair the short cir-
cuit to power in the
harness between
the ECM and front
oxygen (A/F) sen-
sor connector. After
repair, replace the
ECM. <Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
Repair the poor
contact of the ECM
connector.
EN(H4SO)(diag)-247
CK:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT
LOW
GENERAL DESCRIPTION <Ref. to GD(H4SO)-202, DTC P1400 FUEL TANK PRESSURE CONTROL
SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05713
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B136
2
8
2 1
1
5
R1
R68
B97
7
R67
R46
65
R213
R15
B136
B47
3 4
1 2
5 6
SBF-7
5
3
6
4
2
1
B47
B97 R67 R213
E
1 2 3
4 5 6 7 8
1 2
3 4 5 6
R68
1 2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
MAIN RELAY
BATTERY
PRESSURE
CONTROL
SOLENOID
VALVE
ECM
EN(H4SO)(diag)-248
Step Check Yes No
chassis ground.
contact of the ECM
connector.
Go to step 2.
PRESSURE CONTROL SOLENOID VALVE.
and pressure control solenoid valve.
3) Measure the resistance between pressure
control solenoid valve and chassis ground.
more?
ness between
ECM and pressure
control solenoid
valve connector.
ECM and pressure control solenoid valve con-
nector.
(B136) No. 28 (R68) No. 2:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and pressure
control solenoid
valve connector
Poor contact of
coupling connector
VALVE.
Measure the resistance between pressure con-
Terminals
No. 1 No. 2:
100 ?
sure control sole-
EC(H4SO)-12,
Pressure Control
Solenoid Valve.>
5 CHECK POWER SUPPLY TO THE PRES-
SURE CONTROL SOLENOID VALVE.
2) Measure the voltage between pressure con-
trol solenoid valve and chassis ground.
contact of pressure
control solenoid
valve connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
main relay and
pressure control
solenoid valve
connector
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
EN(H4SO)(diag)-249
CL:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4SO)-204, DTC P1420 FUEL TANK PRESSURE CONTROL
SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05713
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B136
2
8
2 1
1
5
R1
R68
B97
7
R67
R46
65
R213
R15
B136
B47
3 4
1 2
5 6
SBF-7
5
3
6
4
2
1
B47
B97 R67 R213
E
1 2 3
4 5 6 7 8
1 2
3 4 5 6
R68
1 2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
MAIN RELAY
BATTERY
PRESSURE
CONTROL
SOLENOID
VALVE
ECM
EN(H4SO)(diag)-250
Step Check Yes No
chassis ground.
circuit to power in
the harness
between ECM and
pressure control
solenoid valve
connector.
Go to step 2.
VALVE.
control solenoid valve terminals.
Terminals
No. 1 No. 2:
Is the resistance less than 1 ? Replace the pres-
sure control sole-
EC(H4SO)-12,
Pressure Control
Solenoid Valve.>
Repair the poor
contact of the ECM
connector.
EN(H4SO)(diag)-251
CM:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM
GENERAL DESCRIPTION <Ref. to GD(H4SO)-206, DTC P1443 VENT CONTROL SOLENOID VALVE
FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper fuel supply
CAUTION:
WIRING DIAGRAM:
EN-05710
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
7
B97 R1
1
2
7
R144 R15 R213
R46 R67
B136
SBF-7
5
3
6
4
2
1
B47
6
1
E
B47
3 4
1 2
5 6
1 2 3
4 5 6 7 8
1 2
3 4 5 6
R67 R213 B97
14
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2
R144
MAIN RELAY
BATTERY
DRAIN
VALVE
ECM
EN(H4SO)(diag)-252
Step Check Yes No
ate DTC using the
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
2 CHECK DRAIN HOSE.
Check the drain hose for clogging.
Is there clogging in the drain
hose?
Replace the drain
hose.
Go to step 3.
3 CHECK DRAIN VALVE OPERATION.
2) Connect the delivery (test) mode connector
at the lower portion of instrument panel (on the
drivers side).
4) Operate the drain valve.
NOTE:
Does the drain valve operate? Repair the poor
contact of the ECM
connector.
Replace the drain
valve. <Ref. to
EC(H4SO)-15,
Drain Valve.>
EN(H4SO)(diag)-253
CN:DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION
PROBLEM
GENERAL DESCRIPTION <Ref. to GD(H4SO)-208, DTC P1491 POSITIVE CRANKCASE VENTILA-
TION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-04049
E61
1 2
3
0
1
0
B21
E2
E
B134
E61
1 2
PCV
DIAGNOSIS
CONNECTOR
ECM
B134
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
B21
1 2 3 4 5 6 7 8 9 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
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
EN(H4SO)(diag)-254
Step Check Yes No
1 CHECK BLOW-BY HOSE.
Check the blow-by hose condition.
Is there any disconnection or
crack in blow-by hose?
Repair or replace
the blow-by hose.
Go to step 2.
PCV HOSE ASSEMBLY.
and PCV hose assembly.
ECM and PCV hose assembly.
(B134) No. 30 (E61) No. 2:
circuit of harness
between ECM and
PCV hose assem-
bly.
PCV HOSE ASSEMBLY.
Measure the resistance between PCV hose
assembly and chassis ground.
more?
ness between
ECM and PCV
hose assembly.
4 CHECK GROUND CIRCUIT OF PCV HOSE
ASSEMBLY.
PCV hose assembly and engine ground.
circuit of harness
between PCV
hose assembly
and engine
ground.
5 CHECK THE PCV HOSE ASSEMBLY.
Measure the resistance between the PCV hose
assembly terminals.
Terminals
No. 1 No. 2:
contact in ECM
and PCV hose
assembly connec-
tor.
Replace the PCV
hose assembly.
EN(H4SO)(diag)-255
CO: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)-256, DTC P1498 EGR SOLE-
NOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic
CP:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
NOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic
CQ:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
CR:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
CS:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
CT:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
EN(H4SO)(diag)-256
CU:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION
(LOW INPUT)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-210, DTC P1492 EGR SOLENOID VALVE SIGNAL #1
CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to
GD(H4SO)-214, DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW IN-
PUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-214, DTC P1496 EGR SO-
LENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC)
Detecting Criteria.> <Ref. to GD(H4SO)-214, 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)-257
WIRING DIAGRAM:
EN-05708
E
B47
E18
2 5
6 4 3 1
B21
E2
E2
B21
5
3
6
4
2
1
4
8
3
0
2
5
2
9
2
6
SBF-7
B134
B47
E18
3 4
1 2
5 6
1 3
4 5 6
2
B134
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
2
0
1
0
8 9
MAIN RELAY
EGR
VALVE
ECM
BATTERY
EN(H4SO)(diag)-258
Step Check Yes No
1 CHECK POWER SUPPLY TO EGR VALVE.
2) Disconnect the connector from the EGR
valve.
4) Measure the voltage between EGR valve
and connector.
NOTE:
the following item:
Open circuit in
harness between
EGR valve and
main relay connec-
tor
Poor contact of
coupling connector
EGR VALVE CONNECTOR.
EGR valve connector.
DTC P1492; (B134) No. 8 (E18) No. 3:
DTC P1494; (B134) No. 9 (E18) No. 1:
DTC P1496; (B134) No. 10 (E18) No. 4:
DTC P1498; (B134) No. 20 (E18) No. 6:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and EGR
valve connector
Poor contact of
coupling connector
chassis ground.
DTC P1492; (B134) No. 8 Chassis
ground:
ground:
ground:
ground:
more?
short in harness
between ECM and
EGR valve con-
nector.
Check poor contact in ECM and EGR valve
connector.
EGR valve connector?
Repair the poor
contact in ECM or
EGR valve con-
nector.
Replace the EGR
valve. <Ref. to FU
(H4SO)-27, EGR
Valve.>
EN(H4SO)(diag)-259
CV:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION
(HIGH INPUT)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-212, DTC P1493 EGR SOLENOID VALVE SIGNAL #1
CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to
GD(H4SO)-214, DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH IN-
PUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-214, DTC P1497 EGR SO-
LENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC)
Detecting Criteria.> <Ref. to GD(H4SO)-214, 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)-260
WIRING DIAGRAM:
Step Check Yes No
2) Disconnect the connector from the EGR
valve.
chassis ground.
DTC P1493; (B134) No. 8 (+) Chassis
ground ():
ground ():
DTC P1497; (B134) No. 10 (+) Chassis
ground ():
DTC P1499; (B134) No. 20 (+) Chassis
ground ():
circuit to power in
the harness
between the ECM
and EGR valve
connectors.
Repair the poor
contact of the ECM
connector.
EN-05708
E
B47
E18
2 5
6 4 3 1
B21
E2
E2
B21
5
3
6
4
2
1
4
8
3
0
2
5
2
9
2
6
SBF-7
B134
B47
E18
3 4
1 2
5 6
1 3
4 5 6
2
B134
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
2
0
1
0
8 9
MAIN RELAY
EGR
VALVE
ECM
BATTERY
EN(H4SO)(diag)-261
CW:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
GENERAL DESCRIPTION <Ref. to GD(H4SO)-215, DTC P1560 BACK-UP VOLTAGE CIRCUIT MAL-
FUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05700
SBF-6 MAIN SBF
SBF-7
B72
No.12
B47
E2
B21
2
1
4
6
5
3
E
3 1
B134
B135
A:
D: B137
C: B136
B:
3 4
1 2
5 6
B47
No.13
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B72
1 3
4 5 6
2
A: B:
D:
A
7
B
2
C
2
3
B
1
9
D
7
D
1
D
3
A
5
B
5
5
2
3
7
3
6
3
4
D
2
3
5
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
E
MAIN RELAY
ECM
IGNITION
SWITCH
BATTERY
EN(H4SO)(diag)-262
Step Check Yes No
chassis ground.
tact of the ECM
connector.
Go to step 2.
MAIN FUSE BOX CONNECTOR.
chassis ground.
more?
ness between
ECM and battery
terminal.
3 CHECK FUSE NO. 13 (IN MAIN FUSE BOX). Is the fuse blown out? Replace the fuse. Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and battery
Poor contact in
ECM connector
Poor contact of
battery terminal
EN(H4SO)(diag)-263
CX:DTC P1602 CONTROL MODULE PROGRAMMING ERROR
GENERAL DESCRIPTION <Ref. to GD(H4SO)-217, DTC P1602 CONTROL MODULE PROGRAMMING
ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine keeps running at a lower speed than the specified idle speed.
Engine stalls.
CAUTION:
EN(H4SO)(diag)-264
WIRING DIAGRAM:
EN-05703
E6 E17
E5 E16
1 2
1 21 21 21 2
1
0
9 8
1
1
4
2
4
8
4
3
4
4
4
5
B137
E5 E16 E6 E17
B21
E2
SBF-7
B47
1
2
4
6
3
5
B47
3 4
1 2
5 6
E
B137 B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
MAIN RELAY
BATTERY
ECM
FUEL INJECTOR
No.1
FUEL INJECTOR
No.2
FUEL INJECTOR
No.3
FUEL INJECTOR
No.4
EN(H4SO)(diag)-265
Step Check Yes No
ate DTC using the
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
2 CHECK ENGINE OIL. Is there a proper amount of
engine oil?
Go to step 3. Replace engine oil.
<Ref. to LU(H4SO)-
9, REPLACEMENT,
Engine Oil.>
on exhaust system?
Repair the exhaust
system.
Go to step 4.
intake system?
Repair the air
intake system.
Go to step 5.
EN-05044
SBF-7
B134 A: B137 B136 D:
B362
C:
E
C
1
C
2
1
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
D
3
A
2
8
A
1
8
C
6
ECM
5
8
7
6
B362 B21 E57 B122
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B134 A:
B136 C: B137 D:
1 2 3 4 5 6
E2
B21
B122
E
E
3
9
2
0
E57
46 123 5
3
6
3
5
3
7
3
4
5
2
*
*
*
1
8
1
7
3
8
1
9
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ELECTRONIC THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC
THROTTLE CONTROL
ARRANGEMENT
EN(H4SO)(diag)-266
WARNING:
working area.
CAUTION:
Measure the fuel pressure. <Ref. to ME(H4SO)-
26, INSPECTION, Fuel Pressure.>
CAUTION:
360.5 kPa (3.5 3.7 kg/cm
2
,
49 52 psi)?
ing item.
Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
SENSOR.
NOTE:
tor.>
General scan tool
coolant tempera-
ture sensor. <Ref.
to FU(H4SO)-20,
Engine Coolant
Temperature Sen-
sor.>
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
5.0 g/s (0.26 0.66 lb/m)?
Go to step 8. Replace the mass air
flow and intake air
temperature sensor.
<Ref. to FU(H4SO)-
26, Mass Air Flow
and Intake Air Tem-
perature Sensor.>
Step Check Yes No
EN(H4SO)(diag)-267
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
(18 90F)?
Go to step 9. Check the mass air
flow and intake air
temperature sensor.
<Ref. to FU(H4SO)-
26, Mass Air Flow
and Intake Air Tem-
perature Sensor.>
FUEL INJECTOR.
cylinders.
more?
ness between
ECM and fuel
injector.
FUEL INJECTOR.
#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:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel in-
jector connector
Poor contact of
coupling connector
Step Check Yes No
EN(H4SO)(diag)-268
Terminals
No. 1 No. 2:
20 ?
to FU(H4SO)-28,
Fuel Injector.>
contact of all con-
nectors in fuel
injector circuit.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the main relay and
fuel injector con-
nector on faulty
cylinders
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
Poor contact of
fuel injector con-
nector on faulty
cylinders
FUEL INJECTOR.
circuit to power in
the harness
between the ECM
and fuel injector.
Go to step 15.
Terminals
No. 1 No. 2:
to FU(H4SO)-28,
Fuel Injector.>
Go to step 16.
CAMSHAFT POSITION SENSOR/CRANK-
SHAFT POSITION SENSOR.
loosely installed?
Tighten the cam-
shaft position sen-
sor or crankshaft
position sensor.
Go to step 17.
Replace the crank
sprocket. <Ref. to
ME(H4SO)-48,
Crank Sprocket.>
Go to step 18.
TIMING BELT.
SOCKET
tion condition of
timing belt. <Ref.
to ME(H4SO)-42,
Timing Belt.>
Go to step 19.
Step Check Yes No
EN(H4SO)(diag)-269
TROL RELAY.
2) Remove the electronic throttle control relay.
3) Connect the battery to terminals No. 5 and
No. 6 of electronic throttle control relay.
throttle control relay terminals.
Terminals
No. 8 No. 7:
Is the resistance less than 1 ? Go to step 20. Replace the elec-
trol relay.
20 CHECK POWER SUPPLY OF ELECTRONIC
THROTTLE CONTROL RELAY.
Measure the voltage between electronic throttle
control relay connector and chassis ground.
of power supply
circuit.
ELECTRONIC THROTTLE CONTROL RE-
LAY.
throttle control relay connector and chassis
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 22.
LAY.
ground.
more?
ness between
ECM and elec-
trol relay.
LAY.
electronic throttle control relay connector.
(B136) No. 21 (B362) No. 6:
(B136) No. 1 (B362) No. 7:
circuit of harness
between ECM and
electronic throttle
control relay.
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
Step Check Yes No
EN(H4SO)(diag)-270
1) Connect the ECM.
more?
ness between ECM
and electronic throt-
tle control connec-
tor. Replace the
ECM if defective.
<Ref. to FU(H4SO)-
37, Engine Control
Module (ECM).>
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
1) Connect the ECM.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 29.
nectors.
(B134) No. 19 (B134) No. 18:
(B134) No. 19 (B134) No. 28:
more?
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
30 CHECK SENSOR OUTPUT.
3) Read the data of main throttle sensor signal
using Subaru Select Monitor.
NOTE:
tor.>
Is the voltage 0.81 0.87 V? Go to step 31. Repair poor con-
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4SO)-11,
Throttle Body.>
Step Check Yes No
EN(H4SO)(diag)-271
Read the data of sub throttle sensor signal
NOTE:
tor.>
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4SO)-11,
Throttle Body.>
ELECTRONIC THROTTLE CONTROL MO-
TOR.
electronic throttle control connector.
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
circuit of harness
between ECM and
electronic throttle
control.
TOR.
1) Connect the ECM.
circuit to power in
the harness
between the ECM
and electronic
throttle control.
Go to step 34.
TOR.
more?
ness between the
ECM and elec-
trol.
TROL MOTOR HARNESS.
Measure the resistance between the electronic
throttle control connector terminals.
(E57) No. 2 (E57) No. 1:
more?
circuit of harness
between ECM and
electronic throttle
control.
TROL GROUND CIRCUIT.
chassis ground.
circuit of the har-
ness between the
ECM and engine
ground.
Step Check Yes No
EN(H4SO)(diag)-272
TROL.
Measure the resistance between electronic
throttle control terminals.
Terminals
No. 2 No. 1:
Is the resistance 50 or less? Go to step 38. Replace the elec-
trol. <Ref. to
FU(H4SO)-11,
Throttle Body.>
TROL.
Move the throttle valve to the fully open and fully
closed positions with fingers.
Check that the valve returns to the specified
position when releasing fingers.
Does the valve return to the
specified position? Standard
value: 3 mm (0.12 in) from fully
closed position
Repair the poor
contact of the ECM
connector.
Replace the elec-
trol. <Ref. to
FU(H4SO)-11,
Throttle Body.>
Step Check Yes No
EN(H4SO)(diag)-273
CY:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1
GENERAL DESCRIPTION <Ref. to GD(H4SO)-219, DTC P2096 POST CATALYST FUEL TRIM SYS-
TEM TOO LEAN BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-04042
3 4
1 2
5 6
B327
SBF-5
B327
B138
E2
B21
B21 E2
E23
E22
1
2
6
4
E E
1 3 4
2
B135 B: B136 C:
E
413
1 2
3 4
E23
FRONT OXYGEN
(A/F) SENSOR
JOINT
CON-
NECTOR
REAR OXYGEN
SENSOR
ECM
OXYGEN SENSOR RELAY
BATTERY
B134
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
B135
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
B:
B136 C:
8
5 6
10 11 12 13 14 15
2 1 3 4
16
30
19 20 22
29
9
17 18 25 24
7
28
21 23
32 31
26 27
33 34 35
B138
3 4
5 6
1 2
7 8
B134 A:
A:
6
: TERMINAL No.
OPTIONAL
ARRANGEMENT
*
E22
3 1
6 5 4
2
50
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1
9
5
3
5
1
3 4 1
* *
*
A
2
9
C
4
B
4
B
1
B
9
B
8
C
2
C
3
EN(H4SO)(diag)-274
Step Check Yes No
1 CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
TOR.
tor?
Completely
remove any water
inside.
Go to step 3.
TOR.
(B135) No. 9 (E22) No. 1:
(B135) No. 8 (E22) No. 3:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Poor contact of
coupling connector
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
1) Connect the ECM.
(A/F) sensor connector and chassis ground.
Measure the voltage between front oxygen (A/
F) sensor connector and chassis ground.
harness between
the ECM and front
oxygen (A/F) sen-
repair, replace the
ECM. <Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
Repair poor con-
tact of the ECM
connector.
EN(H4SO)(diag)-275
on exhaust system?
Repair the exhaust
system.
Go to step 9.
intake system?
Repair the air
intake system.
Go to step 10.
WARNING:
working area.
CAUTION:
1) Connect the front oxygen (A/F) sensor con-
nector.
2) Measure the fuel pressure. <Ref. to
ME(H4SO)-26, INSPECTION, Fuel Pressure.>
CAUTION:
360.5 kPa (3.5 3.7 kg/cm
2
,
49 52 psi)?
ing item.
Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
SENSOR.
NOTE:
tor.>
General scan tool
coolant tempera-
ture sensor. <Ref.
to FU(H4SO)-20,
Engine Coolant
Temperature Sen-
sor.>
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
5.0 g/s (0.26 0.66 lb/m)?
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Step Check Yes No
EN(H4SO)(diag)-276
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
(18 90F)?
flow and intake air
temperature sen-
sor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
maximum)
tool.
NOTE:
Depress the clutch pedal. (MT model)
tor.>
General scan tool
rpm.
tool.
NOTE:
tor.>
General scan tool
Step Check Yes No
EN(H4SO)(diag)-277
tor?
Completely
remove any water
inside.
Go to step 18.
AND REAR OXYGEN SENSOR DATA.
temperature is higher than 75C (167F), then
keep the engine idling for 5 minutes or more.
tool.
NOTE:
tor.>
General scan tool
Is a voltage of 0.8 V or more
maintained for 5 minutes or
more?
Replace the front
oxygen (A/F) sensor.
<Ref. to FU(H4SO)-
33, Front Oxygen (A/
F) Sensor.>
Go to step 18.
rear oxygen sensor.
(B135) No. 4 (E23) No. 3:
(B134) No. 29 (E23) No. 4:
circuit of harness
between ECM and
rear oxygen sen-
sor connector.
1) Connect the ECM.
oxygen sensor.
<Ref. to FU(H4SO)-
35, Rear Oxygen
Sensor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact in
ECM connector
Poor contact of
coupling connector
Step Check Yes No
EN(H4SO)(diag)-278
CZ:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1
GENERAL DESCRIPTION <Ref. to GD(H4SO)-221, DTC P2097 POST CATALYST FUEL TRIM SYS-
TEM TOO RICH BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-04042
3 4
1 2
5 6
B327
SBF-5
B327
B138
E2
B21
B21 E2
E23
E22
1
2
6
4
E E
1 3 4
2
B135 B: B136 C:
E
413
1 2
3 4
E23
FRONT OXYGEN
(A/F) SENSOR
JOINT
CON-
NECTOR
REAR OXYGEN
SENSOR
ECM
OXYGEN SENSOR RELAY
BATTERY
B134
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
B135
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
B:
B136 C:
8
5 6
10 11 12 13 14 15
2 1 3 4
16
30
19 20 22
29
9
17 18 25 24
7
28
21 23
32 31
26 27
33 34 35
B138
3 4
5 6
1 2
7 8
B134 A:
A:
6
: TERMINAL No.
OPTIONAL
ARRANGEMENT
*
E22
3 1
6 5 4
2
50
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1
9
5
3
5
1
3 4 1
* *
*
A
2
9
C
4
B
4
B
1
B
9
B
8
C
2
C
3
EN(H4SO)(diag)-279
Step Check Yes No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
TOR.
tor?
Completely
remove any water
inside.
Go to step 3.
TOR.
(B135) No. 9 (E22) No. 1:
(B135) No. 8 (E22) No. 3:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Poor contact of
coupling connector
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
1) Connect the ECM.
harness between
the ECM and front
oxygen (A/F) sen-
repair, replace the
ECM. <Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
Repair poor con-
tact of the ECM
connector.
EN(H4SO)(diag)-280
on exhaust system?
Repair the exhaust
system.
Go to step 9.
intake system?
Repair the air
intake system.
Go to step 10.
WARNING:
working area.
CAUTION:
nector.
ME(H4SO)-26, INSPECTION, Fuel Pressure.>
CAUTION:
360.5 kPa (3.5 3.7 kg/cm
2
,
49 52 psi)?
ing item.
Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
SENSOR.
NOTE:
tor.>
General scan tool
coolant tempera-
ture sensor. <Ref.
to FU(H4SO)-20,
Engine Coolant
Temperature Sen-
sor.>
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
5.0 g/s (0.26 0.66 lb/m)?
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Step Check Yes No
EN(H4SO)(diag)-281
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
(18 90F)?
flow and intake air
temperature sen-
sor. <Ref. to
FU(H4SO)-26,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
maximum)
tool.
NOTE:
tor.>
General scan tool
rpm.
tool.
NOTE:
tor.>
General scan tool
Step Check Yes No
EN(H4SO)(diag)-282
tor?
Completely
remove any water
inside.
Go to step 18.
tool.
NOTE:
tor.>
General scan tool
more?
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4SO)-33,
Front Oxygen (A/F)
Sensor.>
Go to step 18.
rear oxygen sensor.
(B135) No. 4 (E23) No. 3:
(B134) No. 29 (E23) No. 4:
circuit of harness
between ECM and
rear oxygen sen-
sor connector.
1) Connect the ECM.
oxygen sensor.
<Ref. to FU(H4SO)-
35, Rear Oxygen
Sensor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact in
ECM connector
Poor contact of
coupling connector
Step Check Yes No
EN(H4SO)(diag)-283
DA:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE
/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4SO)-223, DTC P2101 THROTTLE ACTUATOR CONTROL
MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05044
SBF-7
B134 A: B137 B136 D:
B362
C:
E
C
1
C
2
1
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
D
3
A
2
8
A
1
8
C
6
ECM
5
8
7
6
B362 B21 E57 B122
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B134 A:
B136 C: B137 D:
1 2 3 4 5 6
E2
B21
B122
E
E
3
9
2
0
E57
46 123 5
3
6
3
5
3
7
3
4
5
2
*
*
*
1
8
1
7
3
8
1
9
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ELECTRONIC THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC
THROTTLE CONTROL
ARRANGEMENT
EN(H4SO)(diag)-284
Step Check Yes No
TROL RELAY.
Terminals
No. 8 No. 7:
trol relay.
of power supply
circuit.
LAY.
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 4.
LAY.
ground.
more?
ness between
ECM and elec-
trol relay.
LAY.
(B136) No. 21 (B362) No. 6:
(B136) No. 1 (B362) No. 7:
circuit of harness
between ECM and
electronic throttle
control relay.
2) Disconnect the connectors from electronic
throttle control.
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
EN(H4SO)(diag)-285
1) Connect the ECM.
more?
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
1) Connect the ECM.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 11.
nectors.
(B134) No. 19 (B134) No. 18:
(B134) No. 19 (B134) No. 28:
more?
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
NOTE:
tor.>
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4SO)-11,
Throttle Body.>
Step Check Yes No
EN(H4SO)(diag)-286
NOTE:
tor.>
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4SO)-11,
Throttle Body.>
TOR.
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
circuit of harness
between ECM and
electronic throttle
control.
TOR.
1) Connect the ECM.
circuit to power in
the harness
between the ECM
and electronic
throttle control.
Go to step 16.
TOR.
more?
ness between the
ECM and elec-
trol.
TROL MOTOR HARNESS.
(E57) No. 2 (E57) No. 1:
more?
circuit of harness
between ECM and
electronic throttle
control.
chassis ground.
circuit of the har-
ness between the
ECM and engine
ground.
Step Check Yes No
EN(H4SO)(diag)-287
TROL.
Terminals
No. 2 No. 1:
trol. <Ref. to
FU(H4SO)-11,
Throttle Body.>
TROL.
closed position
Repair the poor
contact of the ECM
connector.
Replace the elec-
trol. <Ref. to
FU(H4SO)-11,
Throttle Body.>
Step Check Yes No
EN(H4SO)(diag)-288
DB:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW
MOTOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05044
SBF-7
B134 A: B137 B136 D:
B362
C:
E
C
1
C
2
1
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
D
3
A
2
8
A
1
8
C
6
ECM
5
8
7
6
B362 B21 E57 B122
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B134 A:
B136 C: B137 D:
1 2 3 4 5 6
E2
B21
B122
E
E
3
9
2
0
E57
46 123 5
3
6
3
5
3
7
3
4
5
2
*
*
*
1
8
1
7
3
8
1
9
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ELECTRONIC THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC
THROTTLE CONTROL
ARRANGEMENT
EN(H4SO)(diag)-289
Step Check Yes No
TROL RELAY.
Terminals
No. 8 No. 7:
trol relay.
of power supply
circuit.
LAY.
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 4.
LAY.
ground.
more?
ness between
ECM and elec-
trol relay.
LAY.
(B136) No. 21 (B362) No. 6:
(B136) No. 1 (B362) No. 7:
contact of the ECM
connector.
Repair the open
circuit of harness
between ECM and
electronic throttle
control relay.
EN(H4SO)(diag)-290
DC:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
MOTOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05044
SBF-7
B134 A: B137 B136 D:
B362
C:
E
C
1
C
2
1
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
D
3
A
2
8
A
1
8
C
6
ECM
5
8
7
6
B362 B21 E57 B122
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B134 A:
B136 C: B137 D:
1 2 3 4 5 6
E2
B21
B122
E
E
3
9
2
0
E57
46 123 5
3
6
3
5
3
7
3
4
5
2
*
*
*
1
8
1
7
3
8
1
9
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ELECTRONIC THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC
THROTTLE CONTROL
ARRANGEMENT
EN(H4SO)(diag)-291
DD:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP
PERFORMANCE
NOTE:
Step Check Yes No
TROL RELAY.
Terminals
No. 8 No. 7:
more?
trol relay.
2 CHECK SHORT CIRCUIT OF ELECTRONIC
THROTTLE CONTROL RELAY POWER SUP-
PLY.
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 3.
LAY.
chassis ground.
more?
Repair the poor
contact of the ECM
connector.
Repair the ground
ness between
ECM and elec-
trol relay.
EN(H4SO)(diag)-292
DE:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT
LOW INPUT
SOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05051
B315
E
C:
ECM
B136
B137 D:
B83
B315
*
*
465132
D
1
D
2
1 2 3 4 5 6
B21
E2
D
7
B122
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
B134 A:
C:
D:
B83
D
3
B: B135
A: B134
A
5
3
7
3
4
3
6
3
5
5
2
B122
*
*
*
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
C
6
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ACCELERATOR
PEDAL POSITION
SENSOR
ARRANGEMENT
EN(H4SO)(diag)-293
Step Check Yes No
1 CHECK HARNESS BETWEEN ECM AND AC-
CELERATOR PEDAL POSITION SENSOR.
and accelerator pedal position sensor.
chassis ground.
(B135) No. 23 (B136) No. 6:
more?
short of the har-
ness between the
ECM and acceler-
ator pedal position
sensor connector.
1) Connect the ECM.
2) Measure the resistance between accelera-
tor pedal position sensor connector and chassis
ground.
more?
Replace the accel-
erator pedal. <Ref.
to SP(H4SO)-3,
Accelerator Pedal.>
Repair the ground
short of the har-
ness between the
ECM and acceler-
ator pedal position
sensor connector.
Replace the ECM if
defective. <Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
EN(H4SO)(diag)-294
DF:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT
HIGH INPUT
SOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05051
B315
E
C:
ECM
B136
B137 D:
B83
B315
*
*
465132
D
1
D
2
1 2 3 4 5 6
B21
E2
D
7
B122
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
B134 A:
C:
D:
B83
D
3
B: B135
A: B134
A
5
3
7
3
4
3
6
3
5
5
2
B122
*
*
*
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
C
6
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ACCELERATOR
PEDAL POSITION
SENSOR
ARRANGEMENT
EN(H4SO)(diag)-295
Step Check Yes No
ECM and accelerator pedal position sensor
connector.
(B135) No. 23 (B315) No. 6:
(B135) No. 29 (B315) No. 5:
circuit of the har-
ness between the
ECM and acceler-
ator pedal position
sensor connector.
1) Connect the ECM.
ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
2) Measure the voltage between accelerator
pedal position sensor connector and chassis
ground.
circuit to power
source in the har-
ness between the
ECM and acceler-
ator pedal position
sensor connector.
Go to step 4.
nectors.
(B135) No. 21 (B135) No. 23:
more?
Repair the poor
contact of acceler-
ator pedal position
sensor connector.
Replace the accel-
erator pedal if
defective. <Ref. to
SP(H4SO)-3,
Accelerator Pedal.>
Repair the short
circuit to power
source in the har-
ness between the
ECM and acceler-
ator pedal position
sensor connector.
EN(H4SO)(diag)-296
DG:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT
LOW INPUT
SOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05051
B315
E
C:
ECM
B136
B137 D:
B83
B315
*
*
465132
D
1
D
2
1 2 3 4 5 6
B21
E2
D
7
B122
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
B134 A:
C:
D:
B83
D
3
B: B135
A: B134
A
5
3
7
3
4
3
6
3
5
5
2
B122
*
*
*
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
C
6
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ACCELERATOR
PEDAL POSITION
SENSOR
ARRANGEMENT
EN(H4SO)(diag)-297
Step Check Yes No
chassis ground.
more?
short of the har-
ness between the
ECM and acceler-
ator pedal position
sensor connector.
1) Connect the ECM.
ground.
more?
Replace the accel-
erator pedal. <Ref.
to SP(H4SO)-3,
Accelerator Pedal.>
Repair the ground
short of the har-
ness between the
ECM and acceler-
ator pedal position
sensor connector.
Replace the ECM if
defective. <Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
EN(H4SO)(diag)-298
DH:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT
HIGH INPUT
SOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05051
B315
E
C:
ECM
B136
B137 D:
B83
B315
*
*
465132
D
1
D
2
1 2 3 4 5 6
B21
E2
D
7
B122
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
B134 A:
C:
D:
B83
D
3
B: B135
A: B134
A
5
3
7
3
4
3
6
3
5
5
2
B122
*
*
*
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
C
6
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ACCELERATOR
PEDAL POSITION
SENSOR
ARRANGEMENT
EN(H4SO)(diag)-299
Step Check Yes No
connector.
(B135) No. 31 (B315) No. 3:
(B135) No. 30 (B315) No. 2:
circuit of the har-
ness between the
ECM and acceler-
ator pedal position
sensor connector.
1) Connect the ECM.
ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
ground.
circuit to power
source in the har-
ness between the
ECM and acceler-
ator pedal position
sensor connector.
Go to step 4.
nectors.
(B135) No. 22 (B135) No. 31:
more?
Repair the poor
contact of acceler-
ator pedal position
sensor connector.
Replace the accel-
erator pedal if
defective. <Ref. to
SP(H4SO)-3,
Accelerator Pedal.>
Repair the short
circuit to power
source in the har-
ness between the
ECM and acceler-
ator pedal position
sensor connector.
EN(H4SO)(diag)-300
DI: DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLT-
AGE CORRELATION
SOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05044
SBF-7
B134 A: B137 B136 D:
B362
C:
E
C
1
C
2
1
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
D
3
A
2
8
A
1
8
C
6
ECM
5
8
7
6
B362 B21 E57 B122
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B134 A:
B136 C: B137 D:
1 2 3 4 5 6
E2
B21
B122
E
E
3
9
2
0
E57
46 123 5
3
6
3
5
3
7
3
4
5
2
*
*
*
1
8
1
7
3
8
1
9
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ELECTRONIC THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC
THROTTLE CONTROL
ARRANGEMENT
EN(H4SO)(diag)-301
Step Check Yes No
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
1) Connect the ECM.
more?
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
1) Connect the ECM.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 6.
EN(H4SO)(diag)-302
nectors.
(B134) No. 19 (B134) No. 18:
(B134) No. 19 (B134) No. 28:
more?
Repair poor contact
of the electronic
nector. Replace the
electronic throttle
control if defective.
<Ref. to
FU(H4SO)-11,
Throttle Body.>
Repair the short
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Step Check Yes No
EN(H4SO)(diag)-303
DJ:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E
VOLTAGE CORRELATION
SOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05051
B315
E
C:
ECM
B136
B137 D:
B83
B315
*
*
465132
D
1
D
2
1 2 3 4 5 6
B21
E2
D
7
B122
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
B134 A:
C:
D:
B83
D
3
B: B135
A: B134
A
5
3
7
3
4
3
6
3
5
5
2
B122
*
*
*
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
C
6
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ACCELERATOR
PEDAL POSITION
SENSOR
ARRANGEMENT
EN(H4SO)(diag)-304
Step Check Yes No
1 CHECK ACCELERATOR PEDAL POSITION
SENSOR OUTPUT.
chassis ground.
Main accelerator pedal position sensor
signal
Sub accelerator pedal position sensor
signal
Is the difference in measured
values for the main accelerator
pedal position sensor signal
and the sub accelerator pedal
position sensor signal 0 V?
SENSOR OUTPUT.
ground.
Replace the accel-
erator pedal. <Ref.
to SP(H4SO)-3,
Accelerator Pedal.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and ac-
celerator pedal po-
sition sensor
connector.
Ground short cir-
cuit of harness be-
tween the ECM
and accelerator
pedal position sen-
sor connectors.
Poor contact of
coupling connector
CELERATOR PEDAL POSITION SENSOR
CONNECTOR.
Check the resistance of harness between the
accelerator pedal position sensor connector
and chassis ground.
contact of the ECM
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and ac-
celerator pedal po-
sition sensor
connector.
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
EN(H4SO)(diag)-305
DK:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4SO)-243, DTC P2227 BAROMETRIC PRESSURE CIRCUIT
CAUTION:
DL:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW
CAUTION:
Step Check Yes No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Replace the ECM.
<Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
NOTE:
The barometric
pressure sensor is
built into the ECM.
Step Check Yes No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Replace the ECM.
<Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
NOTE:
The barometric
pressure sensor is
built into the ECM.
EN(H4SO)(diag)-306
DM:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH
CAUTION:
Step Check Yes No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO)(diag)-
tic Trouble Code
(DTC).>
Replace the ECM.
<Ref. to FU(H4SO)-
37, Engine Control
Module (ECM).>
NOTE:
The barometric
pressure sensor is
built into the ECM.
EN(H4SO)(diag)-307
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)-93, Engine Trouble in Gen-
eral.>
Symptom Problem parts
1. Engine stalls during idling.
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
5) EGR valve
4. Poor acceleration
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
12) EGR valve
5. Engine stalls, hesitates, or sputters at accelera-
tion.
6) Purge control solenoid valve
10) EGR valve
EN(H4SO)(diag)-308
*1: Check ignition coil and ignitor assembly and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system.
6. Surging
9) EGR valve
7. Spark knock
4) Knock sensor
7) EGR valve
8. After burning in exhaust system
GD(H4SO)-2
GENERAL DESCRIPTION
1. List of Diagnostic Trouble Code (DTC)
A: LIST
DTC Item Index
<Ref. to GD(H4SO)-8, DTC P0026 INTAKE VALVE CONTROL SOLENOID
CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code
(DTC) Detecting Criteria.>
(Bank 1 Sensor 1)
<Ref. to GD(H4SO)-12, DTC P0030 HO2S HEATER CONTROL CIRCUIT
(Bank 1 Sensor 1)
LOW (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
(Bank 1 Sensor 1)
HIGH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
(Bank 1 Sensor 2)
ria.>
(Bank 1 Sensor 2)
ria.>
P0068 MAP/MAF - Throttle Position Correla-
tion
<Ref. to GD(H4SO)-22, DTC P0068 MAP/MAF - THROTTLE POSITION
Low (Bank 1)
High (Bank 1)
Low (Bank 2)
High (Bank 2)
Range/Performance
<Ref. to GD(H4SO)-28, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT
RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
Input
Input
P0107 Manifold Absolute Pressure/Baromet-
ric Pressure Circuit Low Input
<Ref. to GD(H4SO)-35, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/
BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code
P0108 Manifold Absolute Pressure/Baromet-
ric Pressure Circuit High Input
<Ref. to GD(H4SO)-37, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/
BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble Code
P0111 Intake Air Temperature Sensor 1 Cir-
cuit Range/Performance
<Ref. to GD(H4SO)-39, DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1
CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
cuit Low
cuit High
Low
<Ref. to GD(H4SO)-45, DTC P0117 ENGINE COOLANT TEMPERATURE
GD(H4SO)-3
GENERAL DESCRIPTION
High
<Ref. to GD(H4SO)-47, DTC P0118 ENGINE COOLANT TEMPERATURE
P0122 Throttle/Pedal Position Sensor/
Switch A Circuit Low
<Ref. to GD(H4SO)-49, DTC P0122 THROTTLE/PEDAL POSITION SEN-
SOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
Switch A Circuit High
SOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4SO)-53, DTC P0125 INSUFFICIENT COOLANT TEMPERA-
TURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code
P0126 Insufficient Engine Coolant Tempera-
ture for Stable Operation
<Ref. to GD(H4SO)-56, DTC P0126 INSUFFICIENT ENGINE COOLANT
TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code (DTC)
Detecting Criteria.>
Temperature Below Thermostat Reg-
ulating Temperature)
<Ref. to GD(H4SO)-58, DTC P0128 COOLANT THERMOSTAT (ENGINE
COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEM-
PERATURE), Diagnostic Trouble Code (DTC) Detecting Criteria.>
(Bank 1 Sensor 1)
<Ref. to GD(H4SO)-60, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE
(Bank 1 Sensor 1)
<Ref. to GD(H4SO)-62, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE
(Bank 1 Sensor 1)
<Ref. to GD(H4SO)-64, DTC P0133 O2 SENSOR CIRCUIT SLOW
RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4SO)-67, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY
DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
(Bank 1 Sensor 2)
<Ref. to GD(H4SO)-69, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE
(Bank 1 Sensor 2)
<Ref. to GD(H4SO)-72, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE
(Bank 1 Sensor 2)
<Ref. to GD(H4SO)-73, DTC P0139 O2 SENSOR CIRCUIT SLOW
RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4SO)-80, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY
DETECTED (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0171 System Too Lean (Bank 1) <Ref. to GD(H4SO)-82, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnos-
P0172 System Too Rich (Bank 1) <Ref. to GD(H4SO)-83, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnos-
Range/Performance
<Ref. to GD(H4SO)-85, DTC P0181 FUEL TEMPERATURE SENSOR A
ing Criteria.>
Low Input
High Input
P0196 Engine Oil Temperature Sensor Cir-
<Ref. to GD(H4SO)-92, DTC P0196 ENGINE OIL TEMPERATURE SENSOR
ing Criteria.>
P0197 Engine Oil Temperature Sensor Low <Ref. to GD(H4SO)-94, DTC P0197 ENGINE OIL TEMPERATURE SENSOR
P0198 Engine Oil Temperature Sensor High <Ref. to GD(H4SO)-95, DTC P0198 ENGINE OIL TEMPERATURE SENSOR
DTC Item Index
GD(H4SO)-4
GENERAL DESCRIPTION
Switch B Circuit Low
SOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
Switch B Circuit High
SOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0301 Cylinder 1 Misfire Detected <Ref. to GD(H4SO)-100, DTC P0301 CYLINDER 1 MISFIRE DETECTED,
<Ref. to GD(H4SO)-108, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW
(BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4SO)-110, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH
Criteria.>
P0335 Crankshaft Position Sensor A Circuit <Ref. to GD(H4SO)-112, DTC P0335 CRANKSHAFT POSITION SENSOR
A CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
Range/Performance
<Ref. to GD(H4SO)-114, DTC P0336 CRANKSHAFT POSITION SENSOR
A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC)
<Ref. to GD(H4SO)-116, DTC P0340 CAMSHAFT POSITION SENSOR A
CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC)
Range/Performance
<Ref. to GD(H4SO)-118, DTC P0341 CAMSHAFT POSITION SENSOR A
CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR), Diag-
P0400 Exhaust Gas Recirculation Flow <Ref. to GD(H4SO)-120, DTC P0400 EXHAUST GAS RECIRCULATION
Threshold (Bank 1)
<Ref. to GD(H4SO)-124, DTC P0420 CATALYST SYSTEM EFFICIENCY
BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0442 Evaporative Emission Control Sys-
tem Leak Detected (Small Leak)
<Ref. to GD(H4SO)-127, DTC P0442 EVAPORATIVE EMISSION CONTROL
SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC)
tem Vent Control Circuit Open
SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC)
tem Vent Control Circuit Shorted
SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code
tem Pressure Sensor
SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
tem Pressure Sensor Low Input
SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC)
tem Pressure Sensor High Input
SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code
DTC Item Index
GD(H4SO)-5
GENERAL DESCRIPTION
tem Leak Detected (Very Small Leak)
SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble Code
tem Leak Detected (Fuel Cap Loose/
Off)
SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble
<Ref. to GD(H4SO)-154, DTC P0458 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC)
<Ref. to GD(H4SO)-156, DTC P0459 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC)
P0461 Fuel Level Sensor A Circuit Range/
Performance
<Ref. to GD(H4SO)-158, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT
ria.>
P0462 Fuel Level Sensor A Circuit Low <Ref. to GD(H4SO)-160, DTC P0462 FUEL LEVEL SENSOR A CIRCUIT
P0463 Fuel Level Sensor A Circuit High <Ref. to GD(H4SO)-162, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT
P0464 Fuel Level Sensor Circuit Intermittent <Ref. to GD(H4SO)-164, DTC P0464 FUEL LEVEL SENSOR CIRCUIT
INTERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0500 Vehicle Speed Sensor A <Ref. to GD(H4SO)-168, DTC P0500 VEHICLE SPEED SENSOR A, Diag-
Than Expected
<Ref. to GD(H4SO)-170, DTC P0506 IDLE AIR CONTROL SYSTEM RPM
LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
Than Expected
<Ref. to GD(H4SO)-172, DTC P0507 IDLE AIR CONTROL SYSTEM RPM
HIGHER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
P0512 Starter Request Circuit <Ref. to GD(H4SO)-174, DTC P0512 STARTER REQUEST CIRCUIT, Diag-
P0513 Incorrect Immobilizer Key <Ref. to GD(H4SO)-175, DTC P0513 INCORRECT IMMOBILIZER KEY, Diag-
P0600 Serial Communication Link <Ref. to GD(H4SO)-176, DTC P0600 SERIAL COMMUNICATION LINK, Diag-
<Ref. to GD(H4SO)-178, DTC P0604 INTERNAL CONTROL MODULE RAN-
DOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC)
Memory (ROM) Error
<Ref. to GD(H4SO)-180, DTC P0605 INTERNAL CONTROL MODULE READ
ONLY MEMORY (ROM) ERROR, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0607 Control Module Performance <Ref. to GD(H4SO)-181, DTC P0607 CONTROL MODULE PERFORMANCE,
P0638 Throttle Actuator Control Range/ Per-
formance (Bank 1)
<Ref. to GD(H4SO)-184, DTC P0638 THROTTLE ACTUATOR CONTROL
RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
P0700 Transmission Control System (MIL
Request)
<Ref. to GD(H4SO)-187, DTC P0700 TRANSMISSION CONTROL SYSTEM
(MIL REQUEST), Diagnostic Trouble Code (DTC) Detecting Criteria.>
(AT Model)
<Ref. to GD(H4SO)-188, DTC P0851 PARK/NEUTRAL SWITCH INPUT CIR-
CUIT LOW (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0851 Neutral Switch Input Circuit Low
(MT Model)
<Ref. to GD(H4SO)-189, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT
(AT Model)
<Ref. to GD(H4SO)-191, DTC P0852 PARK/NEUTRAL SWITCH INPUT CIR-
CUIT HIGH (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
(MT Model)
<Ref. to GD(H4SO)-192, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT
DTC Item Index
GD(H4SO)-6
GENERAL DESCRIPTION
P1152 O2 Sensor Circuit Range/Perfor-
mance (Low) (Bank 1 Sensor 1)
<Ref. to GD(H4SO)-194, DTC P1152 O2 SENSOR CIRCUIT RANGE/PER-
FORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC)
mance (High) (Bank 1 Sensor 1)
<Ref. to GD(H4SO)-197, DTC P1153 O2 SENSOR CIRCUIT RANGE/PER-
FORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC)
P1160 Return Spring Failure <Ref. to GD(H4SO)-200, DTC P1160 RETURN SPRING FAILURE, Diagnostic
Trouble Code (DTC) Detecting Criteria.>
Valve Circuit Low
<Ref. to GD(H4SO)-202, DTC P1400 FUEL TANK PRESSURE CONTROL
SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P1420 Fuel Tank Pressure Control Sol. Valve
Circuit High
<Ref. to GD(H4SO)-204, DTC P1420 FUEL TANK PRESSURE CONTROL
SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
Problem
<Ref. to GD(H4SO)-206, DTC P1443 VENT CONTROL SOLENOID VALVE
P1491 Positive Crankcase Ventilation (Blow-
by) Function Problem
<Ref. to GD(H4SO)-208, DTC P1491 POSITIVE CRANKCASE VENTILATION
(BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
<Ref. to GD(H4SO)-210, DTC P1492 EGR SOLENOID VALVE SIGNAL #1
CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC)
CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC)
P1560 Back-up Voltage Circuit Malfunction <Ref. to GD(H4SO)-215, DTC P1560 BACK-UP VOLTAGE CIRCUIT MAL-
P1570 Antenna <Ref. to GD(H4SO)-216, DTC P1570 ANTENNA, Diagnostic Trouble Code
P1571 Reference Code Incompatibility <Ref. to GD(H4SO)-216, DTC P1571 REFERENCE CODE INCOMPATIBIL-
ITY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
(Except Antenna Curcuit)
<Ref. to GD(H4SO)-216, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
ANTENNA CIRCUIT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1574 Key Communication Failure <Ref. to GD(H4SO)-216, DTC P1574 KEY COMMUNICATION FAILURE,
P1576 EGI Control Module EEPROM <Ref. to GD(H4SO)-216, DTC P1576 EGI CONTROL MODULE EEPROM,
DTC Item Index
GD(H4SO)-7
GENERAL DESCRIPTION
P1577 IMM Control Module EEPROM <Ref. to GD(H4SO)-216, DTC P1577 IMM CONTROL MODULE EEPROM,
P1578 Meter Failure <Ref. to GD(H4SO)-216, DTC P1578 METER FAILURE, Diagnostic Trouble
P1602 Control Module Programming Error <Ref. to GD(H4SO)-217, DTC P1602 CONTROL MODULE PROGRAMMING
Lean Bank 1
<Ref. to GD(H4SO)-219, DTC P2096 POST CATALYST FUEL TRIM SYSTEM
TOO LEAN BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
Rich Bank 1
<Ref. to GD(H4SO)-221, DTC P2097 POST CATALYST FUEL TRIM SYSTEM
TOO RICH BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
Range/Performance
MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC)
Low
High
SOR A MINIMUM STOP PERFORMANCE, Diagnostic Trouble Code (DTC)
Switch D Circuit Low Input
SOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC)
Switch D Circuit High Input
SOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC)
Switch E Circuit Low Input
SOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC)
Switch E Circuit High Input
SOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC)
Switch A/B Voltage Correlation
SOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code
Switch D/E Voltage Correlation
SOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code
P2227 Barometric Pressure Circuit Range/
Performance
<Ref. to GD(H4SO)-243, DTC P2227 BAROMETRIC PRESSURE CIRCUIT
ria.>
P2228 Barometric Pressure Circuit Low <Ref. to GD(H4SO)-244, DTC P2228 BAROMETRIC PRESSURE CIRCUIT
P2229 Barometric Pressure Circuit High <Ref. to GD(H4SO)-245, DTC P2229 BAROMETRIC PRESSURE CIRCUIT
DTC Item Index
GD(H4SO)-8
Diagnostic Trouble Code (DTC) Detecting Criteria
GENERAL DESCRIPTION
2. Diagnostic Trouble Code (DTC) Detecting Criteria
A: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PER-
FORMANCE (BANK 1)
1. OUTLINE OF DIAGNOSIS
Judge as NG with 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
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.
Oil switching solenoid valve duty Intake valve
Variable valve lift diagnosis
oil pressure switch
Large High mode ON
Minimum Low mode OFF
(A) Low lift (B) High lift
EN-05565
(A)
(B)
GD(H4SO)-9
GENERAL DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
Perform the diagnosis continuously 6 seconds after engine start while variable valve lift is being controlled
Secondary Parameters Enable Conditions
Battery voltage 10.9 V
After engine starting 6000 ms
Engine oil temperature 15 C (59 F)
Variable valve lift control Operation
GD(H4SO)-10
GENERAL DESCRIPTION
5. DIAGNOSTIC METHOD
Abnormality Judgment
If the duration of time while the following conditions are met is longer than the time indicated, judge as NG.
Time Needed for Diagnosis:
Low side: 784 ms
High side: 3000 ms
Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
Normality Judgment
Judge as OK and clear the NG if the continuous time while the following conditions are established is more
than the predetermined time.
Low side: 208 ms
High side: 3000 ms
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 CONDITIONS
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)
Judgment Value
Malfunction Criteria Threshold Value
Low
Duty ratio 62 %
Variable valve lift diagnosis oil pressure
switch
OFF
High
Duty ratio < 33 %
switch
ON
Judgment Value
Low
Duty ratio 62 %
switch
ON
High
Duty ratio < 33 %
switch
OFF
GD(H4SO)-11
GENERAL DESCRIPTION
B: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PER-
FORMANCE (BANK 2)
NOTE:
For the detection standard, refer to DTC P0026. <Ref. to GD(H4SO)-8, DTC P0026 INTAKE VALVE CON-
TROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
GD(H4SO)-12
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 when looking at en-
gine status such as deceleration fuel cut.
3. ENABLE CONDITION
Perform the diagnosis continuously after 42000 ms or more have passed since the engine started.
(1) Gasket (3) Sensor housing (4) Protection tube
(2) Ceramic heater
Condition established time 42000 ms
Heater current Permitted
Control duty 35 % Experienced
After fuel cut 20000 ms
EN-02181
( 1 ) ( 2 )
( 3 ) ( 4 )
GD(H4SO)-13
GENERAL DESCRIPTION
Time Needed for Diagnosis: 10000 ms
Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cy-
cles.
Normality Judgment
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.
Memorize the diagnostic value and trouble standard value. (For test mode $06)
Judgment Value
Front oxygen (A/F) sensor impedance > 50
Judgment Value
Front oxygen (A/F) sensor impedance 50
GD(H4SO)-14
GENERAL DESCRIPTION
D: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)
Detect front oxygen (A/F) sensor heater open or short circuit.
The front oxygen (A/F) 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.
Judge as NG when the terminal voltage remains Low.
3. ENABLE CONDITION
Always perform the diagnosis continuously.
(A) Battery voltage (C) 128 milliseconds (D) Low error
(B) Front oxygen (A/F) sensor heater
output voltage

EN-01792
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H4SO)-15
GENERAL DESCRIPTION
Time Needed for Diagnosis: 4 ms 250 time
Normality Judgment
Time Needed for Diagnosis: Less than 1 second
8. FAIL SAFE
Front oxygen (A/F) sensor heater control: Not allowed to turn on 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.
Judgment Value
Output voltage level Low
Front oxygen (A/F) sensor heater control
duty
< 87.5 %
Judgment Value
Output voltage level High
GD(H4SO)-16
GENERAL DESCRIPTION
E: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)
Judge as NG when the terminal voltage remains High.
3. ENABLE CONDITION
(A) Battery voltage (C) 128 milliseconds (D) High error
output voltage

EN-01793
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H4SO)-17
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Front oxygen (A/F) sensor heater control: Not allowed to turn on the heater.
Judgment Value
duty
12.5 %
Judgment Value
GD(H4SO)-18
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.
3. ENABLE CONDITION
After starting the engine, perform the diagnosis continuously when engine is low speed.
(A) Battery voltage (C) 256 milliseconds (cycles) (D) Low error
(B) Output voltage of the rear oxygen
sensor heater

Elapsed time after engine starting 1 second
Engine speed < 8000 rpm
EN-01792
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H4SO)-19
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Sub feedback control: Not allowed
Judgment Value
Rear oxygen sensor heater control duty < 75 %
Judgment Value
GD(H4SO)-20
GENERAL DESCRIPTION
3. ENABLE CONDITION
(A) Battery voltage (C) 256 milliseconds (cycles) (D) High error
sensor heater

Elapsed time after engine starting 1 second
EN-01793
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H4SO)-21
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
Rear oxygen sensor heater control duty 20 %
Judgment Value
GD(H4SO)-22
GENERAL DESCRIPTION
H: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
Detect problems in the intake manifold pressure sensor output properties.
Judge as 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.
3. ENABLE CONDITION
Perform the diagnosis continuously after idling.
(1) Connector (3) O-ring (A) Output voltage
(2) Terminals (B) Absolute pressure
Engine coolant temperature 75 C (167 F)
EN-01765
(B)
(A)
(2)
(3)
(1)
GD(H4SO)-23
GENERAL DESCRIPTION
Judge as NG when Low side or High side becomes NG.
Low side: 3000 ms
High side: 7000 msec
cles.
Normality Judgment
Judge as OK and clear the NG when both Low side and High side become OK.
If the duration of time while the following conditions are met is longer than the time indicated, judge as OK.
Low side: Less than 1 second
High side: Less than 1 second
Judgment Value
Low
Throttle position 12 deg
Output voltage < 1.4 V
Engine load > 0.55 g/rev (0.019 oz/rev)
High
Engine speed 600 rpm 900 rpm
Throttle position < 2.44 deg
Output voltage 3.4 V
Engine load < 0.4 g/rev (0.014 oz/rev)
Judgment Value
Low
Throttle position 12 deg
Engine load > 0.55 g/rev (0.019 oz/rev)
High
GD(H4SO)-24
GENERAL DESCRIPTION
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)-25
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
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Duty ratio 30 %
Control current < 0.026 A
Judgment Value
|Oil switching solenoid valve target cur-
rent value Oil switching solenoid valve
current value|
< 0.08 A
Target current 0.11 A
GD(H4SO)-26
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
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Duty ratio < 7 %
Control current 0.465 A
Judgment Value
current value|
< 0.08 A
GD(H4SO)-27
GENERAL DESCRIPTION
K: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)
NOTE:
TROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
L: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)
NOTE:
TROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4SO)-28
GENERAL DESCRIPTION
M: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE
Detect the malfunction of air flow sensor output properties.
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 val-
ue 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.
3. ENABLE CONDITION
(1) Air flow sensor (3) Voltage (V) (A) Air
(2) Intake air temperature sensor (4) Amount of intake air (kg (lb)/s)
EN-01766
(3)
(4)
(2)
(1)
(A)
GD(H4SO)-29
GENERAL DESCRIPTION
Low: 3000 ms
High: 10000 ms
cles.
Normality Judgment
Judgment Value
Low
Engine speed 2000 rpm
Throttle opening angle 13 deg
Intake manifold pressure 53.32 kPa (400 mmHg,
15.748 inHg)
High (1)
Throttle opening angle < 2.44 deg
11.811 inHg)
High (2)
11.811 inHg)
Fuel system diagnosis Rich side malfunction
Judgment Value
Low
Throttle opening angle 13 deg
15.748 inHg)
High
Intake manifold pressure < 39.99 kPa (300 mmHg,
11.811 inHg)
Fuel system diagnosis Rich side normal
GD(H4SO)-30
GENERAL DESCRIPTION
Low: Less than 1 second
High: Less than 1 second
8. FAIL SAFE
None
GD(H4SO)-31
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 out of specification.
3. ENABLE CONDITION
None
EN-01766
(3)
(4)
(2)
(1)
(A)
GD(H4SO)-32
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
Output voltage > 0.22 V
GD(H4SO)-33
GENERAL DESCRIPTION
O: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-01766
(3)
(4)
(2)
(1)
(A)
GD(H4SO)-34
GENERAL DESCRIPTION
8. FAIL SAFE
None
GD(H4SO)-35
GENERAL DESCRIPTION
P: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT LOW INPUT
Detect the open or short circuit of intake manifold pressure sensor.
3. ENABLE CONDITION
None
EN-01765
(B)
(A)
(2)
(3)
(1)
GD(H4SO)-36
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4SO)-37
GENERAL DESCRIPTION
Q: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT HIGH INPUT
3. ENABLE CONDITION
None
EN-01765
(B)
(A)
(2)
(3)
(1)
GD(H4SO)-38
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4SO)-39
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.
3. ENABLE CONDITION
Perform the diagnosis when the vehicle speed condition is met after warming up from a cold condition.
(1) Air flow sensor (3) Resistance value () (A) Air
(2) Intake air temperature sensor (4) Intake air temperature C (F)
Engine coolant temperature at engine
starting
< 30 C (86 F)
Continuous time when the vehicle speed
is less than 60 km/h (37.3 MPH)
600 sec
EN-01767
(3)
(4)
(2)
(1)
(A)
GD(H4SO)-40
GENERAL DESCRIPTION
Judge as NG when the following conditions are established.
cles.
Normality Judgment
Judge as OK and clear the NG if the following conditions are established.
8. FAIL SAFE
Intake air temperature sensor process: Intake air temperature is fixed at 20C (68F).
Judgment Value
Output voltage difference between Max.
and Min.
< 0.02 V(Equivalent to
approximately 0.5C
(0.9F) near 25C)
Judgment Value
and Min.
0.02 V
GD(H4SO)-41
GENERAL DESCRIPTION
S: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
Detect open or short circuit of the intake air temperature sensor.
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-01767
(3)
(4)
(2)
(1)
(A)
GD(H4SO)-42
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4SO)-43
GENERAL DESCRIPTION
T: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-01767
(3)
(4)
(2)
(1)
(A)
GD(H4SO)-44
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4SO)-45
GENERAL DESCRIPTION
U: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
Detect the open or short circuit of the engine coolant temperature sensor.
3. ENABLE CONDITION
Normality Judgment
(1) Connector (A) Resistance value (k)
(2) Thermistor element (B) Temperature C (F)
None
Judgment Value
Judgment Value
EN-02917
(A)
(2)
(1)
(B)
GD(H4SO)-46
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.
GD(H4SO)-47
GENERAL DESCRIPTION
V: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-02917
(A)
(2)
(1)
(B)
GD(H4SO)-48
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4SO)-49
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. ENABLE CONDITION
(1) Throttle position sensor 1 signal (3) Throttle position sensor (4) Engine control module (ECM)
(2) Throttle position sensor 2 signal
Ignition switch ON
Battery voltage 6 V
EN-01859
(1)
(2)
(3)
(4)
GD(H4SO)-50
GENERAL DESCRIPTION
Normality Judgment
When Clear Memory is performed (Only with engine stopped)
8. FAIL SAFE
Stop the continuity to the electronic throttle control motor. (Throttle opening is fixed to 6.)
Judgment Value
Sensor 1 input voltage 0.217 V
Judgment Value
Sensor 1 input voltage > 0.217 V
GD(H4SO)-51
GENERAL DESCRIPTION
X: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT
HIGH
3. ENABLE CONDITION
Ignition switch ON
Battery voltage 6 V
EN-01859
(1)
(2)
(3)
(4)
GD(H4SO)-52
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
Sensor 1 input voltage < 4.858 V
GD(H4SO)-53
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.
3. ENABLE CONDITION
Perform the diagnosis only once after engine start.
Engine speed Value from Map
Map
C (F)
40
(40)
30
(22)
20
(4)
10
(14)
0
(32)
10
(50)
20
(68)
30
(86)
Engine speed
rpm
500 500 500 500 500 500 500 500
C (F)
40
(104)
50
(122)
60
(140)
70
(158)
80
(176)
90
(194)
100
(212)
110
(230)
Engine speed
rpm
500 500 500 500 500 500 500 500
EN-02917
(A)
(2)
(1)
(B)
GD(H4SO)-54
GENERAL DESCRIPTION
Judge as NG if the criteria below are met.
Timer for diagnosis after engine start
a. Timer stop at fuel cut
b. During the driving conditions except a) above, timer counts up as follows.
64 milliseconds + TWCNT milliseconds (the time of at 64 milliseconds)
TWCNT is defined as follows,
TWCNT = 0 at idle switch ON,
TWCNT show on the following table at idle switch OFF.
Judgment value of timer after engine starting
t = 573669 ms 33924 ms/C Ti
Ti : The lowest coolant temperature after engine start
cles.
Normality Judgment
Judge as OK and clear the NG when the malfunction criteria below are met.
8. FAIL SAFE
Judgment Value
Engine coolant temperature < 20 C (68 F)
Timer for diagnosis after engine start Judgment value of
timer after engine start
0 (0) 8 (5) 16 (9.9) 24 (14.9) 32 (19.9) 40 (24.9) 48 (29.8) 56 (34.8)
Tempera-
ture
C (F)
20 (4) 0 ms 32.076 ms 39.977 ms 47.879 ms 82.544 ms 117.209 ms 154.214 ms 185.26 ms
Judgment Value
GD(H4SO)-55
GENERAL DESCRIPTION
GD(H4SO)-56
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.
3. ENABLE CONDITION
Perform the diagnosis only once after starting the engine.
(A) Resistance value (k) (B) Temperature C (F)

(1) Connector (2) Thermistor element
Refueling from the last engine stop till
the current engine start
None
Fuel level 15 L (3.963 US gal,
3.3 Imp gal)
Engine coolant temperature at the last
engine stop
75 C (167 F)
EN-02917
(A)
(2)
(1)
(B)
GD(H4SO)-57
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
engine stop Minimum engine coolant
temperature after the engine start
< 2.5 C (36.5 F)
Fuel temperature at the last engine stop
fuel temperature
5 C (41 F)
Intake air temperature fuel tempera-
ture
< 2.5 C (36.5 F)
Fuel temperature < 35 C (95 F)
Judgment Value
2.5 C (36.5 F)
GD(H4SO)-58
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 becomes to
75C (167F), and the difference is small, before judging NG.
3. ENABLE CONDITION
(1) Valve (4) Piston (7) Stop ring
(2) Spring (5) Guide (8) Wax element
(3) Stopper (6) Rubber seal (9) Jiggle valve
None
EN-01692
(9)
(2)
(6)
(8)
(7)
(5)
(4)
(3)
(1)
(2)
GD(H4SO)-59
GENERAL DESCRIPTION
Time Needed for Diagnosis: 64 ms 3 time 152 time
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Estimate ambient temperature 7 C (19.4 F)
Thermostat malfunction diagnosis Incomplete
starting
< 55 C (131 F)
Estimated coolant temperature 75 C (167 F)
(Estimated Measured) Engine coolant
temperature
> 30 C (86 F)
Vehicle speed 30 km/h (18.6 MPH)
Judgment Value
Estimate ambient temperature 7 C (19.4 F)
starting
< 55 C (131 F)
temperature
30 C (86 F)
GD(H4SO)-60
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 voltage is out of the specified range.
3. ENABLE CONDITION
(1) Atmosphere (A) Electromotive force
(2) Exhaust gas (B) Air fuel ratio
(3) ZrO
2
(C) Lean
(4) Ceramic heater (D) Rich
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4SO)-61
GENERAL DESCRIPTION
Input voltage (+): 1000 ms
Input voltage (): 1000 ms
|Input voltage (+) Input voltage ()|: 1000 ms
Normality Judgment
8. FAIL SAFE
Front oxygen (A/F) sensor heater control: Not allowed to turn on heater.
Judgment Value
Input voltage (+) < 1.128 V
or
Input voltage () < 0.23 V
or
|Input voltage (+) Input voltage ()| < 0.644 V
Judgment Value
Input voltage (+) 1.128 V
Input voltage () 0.23 V
|Input voltage (+) Input voltage ()| 0.644 V
GD(H4SO)-62
GENERAL DESCRIPTION
AC:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
Judge as NG, when the element voltage is out of the specified range.
3. ENABLE CONDITION
(3) ZrO
2
(C) Lean
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4SO)-63
GENERAL DESCRIPTION
Input voltage (+): 1000 ms
Input voltage (): 1000 ms
Normality Judgment
8. FAIL SAFE
Judgment Value
Input voltage (+) > 3.589 V
or
Input voltage () > 3.541 V
Judgment Value
Input voltage (+) 3.589 V
Input voltage () 3.541 V
GD(H4SO)-64
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 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 actual change from rich to lean occurs.
Judge as NG when the actual movement in comparison to the ECM control amount is slow.
(1) Cover (2) Zirconia (3) Clogging
(3) ZrO
2
(C) Lean
EN-01694
(1)
(2)
(3)
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4SO)-65
GENERAL DESCRIPTION
3. ENABLE CONDITION
Perform diagnosis only once at a constant speed of 10 km/h 120 km/h (6.2 MPH 74.6 MPH) 120000 ms
or more after starting the engine.
Calculate faf difference, and the value difference every 32ms 4 . Calculate the diagnosis value after cal-
culating 1640 time.
Time Needed for Diagnosis: 32 ms 4 1640 time
cles.
Time needed for all secondary parame-
ters to be in enable conditions
1024 ms
Barometric pressure > 75.05 kPa (563 mmHg,
22.165 inHg)
Closed loop control with main feedback Operation
Front oxygen (A/F) sensor impedance 0 50
Elapsed time after starting the engine 120000 ms
Vehicle speed 10 km/h 120 km/h (6.2
MPH 74.6 MPH)
Amount of intake air 10 g/s 40 g/s (0.353 oz/
s 1.411 oz/s)
Learning value of EVAP conc. during
purge
< 0.2
Total time of operating canister purge 19.9 sec
Judgment Value
parafca = td2faf/td2lmd > 0.4 (U5 model)
> 0.45 (Except for U5 model)
where,
td2faf (N) = td2faf (n1) + |d2faf (n)|
td2lmd (N) = td2lmd (n1) + |d2lmd (n)|
add up to 32 ms 4 1640 time.
d2faf (n) = (faf (n) faf (n1)) (faf (n1)
faf (n2))
d2lmd (n) = (lmd (n) lmd (n1)) (lmd
(n1) lmd (n2))
faf = main feedback compensation coef-
ficient every 128 milliseconds
lmd = output lambda every 128 millisec-
onds
GD(H4SO)-66
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
A/F sensor sub learning compensation: Not allowed to calculate.
Judgment Value
parafca = td2faf/td2lmd 0.4 (U5 model)
0.45 (Except for U5 model)
where,
faf (n2))
(n1) lmd (n2))
onds
GD(H4SO)-67
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. ENABLE CONDITION
(3) ZrO
2
(C) Lean
None
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4SO)-68
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Time of heater control duty at 70 % or
more
36000 ms
Front oxygen (A/F) sensor impedance. > 500
Judgment Value
Front oxygen (A/F) sensor impedance. 500
GD(H4SO)-69
GENERAL DESCRIPTION
AF:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)
Detect continuity NG of the oxygen sensor. If the oxygen sensor voltage reading is not within the probable
range considering the operating conditions, judge as NG.
(A) Electromotive force (C) Rich (E) Theoretical air fuel ratio
(B) Air fuel ratio (D) Lean (F) Comparative voltage

(1) Atmosphere (2) Exhaust gas (3) Electromotive force
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H4SO)-70
GENERAL DESCRIPTION
3. ENABLE CONDITION
Used for abnormality judgment
High
Secondary air system Not in operation
Closed loop control at the oxygen sensor In operation
Misfire detection every 200 rotations < 5 time
Front oxygen (A/F) sensor compensation
coefficient
Not in limit value
Low (1)
coefficient
Not in limit value
Amount of intake air 10 g/s (0.353 oz/s)
Low (2)
coefficient
Not in limit value
Amount of intake air < 10 g/s (0.353 oz/s)
Current continuation time of the rear oxy-
gen sensor heater
30000 ms
Low (3)
coefficient
Not in limit value
gen sensor heater
30000 ms
Fuel cut Experienced
GD(H4SO)-71
GENERAL DESCRIPTION
After starting the engine, continuously perform the diagnosis with the same engine condition.
Time Needed for Diagnosis
High: 2500 ms
Low (1): 20000 ms
Low (2): 40000 ms
Low (3): Value from Map
cles.
Normality Judgment
Low (1): Less than 1 second
Used for normality judgment
coefficient
Not in limit value
Judgment Value
Malfunction Criteria Threshold Value DTC
High P0138
Sensor output voltage > 1.2 V P0158
Low P0137
Sensor output voltage <0.03 V P0157
Map
Fuel Cut Time (millisecond) 0 2000 10000
Time needed for diagnosis (millisecond) 40000 40000 60000
Judgment Value
High P0138
Sensor output voltage 1.2 V P0158
Low P0137
Sensor output voltage 0.03 V P0157
GD(H4SO)-72
GENERAL DESCRIPTION
8. FAIL SAFE
AG:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
NOTE:
For the detection standard, refer to DTC P0137. <Ref. to GD(H4SO)-69, DTC P0137 O2 SENSOR CIRCUIT
LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4SO)-73
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 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.
(1) Atmosphere (A) Electromotive force (D) Lean
(2) Exhaust gas (B) Air fuel ratio (E) Theoretical air fuel ratio
(3) Electromotive force (C) Rich (F) Comparative voltage
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H4SO)-74
GENERAL DESCRIPTION
3. ENABLE CONDITION
Rich lean diagnosis response
Perform the diagnosis only once when deceleration fuel cut occurs after rapid acceleration. (Pay attention to
the oxygen sensor voltage for the timing of the deceleration.)
A/F main feedback control condition Completed
Deceleration fuel cut time is 6000 ms or
more.
Experienced
Current calculation time of the rear oxy-
gen sensor heater
60000 ms
gen sensor heater
30000 ms
Estimated catalyst temperature 300 C (572 F)
Number of deceleration fuel cut 1 time
GD(H4SO)-75
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.
(A) 0.55 V (E) 0 V (H) Execute the malfunction judg-
ment in 2000 ms from the recov-
ery of fuel cut on deceleration.
(B) 0.5 V (F) More than 6000 ms
(C) 0.2 V (G) Measure the response time.
(D) 0.15 V
(A)
(B)
(C)
(D)
(E)
Diagnosis execution condition
Rear oxygen sensor (V)
(G)
Fuel cut on deceleration
(F)
(H)
EN-05566
GD(H4SO)-76
GENERAL DESCRIPTION
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 cut in deceleration. NG judgment
should be performed after deceleration fuel cut. Even without deceleration fuel cut, judge as OK if the value
is below the threshold.
When the deceleration fuel cut time is 6000 ms or more, judge as NG if the following criteria are met 2000
ms after recovering from the deceleration fuel cut.
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 (6000 ms or more), and even after recovering from a de-
celeration fuel cut, the oxygen sensor voltage is high (0.55 V or more), judge as NG.
Time Needed for Diagnosis: 1 time
cles.
Normality Judgment
1) Regardless of a deceleration fuel cut, if the response time (diagnosis value) when the oxygen sensor volt-
age 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.
8. FAIL SAFE
Judgment Value
Shortest time change from rich (0.5 V O
2
output) to lean (0.2 V) when voltage
reduces from 0.55 V to 0.15 V
> 491 ms
or
Longest time over 0.55 V 2000 ms
Judgment Value
2
491 ms
GD(H4SO)-77
GENERAL DESCRIPTION
10.ENABLE CONDITION
Lean rich response diagnosis
11.GENERAL DRIVING CYCLE
more.
Experienced
gen sensor heater
60000 ms (U5 model)
0 ms
(Except for U5 model)
gen sensor heater
30000 ms (U5 model)
0 ms
Number of deceleration fuel cut 1 time
GD(H4SO)-78
GENERAL DESCRIPTION
12.DIAGNOSTIC METHOD
When the oxygen sensor output voltage changes from 0.25 V (lean) to 0.55 V (rich), calculate the minimum
(A) 0.55 V (H) Measure the response time (diag-
nostic value).
(J) Judge NG when the voltage of
rear oxygen sensor is 0.25 V or
less for 120000 ms or more after
recovery of fuel cut on decelera-
tion.
(B) 0.5 V
(C) 0.3 V (I) Execute the malfunction judg-
(D) 0.25 V
(E) 0 V
(F) More than 5 seconds
(G) More than 120000 ms
(I)
(E)
(F)
(G)
(D)
(C)
(B)
(A)
(H)
(J)
EN-05567
GD(H4SO)-79
GENERAL DESCRIPTION
2) If the oxygen sensor voltage is small after recovering from a deceleration fuel cut, and remains small,
judge as NG.
cles.
Normality Judgment
condition.
Response time (diagnosis value) threshold value normal
13.DTC CLEAR CONDITION
14.MALFUNCTION INDICATOR LIGHT CLEAR CONDITIONS
15.FAIL SAFE
16.ECM OPERATION AT DTC SETTING
Judgment Value
Shortest time change from lean (0.3 V
O
2
output) to rich (0.5 V) when voltage
changes from 0.25 V to 0.55 V
> 2000 ms
or
Longest time under 0.25 V 120000 ms
Judgment Value
O
2
2000 ms
GD(H4SO)-80
GENERAL DESCRIPTION
AI: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 2)
Detect the rear oxygen sensor open or short circuit. Judge as NG when the rear oxygen sensor voltage can
be determined to be abnormal considering conditions such as intake air amount, engine coolant tempera-
ture, main feedback control and deceleration fuel cut.
3. ENABLE CONDITION (USED ONLY FOR MALFUNCTION JUDGMENT)
Perform the diagnosis once after starting the engine.

Closed loop control at the rear oxygen
sensor
In operation
Target output voltage of rear oxygen sen-
sor
0.55 V + 0.05 V
coefficient
Not in limit value
Deceleration fuel cut of 6000 ms or
more.
Experienced
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H4SO)-81
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
Minimum output voltage > 0.15 V
or
Maximum output voltage < 0.55 V
Judgment Value
Diagnosis of the rear oxygen sensor volt-
age low side
Incomplete
Minimum output voltage 0.15 V
Maximum output voltage 0.55 V
GD(H4SO)-82
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
Perform the diagnosis continuously at idling or at a constant speed after warming up the engine.
Compare the diagnosed value (fsobd) with the threshold value, and if a condition meeting the malfunction cri-
teria below continues for 10 sec 5 time or more, judge that there is a fault in the fuel system.
Map2
Time Needed for Diagnosis: 10 sec 5 time
cles.
A/F main learning system In operation
Engine load change < 0.02 g/rev (0.001 oz/rev)
Engine load Value of Map 1
Map1
Engine speed (rpm) Idling 650 1000 1500 2000 2500 3000 3500 4000 4500
Measured value (g(oz)/rev) Non-turbo
0.208
(0.007)
0.201
(0.007)
0.185
(0.007)
0.183
(0.006)
0.193
(0.007)
0.206
(0.007)
0.206
(0.007)
0.225
(0.008)
0.245
(0.009)
Judgment Value
fsobd = (sglmd tglmda) + faf + flaf Value of Map 2
In this case: sglmd = measured lambda
tglmda = target lambda
flaf = main feedback learning compensa-
tion coefficient
U5 MODEL
Amount of air (g (oz)/s) 0 (0)
3.2
(0.113)
6.4
(0.226)
9.6
(0.339)
12.8
(0.451)
16
(0.564)
19.2
(0.677)
fsobdL1 (%) 1.4 1.4 1.332 1.25 1.25 1.25 1.25
EXCEPT FOR U5 MODEL
3.2
(0.113)
6.4
(0.226)
9.6
(0.339)
12.8
(0.451)
16
(0.564)
19.2
(0.677)
fsobdL1 (%) 1.4 1.4 1.332 1.265 1.265 1.265 1.265
GD(H4SO)-83
GENERAL DESCRIPTION
Normality Judgment
Time Needed for Diagnosis: 10 sec
When similar driving conditions are repeated 3 times and the result is OK.
7. FAIL SAFE
None
AK:DTC P0172 SYSTEM TOO RICH (BANK 1)
Diagnostic method
measured by sensor.
2. ENABLE CONDITION
Judgment Value
fsobd = (sglmd tglmda) + faf + flaf < 1.2
Engine load change 0.02 g/rev (0.001 oz/rev)
Learning value of EVAP conc. < 0.15
Cumulative time of canister purge after
engine start
20 sec
Continuous period after canister purge
starting
29884 ms
Engine load Value of Map 1
Map1
Engine speed (rpm) Idling 650 1000 1500 2000 2500 3000 3500 4000 4500
Measured value
(g(oz)/rev)
Non-turbo
0.208
(0.007)
0.201
(0.007)
0.185
(0.007)
0.183
(0.006)
0.193
(0.007)
0.206
(0.007)
0.206
(0.007)
0.225
(0.008)
0.245
(0.009)
GD(H4SO)-84
GENERAL DESCRIPTION
cles.
Normality Judgment
Judge as OK when the malfunction criteria below continues for 10 seconds.
7. FAIL SAFE
Purge control solenoid valve control: Not allowed to purge.
Judgment Value
fsobd = (sglmd tglmda) + faf + flaf < Value of Map 2
tion coefficient
Map2
3.2
(0.113)
6.4
(0.226)
9.6
(0.339)
12.8
(0.451)
16
(0.564)
19.2
(0.677)
fsobdL1 (%) 0.6 0.6 0.668 0.735 0.735 0.735 0.735
Judgment Value
fsobd = (sglmd tglmda) + faf + flaf 0.8
GD(H4SO)-85
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.
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.
3. ENABLE CONDITION
DRIFT DIAGNOSIS
(A) Resistance value () (B) Fuel temperature C (F)
None
EN-01700
(A)
(B)
GD(H4SO)-86
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
10.ENABLE CONDITION
Stuck Diagnosis
Judgment Value
Fuel level 9.6 L (2.536 US gal,
2.112 Imp gal)
Elapsed time after starting the engine 20 sec
Engine coolant temperature Engine
coolant temperature at engine start
> 10 C (50 F)
Fuel temperature Engine coolant tem-
perature
10 C (50 F)
Judgment Value
2.112 Imp gal)
> 10 C (50 F)
perature
< 10 C (50 F)
GD(H4SO)-87
GENERAL DESCRIPTION
Always perform diagnosis after 20 seconds have passed since the engine started.
cles.
Normality Judgment
15.FAIL SAFE
None
Judgment Value
Accumulated amount of intake air 551043 g
(19435.287 oz)
Fuel temperature difference between
Max. and Min.
< 2 C (35.6 F)
Judgment Value
Max. and Min.
2 C (35.6 F)
GD(H4SO)-88
GENERAL DESCRIPTION
AM:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT
Detect the open or short circuit of fuel temperature sensor.
3. ENABLE CONDITION
None
EN-01700
(A)
(B)
GD(H4SO)-89
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4SO)-90
GENERAL DESCRIPTION
AN:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT
3. ENABLE CONDITION
None
EN-01700
(A)
(B)
GD(H4SO)-91
GENERAL DESCRIPTION
Normality Judgment
Time Needed for Diagnosis: Within 1 second
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4SO)-92
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
Perform the diagnosis continuously after starting the engine.
Engine speed Value from Map
Map
C (F)
40
(40)
30
(22)
20
(4)
10
(14)
0
(32)
10
(50)
20
(68)
30
(86)
Engine speed
rpm
500 500 500 500 500 500 500 500
C (F)
40
(104)
50
(122)
60
(140)
70
(158)
80
(176)
90
(194)
100
(212)
110
(230)
Engine speed
rpm
500 500 500 500 500 500 500 500
GD(H4SO)-93
GENERAL DESCRIPTION
After engine start oil temperature sensor characteristic diagnosis timer (timer for diagnosis).
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.
After engine start oil temperature characteristic diagnosis timer judgment value (t).
t = 1882940 ms 43302 ms/C Ti (t 2400000)
Ti = The lowest coolant temperature after starting the engine.
cles.
Normality Judgment
7. FAIL SAFE
Oil temperature sensor process: Engine oil temperature is fixed at 70C (158F).
Judgment Value
Engine oil temperature < 15 C (59 F)
After engine start oil temperature sensor
characteristic diagnosis timer.
Judgment value for after engine
start oil temperature sensor char-
acteristic diagnosis timer
0 (0) 8 (5) 16 (9.9) 24 (14.9) 32 (19.9) 40 (24.9) 48 (29.8) 56 (34.8)
Tempera-
ture
C (F)
20 (4) 64 ms 73.3 ms 84 ms 96.6 ms 113.7 ms 135 ms 162 ms 197.4 ms
0 (32) 64 ms 73.5 ms 84.5 ms 97.4 ms 115.6 ms 138.5 ms 168 ms 207.6 ms
10 (50) 102.2 ms 114.8 ms 129.4 ms 146.7 ms 171.7 ms 203.4 ms 245.1 ms 302.1 ms
Judgment Value
Engine oil temperature 15 C (59 F)
GD(H4SO)-94
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 judgment value.
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4SO)-95
GENERAL DESCRIPTION
AQ:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4SO)-96
GENERAL DESCRIPTION
AR:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
LOW
3. ENABLE CONDITION
Ignition switch ON
Battery voltage 6 V
EN-01859
(1)
(2)
(3)
(4)
GD(H4SO)-97
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4SO)-98
GENERAL DESCRIPTION
AS:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
HIGH
3. ENABLE CONDITION
Ignition switch ON
Battery voltage 6 V
EN-01859
(1)
(2)
(3)
(4)
GD(H4SO)-99
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4SO)-100
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 mis-
fire
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
360 Interval Difference Method
2. ENABLE CONDITION
Map1
AT model
MT model
All secondary parameters enable conditions 1024 ms
Intake manifold pressure change at 180 CA < Value of Map 1
Throttle position change during 16 milliseconds < 21 deg
Fuel shut-off function Not in operation
2.112 Imp gal)
Vehicle dynamic control or AT torque control Not in operation
Evaporative system leak check Not in operation
Intake manifold pressure Value of Map 2
Battery voltage 8 V
Fuel parameter determination Not extremely low volatility
Engine load change during 32 milliseconds < 1000 rpm
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300
kPa
(mmHg,
inHg)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
rpm 650 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300
kPa
(mmHg,
inHg)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
GD(H4SO)-101
GENERAL DESCRIPTION
Map2
AT model (U5 model)
AT model (Except for U5 model)
MT model (U5 model)
MT model (Except for U5 model)
If conditions are met, it is possible to detect the misfires from idling to high engine speed. However, to
avoid excessive load or harm to the engine, perform diagnosis at idle.
Perform the diagnosis continuously.
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300
kPa
(mmHg,
inHg)
25.99
(195.0 ,
7.677)
23.93
(179.5 ,
7.067)
23.29
(174.7 ,
6.878)
23.09
(173.2 ,
6.819)
23.57
(176.8 ,
6.961)
25.06
(188.0 ,
7.402)
26.25
(196.9 ,
7.752)
26.61
(199.6 ,
7.858)
26.86
(201.5 ,
7.933)
29.99
(225.0 ,
8.858)
33.38
(250.4 ,
9.858)
37.79
(283.5 ,
11.161)
39.46
(296.0 ,
11.654)
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300
kPa
(mmHg,
inHg)
25.99
(195.0 ,
7.677)
23.93
(179.5 ,
7.067)
23.29
(174.7 ,
6.878)
23.09
(173.2 ,
6.819)
23.57
(176.8 ,
6.961)
25.06
(188.0 ,
7.402)
26.25
(196.9 ,
7.752)
26.61
(199.6 ,
7.858)
26.86
(201.5 ,
7.933)
29.99
(225.0 ,
8.858)
33.38
(250.4 ,
9.858)
37.79
(283.5 ,
11.161)
39.46
(296.0 ,
11.654)
Vehicle speed < 64 km/h (39.8 MPH)
rpm 650 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300
kPa
(mmHg,
inHg)
24.53
(184,
7.244)
22.7
(170.3,
6.705)
21.35
(160.2,
6.307)
21.54
(161.6,
6.362)
21.51
(161.4,
6.354)
23.25
(174.4,
6.866)
24.73
(185.5,
7.303)
25.77
(193.3,
7.61)
27.09
(203.2,
8)
28.83
(216.3,
8.516)
32.29
(242.2,
9.535)
36.26
(272,
10.709)
37.92
(284.5,
11.201)
rpm 650 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300
kPa
(mmHg,
inHg)
31.59
(237,
9.331)
31.59
(237,
9.331)
31.59
(237,
9.331)
31.06
(233,
9.173)
31.33
(235,
9.252)
33.06
(248,
9.764)
33.86
(254,
10)
28.79
(216,
8.504)
30.13
(226,
8.898)
33.33
(250,
9.843)
36.92
(277,
10.905)
40.12
(301,
11.85)
43.19
(324,
12.756)
rpm 650 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300
kPa
(mmHg,
inHg)
24.53
(184,
7.244)
22.7
(170.3,
6.705)
21.35
(160.2,
6.307)
21.54
(161.6,
6.362)
21.51
(161.4,
6.354)
23.25
(174.4,
6.866)
24.73
(185.5,
7.303)
25.77
(193.3,
7.61)
27.09
(203.2,
8)
28.83
(216.3,
8.516)
32.29
(242.2,
9.535)
36.26
(272,
10.709)
37.92
(284.5,
11.201)
rpm 650 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300
kPa
(mmHg,
inHg)
31.59
(237,
9.331)
31.59
(237,
9.331)
31.59
(237,
9.331)
31.06
(233,
9.173)
31.33
(235,
9.252)
33.06
(248,
9.764)
33.86
(254,
10)
28.79
(216,
8.504)
30.13
(226,
8.898)
33.33
(250,
9.843)
36.92
(277,
10.905)
40.12
(301,
11.85)
43.19
(324,
12.756)
GD(H4SO)-102
GENERAL DESCRIPTION
When a misfire occurs, the engine speed will decreased and the crankshaft position speed will change. Cal-
culate the interval difference value (diagnostic value) from crankshaft position speed by the following formu-
la, 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 revs. or 200 revs., Judge corre-
sponding cylinders as NG.
As shown in the following figure, pick a cylinder as the standard and name it omg 0. And the former crank-
shaft position speed is named omg 1, the second former crankshaft position speed is named omg 2, the third
is named omg 3, etc.
Diagnostic value cal-
culation
(Calculate from angle
speed)
Misfire detection every single
ignition
(Compare diagnostic value
with judgment value)
NG judgment (Misfire occurrence judg-
ment required by the law) (Compare
number of misfire with judgment)
180 Interval Difference
Method
Method
Method
FTP 1.5 times misfire NG judgment
Catalyst damage misfire NG judgment
(A) Ignition order (B) Crankshaft position speed
EN-01774
#3 #2 #4 #1 #3 #2 #4 #1 #3 #2 (A)
(B) omg0 omg1 omg2 omg3 omg4 omg5 omg6 omg7
GD(H4SO)-103
GENERAL DESCRIPTION
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 180 CA)
Diagnostic value domg 360 = (omg 1 omg 0) (omg 3 omg 2)
Misfire judgment domg 360 > Judgment value Judge as misfire
Judged as misfire.
Threshold valve (positive number)
Threshold valve (negative number)
domg180
domg180
EN-02877
Judged as misfire.
Threshold valve
domg360
domg360
EN-03273
GD(H4SO)-104
GENERAL DESCRIPTION
FTP 1.5 times misfire (Misfire occurrence level which influences exhaust gas)
Time Needed for Diagnosis: 1000 engine revs.
cles.
Normality Judgment
Judgment Value (Judge that malfunction occurs when the misfire ratio is high in 1000 engine revs.)
FTP emission judgment value 18 100/2000% in
1000 revs. (U5 model)
20 100/2000% in
1000 revs. (Except for
U5 model)
Judgment Value
FTP emission judgment value < 18 100/2000% in
1000 revs. (U5 model)
< 20 100/2000% in
1000 revs. (Except for
U5 model)
Judged as misfire.
Threshold valve
domg720
domg720
EN-03274
GD(H4SO)-105
GENERAL DESCRIPTION
Catalyst damage misfire (Misfire occurrence level damaging catalyst)
Map 3
Normality Judgment
Judgment Value
Catalyst damage misfire judgment value Value of Map 3
U5 MODEL
Intake air (g(oz)/rev)
0.16
(0.006)
0.28 (0.01) 0.4 (0.014)
0.52
(0.018)
0.64
(0.023)
0.76
(0.027)
0.92
(0.032)
1.1 (0.039)
Engine
speed
(rpm)
700 100 100 100 100 90 80 64 48
1000 100 100 100 100 90 80 52 24
1500 100 100 90 80 69 57 39 22
2000 80 80 80 80 62 44 33 21
2500 67 67 58 50 40 31 25 20
3000 57 57 49 40 30 20 20 20
3500 44 44 34 24 20 20 20 20
4000 36 36 28 20 20 20 20 20
4500 27 27 20 20 20 20 20 20
5000 20 20 20 20 20 20 20 20
5500 20 20 20 20 20 20 20 20
6000 20 20 20 20 20 20 20 20
6300 20 20 20 20 20 20 20 20
EXCEPT FOR U5 MODEL
0.16
(0.006)
0.28 (0.01) 0.4 (0.014)
0.52
(0.018)
0.64
(0.023)
0.76
(0.027)
0.92
(0.032)
1.1 (0.039)
Engine
speed
(rpm)
700 100 100 100 100 90 80 64 48
1000 100 100 100 100 90 80 63 44
1500 100 100 90 80 73 67 54 40
2000 80 80 80 80 68 57 51 44
2500 80 80 73 67 62 57 51 44
3000 67 67 62 57 51 44 44 44
3500 67 67 56 44 40 36 34 31
4000 57 57 44 31 24 20 20 20
4500 44 44 33 31 20 20 20 20
5000 44 44 38 31 20 20 20 20
5500 36 36 31 27 20 20 20 20
6000 20 20 20 20 20 20 20 20
6300 20 20 20 20 20 20 20 20
Judgment Value
Catalyst damage misfire judgment value < Value of Map 3
GD(H4SO)-106
GENERAL DESCRIPTION
7. FAIL SAFE
None
GD(H4SO)-107
GENERAL DESCRIPTION
NOTE:
For the detection standard, refer to DTC P0301. <Ref. to GD(H4SO)-100, DTC P0301 CYLINDER 1 MIS-
FIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
NOTE:
AW:DTC P0304 CYLINDER 4 MISFIRE DETECTED
NOTE:
GD(H4SO)-108
GENERAL DESCRIPTION
AX:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE
SENSOR)
Detect the open or short circuit of knock sensor.
3. ENABLE CONDITION
(1) Case (4) Nut (A) To knock sensor harness
(2) Weight (5) Resistance
(3) Piezoelectric element
None
EN-01707
(1)
(2)
(3)
(4) (5)
(A)
GD(H4SO)-109
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4SO)-110
GENERAL DESCRIPTION
AY:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE
SENSOR)
3. ENABLE CONDITION
None
EN-01707
(1)
(2)
(3)
(4) (5)
(A)
GD(H4SO)-111
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4SO)-112
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 rotated.
3. ENABLE CONDITION
(A) Cam signal (B) Crankshaft signal
(1) Crankshaft position sensor (2) Crank sprocket (3) Crankshaft half-turn
None
(A)
(B)
10 CA
#1BTDC10 CA #3BTDC10 CA #2BTDC10 CA #4BTDC10 CA #1BTDC10 CA
30 CA 30 CA
EN-05538
(1)
(2)
(3)
EN-05539
GD(H4SO)-113
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Starter switch ON
Crankshaft position sensor signal Not detected
Battery voltage 8 V
Judgment Value
Crankshaft position sensor signal Input exists
Battery voltage 8 V
GD(H4SO)-114
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.
3. ENABLE CONDITION
(A) Cam signal (B) Crankshaft signal
Battery voltage 8 V
(A)
(B)
10 CA
30 CA 30 CA
EN-05538
(1)
(2)
(3)
EN-05539
GD(H4SO)-115
GENERAL DESCRIPTION
Perform the diagnosis continuously under 3000 rpm engine speed.
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Cylinder number identification Completed
Amount of crank sensor signal during 1
rev.
Not = 30
Judgment Value
Amount of crank sensor signal during 1
rev.
= 30
GD(H4SO)-116
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.
3. ENABLE CONDITION
(A) Camshaft signal (B) Crankshaft signal
None
(A)
(B)
Number of camshaft signal = 2 is normal at two engine revolution.
10 CA
#2BTDC10 CA #4BTDC10 CA
30 CA 30 CA
#1BTDC10 CA #3BTDC10 CA #1BTDC10 CA
EN-05541
GD(H4SO)-117
GENERAL DESCRIPTION
Time Needed for Diagnosis: Two engine revolutions 4 time
Normality Judgment
Time Needed for Diagnosis: Two engine revolutions
8. FAIL SAFE
None
Judgment Value
Battery voltage 8 V
Amount of camshaft sensor signal during
2 revs.
Not = 2
Judgment Value
Voltage 8 V
2 revs.
= 2
GD(H4SO)-118
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 as NG when the camshaft line signal input timing is shifted from the crankshaft signal because of tim-
ing belt tooth chip etc.
(A) Camshaft signal (B) Crankshaft signal
(1) Boss (3) Air gap (5) Camshaft one revolution (engine
two revolutions)
(2) Cam sprocket (4) Camshaft position sensor
(A)
(B)
OK OK NG NG
10 CA
#2BTDC10 CA #4BTDC10 CA #1BTDC10 CA
30 CA 30 CA
EN-05542
EN-01782
(1)
(1)
(3)
(4)
(5)
(2)
GD(H4SO)-119
GENERAL DESCRIPTION
3. ENABLE CONDITION
Always perform the diagnosis continuously at idle speed.
cles.
Normality Judgment
8. FAIL SAFE
None
Battery voltage 8 V
Engine operation Idling
Misfire Not detected
Engine load change during 4 millisec-
onds
12799.8 rpm
Judgment Value
Position of camshaft position sensor sig-
nal
Not between BTDC
10CA and BTDC
80CA
Judgment Value
Position of camshaft position sensor sig-
nal
Between BTDC10CA
and BTDC80CA
GD(H4SO)-120
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 de-
celeration 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.
(1) ECM (4) CPU (6) Main relay
(2) Detecting circuit (5) EGR valve (7) Battery power supply
(3) Switching circuit
(1)
(2)
(3)
(4)
(5)
(6)
(7)
EN-02192
GD(H4SO)-121
GENERAL DESCRIPTION
3. ENABLE CONDITION
During deceleration fuel cut from 53 km/h (approx. 33 MPH) or more, perform diagnosis once.
Be careful of vehicle speed and engine speed. (Diagnosis will not be completed if the vehicle speed and en-
gine speed conditions become out of specification due to deceleration.)
Measure the pressure values when the enable conditions are established, and perform diagnosis by calcu-
lating those results.
1. Label the intake manifold pressure value as PMOF1, which is observed when enable conditions are es-
tablished, 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 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).
Engine coolant temperature 75 C(167 F)
Intake manifold pressure (absolute pressure) < 43.99 kPa (330 mmHg, 12.992 inHg)
Ambient air temperature 5 C(41 F)
Barometric pressure 75.05 kPa (563 mmHg, 22.165 inHg)
Fuel shut-off function In operation
Neutral switch OFF
After neutral switch ON/OFF change Value from Map
No load change (A/C, power steering, light-
ing, rear defogger, heater fan and radiator
fan)
5000 ms
Map
C (F)
40
(40)
30
(22)
20
(4)
10
(14)
0
(32)
10
(50)
20
(68)
30
(86)
After neutral switch change
msec
0 0 0 0 0 0 0 0
C (F)
40
(104)
50
(122)
60
(140)
70
(158)
80
(176)
90
(194)
100
(212)
110
(230)
msec
0 0 0 0 0 0 0 0
Judgment Value
PMON (PMOF1 + PMOF2)/2 < 2.48 kPa (18.63
mmHg, 0.733 inHg)
GD(H4SO)-122
GENERAL DESCRIPTION
cles.
Normality Judgment
(A) 3000 ms (C) 1000 ms (D) 45 STEP
(B) 1000 ms
Judgment Value
PMON (PMOF1 + PMOF2)/2 2.48 kPa (18.63
mmHg, 0.733 inHg)
EN-05568
ON
OFF
(Open)
(Close)
(Open)
(Close)
PMOF1
PMON
PMOF2
Deceleration fuel cut
Diagnosis enable condition
EGR target step
EGR actual step
DIagnostic mode timer
Start dignosis
(D)
(A) (B) (C)
Intake manifold pressure
(During normal condition)
GD(H4SO)-123
GENERAL DESCRIPTION
8. FAIL SAFE
A/F main learning = Not allowed.
Knock learning = Not allowed.
EGR control: Operation prohibited.
GD(H4SO)-124
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 de-
teriorated 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 com-
paring it with the front oxygen (A/F) sensor output.
(1) Front oxygen (A/F) sensor (A) Normal (D) Output waveform from the rear
oxygen Sensor
(2) Front oxygen sensor (B) Deterioration
(3) Catalytic converter (C) Output waveform from the front
oxygen (A/F) sensor
EN-01713
(A)
(B)
(C) (D)
(1) (2)
(3)
(3)
GD(H4SO)-125
GENERAL DESCRIPTION
3. ENABLE CONDITION
Perform the diagnosis only once at a constant 70 km/h (43.5 MPH) or higher.
After establishing the execution conditions, calculate the front oxygen (A/F) sensor lambda deviation cumu-
lative value ( |(sglmd
n
sglmd
n1
)|) and rear oxygen sensor output voltage deviation cumulative value (
|(ro2sad
n
ro2sad
n1
)|) per 32 milliseconds 4 , and when the front oxygen (A/F) sensor lambda deviation
cumulative value ( |(sglmd
n
sglmd
n1
)|) becomes the predetermined value or more, calculate the diag-
nostic value.
If the duration of time while the following conditions are met is within the time indicated, judge as NG.
Time Needed for Diagnosis: 30 55 seconds
cles.
Learning value of evaporation gas density < 0.2
Sub feedback In operation
Evaporative system diagnosis Not in operation
Time of difference (< 0.10) between actual
lambda and target lambda
1000 ms
Vehicle speed > 70 km/h (43.5 MPH)
and
< 40 g/s (1.411 oz/s)
Engine load change every 0.5 engine revs. < 0.02 g/rev (0.001 oz/rev)
Rear oxygen output change from 660 mV or
less to 660 mV or more
Experienced after fuel cut
Purge execution calculated time 0 sec
Judgment Value
|(ro2sad
n
ro2sad
n1
)| / |(sglmd
n

sglmd
n1
)|
> 10 (U5 model)
> 15.5 (Except for U5
model)
GD(H4SO)-126
GENERAL DESCRIPTION
Normality Judgment
Judge as OK and clear the NG if the continuous time while the following conditions are established is within
the predetermined time.
8. FAIL SAFE
None
Judgment Value
|(ro2sad
n
ro2sad
n1
)| / |(sglmd
n

sglmd
n1
)|
10 (U5 model)
15.5 (Except for U5
model)
GD(H4SO)-127
GENERAL DESCRIPTION
BF:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK
Check if there is a leakage in fuel system or not, and perform the function diagnosis of valve.
In this system diagnosis, check for leakage and valve function is conducted by changing the fuel tank pres-
sure 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.
(1) Fuel gauge (7) Pressure control valve (12) Fuel level sensor
(2) Intake manifold (8) Drain valve (13) Fuel tank
(3) Throttle body (9) Drain filter (14) Fuel cut valve
(4) Purge control solenoid valve (10) Shut-off valve (15) Fuel tank pressure sensor
(5) Engine control module (ECM) (11) Fuel temperature sensor (16) Vent valve
(6) Canister
(1)
(2)
(3)
(4)
(5)
(7)
(8)
(9)
(6)
(11)
(10)
(12)
(13)
(16)
(14)
(15)
EN-04151
GD(H4SO)-128
GENERAL DESCRIPTION
0.04-inch Diagnosis
Mode Mode Description Diagnosis Period
Mode Z
(Purge control solenoid valve open-
ing failure diagnosis)
Perform purge control solenoid valve opening failure diagnosis
from the size of tank pressure variation from diagnosis start.
0 ms + 3000 ms
0 ms + 3000 ms +
13000 ms
Mode A
(Estimated evaporation amount)
Calculate the tank pressure change amount (P1).
10000 ms
Mode B
(Sealed negative pressure, large
leakage judgment)
Decrease the pressure in the tank to the target value by introduc-
ing the intake manifold pressure to the fuel tank.
If the tank pressure cannot be reduced, it is diagnosed as large
leak.
0 10000 ms +
25000 ms
Mode C
(Pressure increase check,
advanced OK judgment)
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.
0 18500 ms
Mode D
(Negative pressure variation mea-
surement, evaporation leakage
diagnosis)
Calculate the tank pressure variation (P2), and obtain the diag-
nostic value using P1 found in Mode A.
Perform the evaporation diagnosis using the diagnostic value.
0 ms + 10000 ms
Mode
Z
Mode
A
Mode
B
Mode
C
Mode
D
OK OK OK OK OK
NG
Early OK
Large leakage judgement
Cancel
Mode
Z
Extend
NG
NG
OK
END
EN-02872
GD(H4SO)-129
GENERAL DESCRIPTION
Mode Table for Evaporative Emission Control System Diagnosis
Mode
Behavior of tank internal pressure under
normal conditions
Diagnostic item DTC
Mode Z
Roughly the same as barometric pres-
sure (Same as 0 kPa (0 mmHg, 0 inHg))
Purge control solenoid valve is judged to
be open.
P0457
Mode A
Pressure is in proportion to amount of
evaporative emission.
None
Mode B
Negative pressure is formed due to
intake manifold negative pressure
Large leak
P0457
Mode C Reaches target pressure None
Mode D Pressure change is small.
EVAP system large leak determination.
[1.0 mm (0.04 in)]
P0442
GD(H4SO)-130
GENERAL DESCRIPTION
0.02-inch Diagnosis
Mode A
(0 point compensation)
When the pressure in the tank is not near 0 mmHg, wait until it
returns to 0 point (near 0 mmHg).
0 Value of Map 1
Mode B
(Negative pressure introduced)
0 Value of Map 2
Mode C
(Negative pressure maintained)
calculation).
0 20000 ms + 0 +
Value of Map 2
Mode D
(Negative pressure change cal-
culated)
Calculate the time it takes for the tank pressure to change to the
Mode E shifting pressure. If the tank pressure does not change to
the Mode E shifting pressure, make advanced OK judgment.
0 0 ms + 200000 ms
Mode E
(Evaporation generated amount
calculation)
Calculate the amount of evaporation (P1).
0 0 ms + 200000 ms +
Value of Map 3
Map1
Fuel level (2, US gal, Imp gal) 0
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Time Needed for Diagnosis (ms) 12000 12000 11000 10000 7500 5000 5000
Map2
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Map 3
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
EN-02871
Mode A Mode B Mode C Mode D Mode E
Cancel
Early OK 2
Early OK 1
OK OK OK OK
Cancel
Cancel
Cancel
Cancel
END
GD(H4SO)-131
GENERAL DESCRIPTION
Pressure control solenoid valve
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.
The valve is forcibly opened by setting the solenoid to ON at the time of diagnosis.
(1) Solenoid (3) Valve (a) Barometric pressure
(2) Diaphragm (4) Spring (b) Fuel tank
(c) Canister
EN-01715
(a)
(b) (c)
(4)
(1)
(2)
(3)
GD(H4SO)-132
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.
When A < B (solenoid OFF)
(a) Barometric pressure (b) Fuel tank (c) Canister
Condition of pressure Flow
A < B (solenoid OFF) B C
B < C (solenoid OFF) C B
Solenoid ON B C
EN-01716
A
B C
X X Y
(a)
(b) (c)
EN-01717
A
B C
(a)
(b) (c)
GD(H4SO)-133
GENERAL DESCRIPTION
When B < C (solenoid OFF)
When Solenoid is ON
(1) Valve (a) Barometric pressure
(b) Fuel tank
(c) Canister
EN-01718
A
B C
(a)
(b) (c)
(1)
EN-01719
A
B C
(a)
(b) (c)
GD(H4SO)-134
GENERAL DESCRIPTION
Drain valve
Drain valve controls the ambient air to be introduced to the canister.
3. ENABLE CONDITION
0.04-inch Diagnosis
Total time of canister purge operation 120000 ms
Fuel tank pressure 4 kPa (30 mmHg, 1.181 inHg)
Intake manifold relative vacuum (relative pres-
sure)
26.66 kPa ( 200 mmHg, 7.874 inHg)
Fuel level 9.6 L (2.536 US gal, 2.112 Imp gal)
54.4 L (14.372 US gal, 11.968 Imp gal)
Closed air/fuel ratio control In operation
Fuel temperature 10 C (14 F) 45 C (113 F)
Intake air temperature 10 C (14 F)
Pressure change every one second < 1.7 mmHg (Mode A)
< 1.7 mmHg (Mode D)
Minimum pressure change value every one sec-
ond Maximum pressure change value every
one second
< 1.7 mmHg (Mode A)
< 1.7 mmHg (Mode D)
Change of fuel level per 128 milliseconds < 2 L (0.528 US gal, 0.44 Imp gal)
Air fuel ratio 0.76 1.25
EN-02293
GD(H4SO)-135
GENERAL DESCRIPTION
0.02-inch Diagnosis
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 (20 MPH) or more.
Pay attention to the fuel temperature and fuel level.
0.02-inch Diagnosis
Perform the diagnosis 125 seconds or more at a constant engine speed of 50 km/h (31 MPH) or higher to
judge as NG or OK.
If judgment cannot be made, repeat the diagnosis.
Pay attention to the fuel level.
At starting a diagnosis
Evap. diagnosis Incomplete
Time since last incomplete 0.02-inch leakage
diagnosis
When cancelling in mode A > 120000 ms
When cancelling in other than mode A > 600000 ms
Total time of canister purge operation 120000 ms
Fuel level 9.6 L (2.536 US gal, 2.112 Imp gal) 54.4 L
(14.372 US gal, 11.968 Imp gal)
sure)
8 kPa ( 60 mmHg, 2.362 inHg)
Fuel tank pressure 0.67 kPa (5 mmHg, 0.197 inHg) 1.43 kPa
(10.7 mmHg, 0.421 inHg)
Vehicle speed 50 km/h (31.1 MPH) 510 km/h (316.9 MPH) contin-
ues for 125000 ms
During diagnosis
Change of fuel level Value of Map 4
Pressure change every one second < 0.06 kPa (0.44 mmhg, 0.017 inHg)
one second
< 0.07 kPa (0.51 mmhg, 0.02 inHg) (Mode D)
| Pressure change in tank every second | 0.1 kPa (0.75 mmhg, 0.03 inHg)
Barometric pressure change 0.48 kPa (3.6 mmhg, 0.142 inHg) 0.32 kPa
(2.4 mmhg, 0.094 inHg) (Mode D)
0.32 kPa (2.4 mmhg, 0.094 inHg) 0.32 kPa
(2.4 mmhg, 0.094 inHg) (Mode E)
Map4
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Change (2, US gal, Imp gal)
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
GD(H4SO)-136
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 nor-
mally. 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 can-
celled.
Diagnostic method
Purge control solenoid valve functional diagnosis is performed by monitoring the tank pressure in mode Z.
If OK judgment cannot be made, extend Mode Z 16, and Judge as NG when the following conditions are es-
tablished after predetermined amount of time.
Time Needed for Diagnosis: 0 ms + 3000 ms + 13000 ms
cles.
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.
Normality Judgment
Judge as OK and change to Mode A when the following conditions are established after predetermined time
has passed since Mode Z started.
Judgment Value
evptez evptezha > 0.87 kPa (6.5
mmHg, 0.256 inHg)
P0457
evptezini 1.43 kPa (10.7
mmHg, 0.421 inHg)
Time of 2 L (0.528 US gal, 0.44 Imp gal)
or more fuel no sloshing
40000 ms
Judgment Value
evptez evptezha 0.4 kPa (3 mmHg,
0.118 inHg)
P0457
GD(H4SO)-137
GENERAL DESCRIPTION
Normal
evptez evptezha 0.4 kPa (3 mmHg, 0.118 inHg) Normal when above is established
Time Needed for Diagnosis: 0 ms + 3000 ms
(1) Mode Z (3) Fuel tank pressure (5) OK judgment
(2) 3000 ms (4) 0.4 kPa (3 mmHg, 0.118 inHg)
EN-02869
(1)
(2)
(4)
evptez
evptezini
evptezha
0
(3)
(5)
GD(H4SO)-138
GENERAL DESCRIPTION
Purge control solenoid valve Open Fixation
evptezini 1.43 kPa (10.7 mmHg, 0.421 inHg)
evptez evptezha > 0.87 kPa (6.5 mmHg, 0.256 inHg)
No fuel sloshing of over 2 L (0.528 US gal, 0.44 Imp gal) lasts for more than 40000 ms.
Judge as abnormal when all are established.
(1) Mode Z (5) 0.87 kPa (6.5 mmHg, 0.256 inHg) (7) 40000 ms no fuel sloshing
(2) Extended mode Z (6) 1.43 kPa (10.7 mmHg, 0.421
inHg)
(8) NG judgment
(3) 3000 ms + 13000 ms
(4) Fuel tank pressure
EN-02870
(8)
(7)
(6)
(4)
(5)
evptez
evptezini
evptezha
0
(3)
(2) (1)
GD(H4SO)-139
GENERAL DESCRIPTION
Leak Diagnosis
DTC
P0442 Evaporative Emission Control System Leak Detected (Small Leak)
The diagnostic 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 barometric 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.
Approx. 0 1.4 kPa (0 10.5 mmHg, 0 0.413 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 leak-
age in the system and terminate the evaporative emission control system diagnosis.
Judge as NG (large leakage) when the following conditions are established.
Time Needed for Diagnosis: 0 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms
Mode C: (Check pressure rise)
Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 cal-
culation.)
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.
Time Needed for Diagnosis: 0 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 18500 ms
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 barometric pressure) because evaporation occurs. However, if any leakage exists, the pressure in-
creases 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.
Judgment Value
Time to reach target negative pressure 10000 ms + 25000 ms P0457
or
Mode B time 10000 ms
(Min. pressure value in tank when in
mode B) (Tank pressure when mode B
started)
> 0.33 kPa (2.5
mmHg, 0.098 inHg)
Tank pressure when starting cal-
culation of P2
Time for advanced OK
judgment
1.3 kPa (9.75 mmHg, 0.384
inHg)
18500 ms
GD(H4SO)-140
GENERAL DESCRIPTION
Judge as NG when the following conditions are established within the predetermined time. Judge as OK and
clear the NG if the following conditions are not established within the predetermined time.
*1.5 -: Evaporation amount compensation value when below negative pressure (Amount of evaporation occurrence increases as
a vacuum condition increases.)
Time Needed for Diagnosis: 0 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 18500 ms + 10000 ms
cles.
Leak Diagnosis
DTC
P0456 Evaporative Emission Control System Leak Detected (very small leak)
Mode A: (0 point compensation)
When the pressure in the tank is not near 0 mmHg, 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)
Approx. 0 2 kPa (0 15 mmHg, 0 0.591 inHg)
When the tank internal pressure does not reach the target negative pressure, the diagnosis is cancelled.
Judgment Value
P2 1.5 - P1 > Value of Map 5 P0442
P2: Tank pressure that changes every
10000 ms in mode D
10000 ms in mode A
Map 5 Malfunction criteria limit for evaporation diagnosis
Fuel temperature vs. Fuel level 25 C (77 F) 30 C (86 F) 35 C (95 F) 40 C (104 F) 45 C (113 F)
0 L (0 US gal, 0 Imp gal)
0.28 kPa
(2.1 mmHg,
0.083 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.35 mmHg,
0.093 inHg)
0.32 kPa
(2.4 mmHg,
0.094 inHg)
10 L (2.642 US gal, 2.2 Imp gal)
0.28 kPa
(2.1 mmHg,
0.083 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.35 mmHg,
0.093 inHg)
0.32 kPa
(2.4 mmHg,
0.094 inHg)
20 L (5.284 US gal, 4.4 Imp gal)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.32 kPa
(2.4 mmHg,
0.094 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
0.35 kPa
(2.6 mmHg,
0.102 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
30 L (7.926 US gal, 6.6 Imp gal)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.41 kPa
(3.05 mmHg,
0.12 inHg)
0.42 kPa
(3.15 mmHg,
0.124 inHg)
0.43 kPa
(3.25 mmHg,
0.128 inHg)
0.45 kPa
(3.35 mmHg,
0.132 inHg)
40 L (10.568 US gal, 8.8 Imp gal)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.42 kPa
(3.15 mmHg,
0.124 inHg)
0.44 kPa
(3.3 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
50 L (13.21 US gal, 11 Imp gal)
0.43 kPa
(3.2 mmHg,
0.126 inHg)
0.44 kPa
(3.3 mmHg,
0.13 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.48 kPa
(3.6 mmHg,
0.142 inHg)
0.49 kPa
(3.7 mmHg,
0.146 inHg)
60 L (15.852 US gal, 13.2 Imp gal)
0.43 kPa
(3.2 mmHg,
0.126 inHg)
0.44 kPa
(3.3 mmHg,
0.13 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.48 kPa
(3.6 mmHg,
0.142 inHg)
0.49 kPa
(3.7 mmHg,
0.146 inHg)
GD(H4SO)-141
GENERAL DESCRIPTION
Mode C: (Negative pressure maintained)
culation.)
Change to Mode D either when the tank pressure returns to the start level of P2 calculation, or when the pre-
determined 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 change to the Mode E shifting pressure. When the Mode E shifting pres-
sure is reached, Mode E is entered. If it does not change to the Mode E shifting pressure after the predeter-
mined amount of time has passed, make advanced OK judgment or cancel the diagnosis.
Normality Judgment
Judge as OK when the following conditions are established.
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).
Judgment Value
Advanced OK judgment 1
Mode D time 0 ms + 20000 ms
Tank internal pressure Value of Map 6
Mode D time 0 ms + 200000 ms
P2 Value of Map 7
Map6
Fuel level (2, US gal, Imp gal) 0, 0, 0
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Tank pressure
(kPa, mmHg, inHgl)
1.85,
13.9,
0.547
1.85,
13.9,
0.547
1.84,
13.8,
0.543
1.83,
13.7,
0.539
1.81,
13.6,
0.535
1.8,
13.5,
0.531
1.8,
13.5,
0.531
Map7
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Tank pressure
(kPa, mmHg, inHgl)
0.93, 7,
0.276
0.93, 7,
0.276
0.94, 7.05,
0.278
0.95, 7.1,
0.28
1.09, 8.2,
0.323
1.28, 9.6,
0.378
1.28, 9.6,
0.378
GD(H4SO)-142
GENERAL DESCRIPTION
Time Needed for Diagnosis: Value of Map1+ Value of Map2 + 20000 ms + 0 + Value of Map2 + 0 ms +
200000 ms + Value of Map3 + 0 ms + 200000 ms
cles.
Judgment Value
P1 < Value of Map 8
Time (evpdset) vs. Fuel level 0 ms 30000 ms 50000 ms 100000 ms 160000 ms 200000 ms
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa
(1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
10 L (2.642 US gal, 2.2 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa
(1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
20 L (5.284 US gal, 4.4 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa
(1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
30 L (7.926 US gal, 6.6 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa
(1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
40 L (10.568 US gal, 8.8 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.25 kPa
(1.85 mmHg,
0.073 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
50 L (13.21 US gal, 11 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.27 kPa
(2 mmHg,
0.079 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0 kPa
(0 mmHg,
0 inHg)
60 L (15.852 US gal, 13.2 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.27 kPa
(2 mmHg,
0.079 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0 kPa
(0 mmHg,
0 inHg)
GD(H4SO)-143
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
P1 > Value of Map 9
0.13 kPa
(1 mmHg,
0.039 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
10 L (2.642 US gal, 2.2 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
20 L (5.284 US gal, 4.4 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.43 kPa
(3.25 mmHg,
0.128 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
30 L (7.926 US gal, 6.6 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.4 kPa
(3 mmHg,
0.118 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
40 L (10.568 US gal, 8.8 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.3 kPa
(2.25 mmHg,
0.089 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 L (13.21 US gal, 11 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.2 kPa
(1.5 mmHg,
0.059 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
60 L (15.852 US gal, 13.2 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.2 kPa
(1.5 mmHg,
0.059 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
GD(H4SO)-144
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.
3. ENABLE CONDITION
(1) Bobbin (8) Magnetic plate (15) Diaphragm
(2) Coil (9) Shaft (16) Movable core
(3) Diode (10) Plate (17) Spring
(4) Stator core (11) Valve (18) Cover
(5) End plate (12) Housing (19) O-ring
(6) Body (13) Filter
(7) Yoke (14) Retainer
None
(1) (2) (3)
(4) (5) (6) (7) (8)
(9) (10) (11) (12) (13) (17)
(14) (15) (16) (18) (19) (19)
EN-02294
GD(H4SO)-145
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Pressure control solenoid valve control: Open the pressure control solenoid valve.
Judgment Value
Elapsed time after starting the engine 1 second
Terminal output voltage when ECM out-
puts OFF signal
Low
Judgment Value
puts OFF signal
High
GD(H4SO)-146
GENERAL DESCRIPTION
BH:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL
CIRCUIT SHORTED
3. ENABLE CONDITION
(1) Bobbin (8) Magnetic plate (15) Diaphragm
(2) Coil (9) Shaft (16) Movable core
(3) Diode (10) Plate (17) Spring
(4) Stator core (11) Valve (18) Cover
(5) End plate (12) Housing (19) O-ring
(6) Body (13) Filter
(7) Yoke (14) Retainer
None
(1) (2) (3)
(4) (5) (6) (7) (8)
(9) (10) (11) (12) (13) (17)
(14) (15) (16) (18) (19) (19)
EN-02294
GD(H4SO)-147
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
puts ON signal
High
Judgment Value
puts ON signal
Low
GD(H4SO)-148
GENERAL DESCRIPTION
BI: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR
Detect the tank pressure sensor output property abnormality.
Judge as NG when there is no pressure variation, which should exist in the tank, considering the engine sta-
tus.
3. ENABLE CONDITION
Perform the diagnosis continuously after 60 sec have passed since the engine started.
Pay attention to the fuel level and temperature.
(1) Connector (A) Output voltage (C) To fuel tank
(2) Terminals (B) Input voltage
2.112 Imp gal)
Barometric pressure 75.05 kPa (563
mmHg, 22.165 inHg)
EN-04462
(A)
(B)
(2) (1)
(C)
GD(H4SO)-149
GENERAL DESCRIPTION
If the difference between the Max. fuel level every 60 sec and Min. fuel level every 60 sec is less than 2 L
(0.528 US gal, 0.44 Imp gal), extend 60 sec and make judgment with the Max. and Min. values for the fuel
level in 60 sec 2. If a difference does not appear, extend the time (60 sec 3, 60 sec 4, 60 sec 5) and
continue the judgment. If the difference between the Max. fuel level every 60 sec and Min. fuel level every 60
sec is 2 L (0.528 US gal, 0.44 Imp gal) or more, the diagnosis counter counts up.
Time Needed for Diagnosis: 60 sec 16 time or more
cles.
Normality Judgment
8. FAIL SAFE
Purge control solenoid valve control: Purge fixed mode is prohibited.
Judgment Value
Number of times that the difference
between the Max. fuel level every 60 sec
and Min. fuel level every 60 sec is 2 L
(0.528 US gal, 0.44 Imp gal) or more
(with enable condition established)
16 time
Maximum Minimum tank pressure
(with enable condition completed)
< 0.05 kPa (0.375
mmHg, 0.015 inHg)
Maximum Minimum fuel temperature
7 C (44.6 F)
Judgment Value
Maximum Minimum tank pressure 0.05 kPa (0.375
mmHg, 0.015 inHg)
GD(H4SO)-150
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.
3. ENABLE CONDITION
None
EN-04462
(A)
(B)
(2) (1)
(C)
GD(H4SO)-151
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Fuel tank pressure < 7.41 kPa (55.6 mmHg,
2.189 inHg)
Judgment Value
Fuel tank pressure 7.41 kPa (55.6 mmHg,
2.189 inHg)
GD(H4SO)-152
GENERAL DESCRIPTION
BK:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR HIGH INPUT
3. ENABLE CONDITION
Perform the diagnosis when purging enable conditions are met without idling.
5000 ms
All conditions of EVAP canister purge Completed
Learning value of evaporation gas con-
centration (left and right)
< 0.08
Main feedback compensation coefficient
(left and right)
0.9
EN-04462
(A)
(B)
(2) (1)
(C)
GD(H4SO)-153
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
BL:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECT-
ED (VERY SMALL LEAK)
NOTE:
For the detection standard, refer to DTC P0442. <Ref. to GD(H4SO)-127, DTC P0442 EVAPORATIVE
EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) De-
tecting Criteria.>
BM:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECT-
ED (FUEL CAP LOOSE/OFF)
NOTE:
For the detection standard, refer to DTC P0442. <Ref. to GD(H4SO)-127, DTC P0442 EVAPORATIVE
tecting Criteria.>
Judgment Value
Fuel tank pressure 7.94 kPa (59.6 mmHg,
2.346 inHg)
Barometric pressure 75.05 kPa (563 mmHg,
22.165 inHg)
Judgment Value
2.346 inHg)
GD(H4SO)-154
GENERAL DESCRIPTION
BN:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT LOW
Detect open or short circuit of the purge control solenoid valve.
3. ENABLE CONDITION
Always perform the diagnosis after starting the engine.
(A) To canister (B) To intake manifold
(A) (B)
EN-02197
GD(H4SO)-155
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Duty ratio of ON < 0.75
Terminal output voltage Low
Judgment Value
Terminal output voltage High
GD(H4SO)-156
GENERAL DESCRIPTION
BO:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT HIGH
3. ENABLE CONDITION
(A) (B)
EN-02197
GD(H4SO)-157
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Duty ratio of ON 0.25
Judgment Value
GD(H4SO)-158
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.
3. ENABLE CONDITION
(A) Fuel level (B) Resistance
None
EN-01734
0
(B)
(A)
GD(H4SO)-159
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
(11672.853 oz)
Max. min. values of fuel level output < 2.6 L (0.687 US gal,
0.572 Imp gal)
Judgment Value
(11672.853 oz)
Max. min. values of fuel level output 2.6 L (0.687 US gal,
0.572 Imp gal)
GD(H4SO)-160
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 out of specification.
3. ENABLE CONDITION
cles.
(1) Engine control module (ECM) (3) Fuel sub level sensor (4) Detecting circuit
(2) Fuel level sensor (5) Body integrated unit
None
Judgment Value
(5)
(4)
(1)
(2) (3)
EN-05371
GD(H4SO)-161
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
GD(H4SO)-162
GENERAL DESCRIPTION
BR:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH
3. ENABLE CONDITION
cles.
None
Judgment Value
(5)
(4)
(1)
(2) (3)
EN-05371
GD(H4SO)-163
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
GD(H4SO)-164
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. val-
ue and cumulative value of output voltage variation of the fuel level sensor is larger than the threshold value.
2. ENABLE CONDITION
Idle switch ON
2.112 Imp gal)
and
< 54.4 L (14.372 US
gal, 11.968 Imp gal)
Vehicle speed = 0 km/h (0 MPH) 10000 ms
GD(H4SO)-165
GENERAL DESCRIPTION
Calculate the Max. value (DELFLMAX) and cumulative value (SUMFL) of output voltage variation of fuel level
sensor during 12.2 seconds. Judge it normal when both max. and cumulative values are not over the thresh-
old value. Otherwise, when either of them is over the threshold value, the diagnosis counter counts up. Judge
as NG if the counter indicated 4 time.
(A) 12288 ms (C) Malfunction (D) Normal
(B) NG at 4 time
Diagnosis condition
Diagnosis timer
(A)
Fuel level sensor
A/D value
Amount of Fuel level
output voltage variation
Diagnosis counter
(B)
Calculate the Max. value (DELFLMAX)
and the cumulative value (SUMFL).
1
2
3
4
5
6
0
(C)
(D)
EN-05569
GD(H4SO)-166
GENERAL DESCRIPTION
The diagnosis counter does not count up when the following conditions are completed within 12288 ms.
cles.
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Integrated times of the condition reaching fol-
lows,
4 time
DELFLMAX Value from Map
or
SUMFL 25.92 V
At this time,
DELFLMAX: Maximum difference of sensor
output for 12288 ms
SUMFL: Integrated value of the sensor out-
put deviation for12288 ms
Map
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Measured voltage (V) 0.27 0.27 0.426 0.582 0.738 0.894 0.894
Maximum value Minimum value of
change of tank pressure for 12288 ms
0.05 kPa (0.375
mmHg, 0.015 inHg)
Maximum value Minimum value of bat-
tery voltage for 12288 ms
0.609 V
Judgment Value
DELFLMAX < Value from Map
SUMFL < 25.92 V
At this time,
DELFLMAX: Maximum difference of sensor
output for 12288 ms
SUMFL: Integrated value of the sensor out-
put deviation for12288 ms
GD(H4SO)-167
GENERAL DESCRIPTION
GD(H4SO)-168
GENERAL DESCRIPTION
BT:DTC P0500 VEHICLE SPEED SENSOR A
Judge NG when the received data from ABSCM&H/U is abnormal vehicle speed, and the vehicle speed data
is impossible.
Vehicle speed signals are taken in to the ABS control module and hydraulic control unit, and normal/errone-
ous data of the ABS wheel speed sensor is received by CAN communication from the ABS control module
and hydraulic control unit.
3. ENABLE CONDITION
Always perform diagnosis more than 2000 ms after starting the engine.
Normality Judgment
Elapsed time after engine starting 2000 ms
Judgment Value
Front ABS wheel speed sensor status Malfunction
Either of the following is established
Front left wheel speed 300 km/h
(186.4 MPH)
Front right wheel speed 300 km/h
(186.4 MPH)
Judgment Value
Front left wheel speed > 0 km/h (0 MPH)
and
< 300 km/h
(186.4 MPH)
Front right wheel speed > 0 km/h (0 MPH)
and
< 300 km/h
(186.4 MPH)
GD(H4SO)-169
GENERAL DESCRIPTION
8. 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 MPH)
Fuel cut control: Not allowed vehicle speed 0 km/h (0 MPH) fuel cut. Normally the high vehicle speed fuel
cut performs on vehicle speed condition and engine speed, but perform the fuel cut only on engine speed
condition (4,400 rpm or more).
ISC control: Open loop compensation is set to specified value (1 g (0.04 oz)/s). Not allowed ISC feedback
volume calculation.
Air conditioner control: Not allowed air conditioner cut at accelerating.
Radiator fan control: Both main and sub fan ON
Gear ratio judgment: Control as fixed in sixth gear
GD(H4SO)-170
GENERAL DESCRIPTION
BU: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
Perform the diagnosis continuously at idling after warming up engine.
cles.
Normality Judgment
mmHg, 22.165 inHg)
2.112 Imp gal)
Elapsed time after starting the engine 10.49 sec
Feedback of ISC In operation
Lambda value (left and right) 0.81
and
< 1.1
After switching air conditioner to ON/
OFF
5.1 sec
After intake manifold pressure changes
by 4 kPa (30 mmHg, 1.181 inHg) or
more.
> 5.1 sec
Elapsed time after switching neutral
position switch to ON/OFF
> 5.1 sec
Vehicle speed 0 km/h (0 MPH)
Judgment Value
Actual engine speed Targeted engine
speed
< 100 rpm
Feedback value for ISC Max.
Judgment Value
speed
100 rpm
GD(H4SO)-171
GENERAL DESCRIPTION
7. FAIL SAFE
None
GD(H4SO)-172
GENERAL DESCRIPTION
BV:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
2. ENABLE CONDITION
cles.
Normality Judgment
mmHg, 22.165 inHg)
2.112 Imp gal)
Elapsed time after starting the engine 10.49 sec
Lambda value (left and right) 0.81
and
< 1.1
OFF
5.1 sec
more.
> 5.1 sec
> 5.1 sec
Judgment Value
Actual Target engine speed 200 rpm
Feedback value for ISC Min.
Judgment Value
Actual Target engine speed < 200 rpm
GD(H4SO)-173
GENERAL DESCRIPTION
7. FAIL SAFE
None
GD(H4SO)-174
GENERAL DESCRIPTION
BW:DTC P0512 STARTER REQUEST CIRCUIT
Detect the open or short circuit of starter SW.
Judge as ON NG when the starter SW signal remains ON.
2. ENABLE CONDITION
cles.
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Engine condition After engine starting
Starter OFF signal Not detected
Battery voltage 8 V
Judgment Value
Starter OFF signal Detected
Battery voltage 8 V
GD(H4SO)-175
GENERAL DESCRIPTION
BX:DTC P0513 INCORRECT IMMOBILIZER KEY
2. ENABLE CONDITION
When starting the engine.
Perform the diagnosis only after starting the engine.
Judge as NG when the conditions for the outline of the diagnosis of the top are established.
DTC Item Outline of Diagnosis
Incorrect immobilizer key (Use of unregistered key in body inte-
grated unit)
P1570 Antenna Faulty antenna
P1571 Reference Code Incompatibility Reference code incompatibility between body integrated unit and
ECM
P1572
IMM Circuit Failure (Except
Antenna Circuit)
Communication failure between body integrated unit and ECM
Failure of body integrated unit to verify key (transponder) ID code
or transponder failure
P1576 EGI Control Module EEPROM ECM malfunctioning
P1577 IMM Control Module EEPROM Body integrated unit malfunctioning
P1578 Meter Failure
Reference code incompatibility between body integrated unit and
combination meter
GD(H4SO)-176
GENERAL DESCRIPTION
BY:DTC P0600 SERIAL COMMUNICATION LINK
Detect malfunction of CAN communication.
When CAN communications is not possible, and CAN communications with AT is not possible, judge as NG
if 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
None
Judgment Value
Battery voltage > 10.9 V
Starter switch OFF
Engine run
bus off flag or error warning flag set (error)
or
ID received from body integrated unit,
TCM, ABSCM or VDCCM
None during 500 milli-
seconds
or
Data updated from body integrated unit,
TCM, ABSCM or VDCCM
None during 500 milli-
seconds
GD(H4SO)-177
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Starter switch OFF
Engine run
bus off flag or error warning flag clear (No error)
TCM, ABSCM and VDCCM
Yes
Yes
GD(H4SO)-178
GENERAL DESCRIPTION
BZ: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
Diagnosis with the initial routine.
Perform the diagnosis as soon as the ignition switch is turned to ON.
Time Needed for Diagnosis: Undetermined
Normality Judgment
None
Judgment Value
Main CPU normal RAM abnormal
Write 5AA5A55A and then read. (Whole
area of RAM)
5AA5A55A cannot be
read.
Write A55A5AA5 and then read. (Whole
area of RAM)
A55A5AA5 cannot be
read.
Sub CPU normal RAM abnormal
Write 5AA5 and then read.
(Whole area of RAM)
5AA5 cannot be read.
Write A55A and then read.
(Whole area of RAM)
A55A cannot be read.
Judgment 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)
5AA5 can be read.
And write A55A and then read.
(Whole area of RAM)
A55A can be read.
GD(H4SO)-179
GENERAL DESCRIPTION
7. FAIL SAFE
None
GD(H4SO)-180
GENERAL DESCRIPTION
CA: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
Time Needed for Diagnosis: Undetermined
7. FAIL SAFE
Ignition switch ON
Judgment Value
SUM value of ROM Standard
GD(H4SO)-181
GENERAL DESCRIPTION
CB:DTC P0607 CONTROL MODULE PERFORMANCE
Judge as NG when any one of the followings is established.
1) When the read value of throttle position sensor 1 signal is mismatched between main CPU and sub CPU.
2) When the read value of accelerator pedal position sensor 1 signal is mismatched between main CPU and
sub CPU.
3) When the sub CPU operates abnormally.
4) When the communication between main CPU sub CPU is abnormal.
5) When the input amplifier circuit of throttle position sensor 1 is abnormal.
6) When the cruise control cannot be canceled correctly.
7) When the signal of brake SW1 and 2 is mismatched.
(1) Throttle position sensor (6) Accelerator pedal position sensor 2 (11) Amplifier circuit
(2) Throttle position sensor 1 (7) Battery (12) Engine control module (ECM)
(3) Throttle position sensor 2 (8) Stop light (13) Sub CPU
(4) Accelerator pedal position sensor (9) Brake switch (14) Main CPU
(5) Accelerator pedal position sensor 1 (10) I/F circuit
EN-01862
(1)
(4)
(2)
(3)
(5)
(6)
(7)
(8)
(9)
(12)
(11) (10)
(10)
(10)
(10)
(13)
(14)
GD(H4SO)-182
GENERAL DESCRIPTION
3. ENABLE CONDITION
(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.
1. 600 milliseconds
2. 830 milliseconds
3. 200 milliseconds
4. 200 milliseconds
5. 24 milliseconds
6. 250 milliseconds
7. 200 milliseconds
(3) None
(4) None
(5) Throttle opening angle
(6) Brake switch (only with cruise control) ON
(7) None
Judgment Value
(1) Difference of CPU reading value of
the throttle position sensor signal
0.0858 V
(2) Difference of CPU read value of the
accelerator pedal position sensor signal
0.35 V
(3) WD pulse from sub CPU WD pulse occur
(4) Communication between CPU Possible to communi-
cate
(5) |Throttle position sensor 1 opening
angle (Throttle position sensor 1
opening angle after passing amplifier)
1/4|
< 3
(6) Cruise control cancel signal at brake
ON
Cruise control cancel
signal ON
(7) Brake switch 1, 2 signal SW 1 and 2 are
matched
GD(H4SO)-183
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4SO)-184
GENERAL DESCRIPTION
CC: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 the specified duty or more for specified time continuously.
3. ENABLE CONDITION
Always perform the diagnosis continuously when the electronic throttle control is operating.
Target opening angle and actual opening angle: 250 milliseconds (For NG) 2000 milliseconds (For OK)
Output duty to drive circuit: 2000 milliseconds
(1) Motor (3) Engine control module (ECM) (4) Drive circuit
(2) Throttle position sensor
Ignition switch ON
Normal operation of electric throttle con-
trol
ON
Judgment Value
Difference between target opening angle
and actual opening angle
3.5 or less
Output duty to drive circuit 95% or less
EN-01863
(3)
(4)
(1)
(2)
GD(H4SO)-185
GENERAL DESCRIPTION
Details of Judgment Value
Details of Judgment time (The actual opening angle target opening angle is always 1000 milliseconds)
(1) Difference between target opening
angle and actual opening angle ()
(2) Target throttle opening angle () (3) NG area
(1) Judgment time (milliseconds) (2) Throttle position sensor 1 open-
ing angle
(3) NG area
EN-03129
30
20
10
0
(25.0)
(12.0)
(5.0)
(3.5)
0 5 (6.15) 10
(9.65) (14.65)
15 20 25 (26.65) 30
(1)
(3)
(2)
EN-01865
0 5(5.5) 10 (9.0) (13.0) 15 20 25 30
(2)
0
1000
(250)
(22.0)
(300)
(400)
500
(3)
(1)
GD(H4SO)-186
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4SO)-187
GENERAL DESCRIPTION
CD:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
Judge as NG when there is CAN communication with the AT and there is a MIL lighting request.
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
MIL lighting request from TCM Yes
Judgment Value
MIL lighting request from TCM None
GD(H4SO)-188
GENERAL DESCRIPTION
CE:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)
Judge the open or short circuit of the neutral SW.
Judge as NG when the ECM neutral terminal input differs from the reception data from TCM.
2. ENABLE CONDITION
Perform the diagnosis continuously in 2 seconds after starting the engine.
cles.
Normality Judgment
7. FAIL SAFE
Control of cruise control: Control prohibited
Starter relay OFF
Judgment Value
Neutral switch signal in ECM when P/
N range in TCM are OFF and when
the other switches are ON
LOW (ON)
Judgment Value
HIGH (OFF)
GD(H4SO)-189
GENERAL DESCRIPTION
CF:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)
Detect the open or short circuit of neutral SW.
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
Judge NG when the malfunction criteria below are completed determined times or more after the neutral SW
change.
cles.
Normality Judgment
Judge as OK and clear NG when there is change in the neutral SW.
Starter relay OFF
Judgment Value
Neutral switch signal (while changing
from a to b below)
LOW (ON) continues.
Driving condition change From a) to b)
a) Engine speed 600 rpm 900 rpm &
Vehicle speed = 0 km/h (0 MPH)
b) Engine speed 1600 rpm 900 rpm &
Judgment Value
from a to b below)
Changes to HIGH
(OFF).
GD(H4SO)-190
GENERAL DESCRIPTION
7. FAIL SAFE
GD(H4SO)-191
GENERAL DESCRIPTION
CG:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)
2. ENABLE CONDITION
cles.
Normality Judgment
7. FAIL SAFE
Starter relay OFF
Judgment Value
N range in TCM are ON and when the
other switches are OFF
HIGH (OFF)
Judgment Value
LOW (ON)
GD(H4SO)-192
GENERAL DESCRIPTION
CH:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)
Judge NG when there is no change in the neutral SW even if the driving shift was applied. (There is neutral
2. ENABLE CONDITION
change.
cles.
Normality Judgment
Starter relay OFF
Judgment Value
from a to b below)
HIGH (OFF) contin-
ues.
Judgment Value
from a to b below)
Changes to LOW
(ON).
GD(H4SO)-193
GENERAL DESCRIPTION
7. FAIL SAFE
GD(H4SO)-194
GENERAL DESCRIPTION
CI: DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW)
(BANK1 SENSOR1)
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) ZrO
2
(C) Lean
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4SO)-195
GENERAL DESCRIPTION
3. ENABLE CONDITION
Perform diagnosis continuously at a constant speed of 20 km/h (12.4 MPH) or more after 60000 ms have
passed since the engine started.
cles.
Normality Judgment
Time needed for all secondary parameters to be in enable
conditions
4096 ms
Rear oxygen sensor sub feedback 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.
180Load change at CA < 0.02 g/rev (0.001 oz/rev)
Targeted lambda value load compensation coefficient 0.030 0.000
Judgment Value
value < 0.85
Judgment Value
value 0.85
GD(H4SO)-196
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4SO)-197
GENERAL DESCRIPTION
CJ:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH)
(BANK1 SENSOR1)
Detect that value remains high.
control, etc.
air fuel ratio
> 1: Lean
< 1: Rich
(3) ZrO
2
(C) Lean
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4SO)-198
GENERAL DESCRIPTION
3. ENABLE CONDITION
cles.
Normality Judgment
conditions
4096 ms
Judgment Value
value > 1.15
Judgment Value
value 1.15
GD(H4SO)-199
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4SO)-200
GENERAL DESCRIPTION
CK:DTC P1160 RETURN SPRING FAILURE
Judge as NG when the valve is opened more than the default opening angle, but does not move to the close
direction with the motor power stopped.
3. ENABLE CONDITION
Ignition switch ON OFF
Ignition switch OFF ON (Only after clearing memory)
Time Needed for Diagnosis: 1880 milliseconds
(1) Opener spring (4) Full closed stopper (7) DC motor
(2) Return spring (5) Throttle valve (8) Main and sub throttle sensor
(3) Intermediate stopper (6) Gear
Motor continuity OFF
Judgment Value
Opening variation after continuity is set
to OFF
2
EN-01866
S S
(8)
(6)
(7)
(5)
(1)
(3)
(2)
(4)
GD(H4SO)-201
GENERAL DESCRIPTION
8. FAIL SAFE
Throttle opening is fixed to 6.
GD(H4SO)-202
GENERAL DESCRIPTION
CL: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.
3. ENABLE CONDITION
(1) Filter (4) Diaphragm (A) Barometric pressure
(2) Coil (5) Valve (B) Shut-off valve
(3) Connector terminal (C) To fuel tank
None
EN-01759
(1)
(2)
(3)
(4)
(5)
(A)
(B) (C)
GD(H4SO)-203
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
puts OFF signal
Low
Judgment Value
puts OFF signal
High
GD(H4SO)-204
GENERAL DESCRIPTION
CM:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
3. ENABLE CONDITION
None
EN-01759
(1)
(2)
(3)
(4)
(5)
(A)
(B) (C)
GD(H4SO)-205
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
puts ON signal
High
Judgment Value
puts ON signal
Low
GD(H4SO)-206
GENERAL DESCRIPTION
CN: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.
3. ENABLE CONDITION
(1) Bobbin (8) Magnetic plate (14) Retainer
(2) Coil (9) Shaft (15) Diaphragm
(3) Diode (10) Plate (16) Movable core
(4) Stator core (11) Valve (17) Spring
(5) End plate (12) Housing (18) Cover
(6) Body (13) Filter (19) O-ring
(7) Yoke
Drain valve Open
22.165 inHg)
Tank pressure when starter is OFF
ON
0.43 kPa (3.2 mmHg,
0.126 inHg)
and
1.43 kPa (10.7 mmHg,
0.421 inHg)
(1) (2) (3)
(4) (5) (6) (7) (8)
(9) (10) (11) (12) (13) (17)
(14) (15) (16) (18) (19) (19)
EN-02294
GD(H4SO)-207
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Fuel tank pressure 4 kPa (30 mmHg,
1.181 inHg)
Judgment Value
Fuel tank pressure > 4 kPa (30 mmHg,
1.181 inHg)
Cumulative time when all the malfunction
criteria below are met.
30000 sec
Purge control solenoid valve duty Not = 0
Fuel temperature 10 C (14 F) 70 C
(158 F)
Intake manifold relative pressure 26.66 kPa (200 mmHg,
7.874 inHg)
GD(H4SO)-208
GENERAL DESCRIPTION
CO: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.
3. ENABLE CONDITION
(1) Engine control module (ECM) (3) PCV diagnosis connector (4) 5 V
(2) Detecting circuit
None
Judgment Value
Positive crankcase ventilation diagnosis
voltage
High
EN-01790
E
(1)
(2)
(3)
(4)
GD(H4SO)-209
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
voltage
Low
GD(H4SO)-210
GENERAL DESCRIPTION
CP:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION
(LOW INPUT)
Detects open or short circuit of EGR.
3. ENABLE CONDITION
Perform diagnosis continuously during EGR operation.
Malfunction Indicator Light: Illuminates as soon as a malfunction occurs.
(1) Engine control module (ECM) (3) Detecting circuit (5) Battery voltage
(2) Computer unit (CPU) (4) Switch circuit (6) Main relay
EGR valve target position > 0 step
Judgment Value
Terminal voltage level when ECM out-
puts OFF signal
Low level
or
Terminal voltage level when EGR oper-
ates
Low level
EN-02051
(1)
(2)
(3)
(4)
(5)
(6)
GD(H4SO)-211
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Knock sensor learning compensation: Calculation prohibited.
Judgment Value
puts OFF signal
High level
ates
High level
GD(H4SO)-212
GENERAL DESCRIPTION
CQ:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION
(HIGH INPUT)
3. ENABLE CONDITION
Judgment Value
puts OFF signal
High level
or
ates
High level
EN-02051
(1)
(2)
(3)
(4)
(5)
(6)
GD(H4SO)-213
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
puts OFF signal
Low level
ates
Low level
GD(H4SO)-214
GENERAL DESCRIPTION
CR:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
For the detection standard, refer to DTC P1492. <Ref. to GD(H4SO)-210, DTC P1492 EGR SOLENOID
VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
CS: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.>
CT:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
teria.>
CU:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
Criteria.>
CV:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
teria.>
CW:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
Criteria.>
GD(H4SO)-215
GENERAL DESCRIPTION
CX:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
Detect the open/short circuit of back-up power supply circuit.
Judge as NG when the backup power voltage is low.
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Voltage of back-up power supply Low
Judgment Value
Voltage of back-up power supply High
GD(H4SO)-216
GENERAL DESCRIPTION
CY:DTC P1570 ANTENNA
NOTE:
For the detection standard, refer to DTC P0513. <Ref. to GD(H4SO)-175, DTC P0513 INCORRECT IMMO-
BILIZER KEY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CZ:DTC P1571 REFERENCE CODE INCOMPATIBILITY
NOTE:
DA:DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)
NOTE:
DB:DTC P1574 KEY COMMUNICATION FAILURE
NOTE:
DC:DTC P1576 EGI CONTROL MODULE EEPROM
NOTE:
DD:DTC P1577 IMM CONTROL MODULE EEPROM
NOTE:
DE:DTC P1578 METER FAILURE
NOTE:
GD(H4SO)-217
GENERAL DESCRIPTION
DF:DTC P1602 CONTROL MODULE PROGRAMMING ERROR
Detect malfunctions of the catalyst advanced idling retard angle control.
Judge as NG when ECM is not controlling the angle properly during catalyst advanced idling retard angle
control.
Judge as NG if there is exhaust gas temperature diagnosis and idle speed diagnosis and if either of them is
NG.
Exhaust gas temperature diagnosis
Judge as NG when the estimated exhausted gas temperature in 14 seconds after the cold start is below the
specified value.
Idle speed diagnosis
Judge as NG when actual engine speed is not close to target engine speed after terminating the retard angle
control.
2. ENABLE CONDITION
Perform the diagnosis at cold start.
Calculate the estimated exhaust gas temperature when the diagnostic enable condition is established. Judge
as NG when the following conditions are established after engine starting within the predetermined time.
Map
U5 model
22.165 inHg)
Cold start diagnosis Incomplete
Misfire within 200 engine revs. < 5
Time after starting = 14 seconds
Judgment Value
Estimated exhaust gas temperature < Value from Map
Coolant temper-
ature after start-
ing the engine
40 C
(40 F)
30 C
(22 F)
20 C
(4 F)
10 C
(14 F)
0 C
(32 F)
10 C
(50 F)
20 C
(68 F)
30 C
(86 F)
40 C
(104 F)
50 C
(122 F)
Threshold value
(AT model)
152 C
(305.6 F)
152 C
(305.6 F)
152 C
(305.6 F)
152 C
(305.6 F)
152 C
(305.6 F)
143 C
(289.4 F)
135 C
(275 F)
127 C
(260.6 F)
121 C
(249.8 F)
118 C
(244.4 F)
Threshold value
(MT model)
135 C
(275 F)
135 C
(275 F)
135 C
(275 F)
135 C
(275 F)
135 C
(275 F)
135 C
(275 F)
134 C
(273.2 F)
129 C
(264.2 F)
126 C
(258.8 F)
119 C
(246.2 F)
GD(H4SO)-218
GENERAL DESCRIPTION
Except for U5
Time Needed for Diagnosis: 14 seconds
cles.
Normality Judgment
Judge as NG when the following conditions are established after the predetermined time.
Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
Normality Judgment
7. FAIL SAFE
None
Coolant tempera-
ture after starting
the engine
40 C
(40 F)
30 C
(22 F)
20 C
(4 F)
10 C
(14 F)
0 C
(32 F)
10 C
(50 F)
20 C
(68 F)
30 C
(86 F)
40 C
(104 F)
50 C
(122 F)
Threshold value
(AT model)
200 C
(392 F)
200 C
(392 F)
200 C
(392 F)
200 C
(392 F)
127 C
(260.6 F)
130 C
(266 F)
127 C
(260.6 F)
114 C
(237.2 F)
111 C
(231.8 F)
117 C
(242.6 F)
Threshold value
(MT model)
200 C
(392 F)
200 C
(392 F)
200 C
(392 F)
200 C
(392 F)
155 C
(311 F)
156 C
(312.8 F)
152 C
(305.6 F)
142 C
(287.6 F)
140 C
(284 F)
140 C
(284 F)
Judgment Value
Estimated exhaust gas temperature Value from Map
Judgment Value
Continuous time of (Target engine speed
Actual engine speed > 100 rpm)
6000 ms
Continuous time of (actual retard amount
> 30 CA)
0 ms
Judgment Value
< 6000 ms
> 30 CA)
< 0 ms
GD(H4SO)-219
GENERAL DESCRIPTION
DG:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1
Detect the malfunction of fuel system from the size of the sub feedback learning value.
Control the sub feedback learning and judge as NG when the learning value is in the lean zone.
3. ENABLE CONDITION
Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km/h (50
MPH) or more.
Conditions for carrying out the sub feed-
back learning
Completed
Continuous time when all conditions are
established.
1 sec
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H4SO)-220
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Sub feedback learning value < 0.04
Judgment Value
Sub feedback learning value 0.04 + 0
GD(H4SO)-221
GENERAL DESCRIPTION
DH:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1
Sub feedback learning is being performed. When the learning value goes to the rich side, judge as NG.
3. ENABLE CONDITION
MPH) or more.
back learning
Completed
established.
1 sec
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H4SO)-222
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Sub feedback learning value 0.028 (U5 model)
0.038
Judgment Value
Sub feedback learning value < 0.028 + 0.002
(U5 model)
< 0.038 + 0.002
GD(H4SO)-223
GENERAL DESCRIPTION
DI: DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/
PERFORMANCE
Judge as NG when the motor current becomes large or drive circuit is heated.
3. ENABLE CONDITION
(1) Engine control module (ECM) (4) Drive circuit (6) Electronic throttle control relay
(2) Detecting circuit (5) Temperature detection circuit (7) Motor
(3) Overcurrent detection circuit
Under control of electronic throttle control ON
EN-01867
(3) (2)
(5) (2)
(4)
(1)
(6)
(7)
12V 12V
GD(H4SO)-224
GENERAL DESCRIPTION
500 milliseconds (For NG)
2000 milliseconds (For OK)
8. FAIL SAFE
Judgment Value
Motor current 8 A
Drive circuit inner temperature 175C (347F)
GD(H4SO)-225
GENERAL DESCRIPTION
DJ: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.
3. ENABLE CONDITION
(1) Engine control module (ECM) (3) Drive circuit (5) Motor
(2) Voltage detection circuit (4) Electronic throttle control relay
Electronic throttle control relay output ON
Judgment Value
Motor power voltage 5 V
EN-01868
(2)
(3)
(1)
(4)
(5)
12V 12V
GD(H4SO)-226
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4SO)-227
GENERAL DESCRIPTION
DK: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 throt-
tle control relay to OFF.
3. ENABLE CONDITION
When ignition switch ON OFF
Electronic throttle control relay output OFF
Judgment Value
Motor power voltage 5 V
EN-01868
(2)
(3)
(1)
(4)
(5)
12V 12V
GD(H4SO)-228
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4SO)-229
GENERAL DESCRIPTION
DL:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP
PERFORMANCE
Judge as NG when full close point learning cannot conducted or abnormal value is detected.
3. ENABLE CONDITION
Perform the diagnosis at full closed point learning.
Time Needed for Diagnosis: 8 80 milliseconds
(1) Engine control module (ECM) (3) Motor (4) Throttle position sensor
(2) Drive circuit
Ignition switch (only after clear memory) OFF ON
Judgment Value
Throttle sensor opening angle at full
close point learning
10.12710.127 or
more, 19.872 or less
Throttle opening angle when the ignition
switch is ON Throttle minimum stop
position
1.683
EN-01869
(1)
(2)
(3)
(4)
GD(H4SO)-230
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4SO)-231
GENERAL DESCRIPTION
DM:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT
LOW INPUT
Detect the open or short circuit of accelerator pedal position sensor 1.
3. ENABLE CONDITION
(1) Engine control module (ECM) (3) Accelerator pedal position sensor
2 signal
(4) Accelerator pedal position sensor
1 signal
Ignition switch ON
Battery voltage 6 V
EN-01861
(2)
(3)
(4)
(1)
GD(H4SO)-232
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Single malfunction: Control with normal sensor
Simultaneous failure: Throttle opening is fixed to 6.
Judgment Value
Judgment Value
GD(H4SO)-233
GENERAL DESCRIPTION
DN:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT
HIGH INPUT
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
Battery voltage 6 V
EN-01861
(2)
(3)
(4)
(1)
GD(H4SO)-234
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4SO)-235
GENERAL DESCRIPTION
DO:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT
LOW INPUT
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
Battery voltage 6 V
EN-01861
(2)
(3)
(4)
(1)
GD(H4SO)-236
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4SO)-237
GENERAL DESCRIPTION
DP:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT
HIGH INPUT
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
Battery voltage 6 V
EN-01861
(2)
(3)
(4)
(1)
GD(H4SO)-238
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4SO)-239
GENERAL DESCRIPTION
DQ: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. ENABLE CONDITION
Ignition switch ON
Battery voltage 6 V
EN-01859
(1)
(2)
(3)
(4)
GD(H4SO)-240
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Signal difference between two sensors > Value from Map
Map
Throttle position sensor 1
opening angle () = d
0 d < 2.125 deg
2.125 deg d <
4.25 deg
4.25 deg d < 9
deg
9 deg d < 31.625
deg
31.625 deg d
Sensor output difference () 5.15 deg 6.15 deg 8.28 deg 10.4 deg 12.4 deg
Judgment Value
Signal difference between two sensors Value from Map
GD(H4SO)-241
GENERAL DESCRIPTION
DR:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E
VOLTAGE CORRELATION
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
Battery voltage 6 V
EN-01861
(2)
(3)
(4)
(1)
GD(H4SO)-242
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Signal difference between two sensors > Map
Map
0 d < 0.6 deg
0.6 deg d < 1.2
deg
1.2 deg d < 2
deg
2 deg d < 4 deg 4 deg d
Judgment Value
Signal difference between two sensors Map
GD(H4SO)-243
GENERAL DESCRIPTION
DS:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE
Detect the malfunction of barometric pressure sensor output property.
Judge as NG when the barometric pressure sensor output is largely different from the intake manifold pres-
sure at engine start.
The barometric pressure sensor is built into the ECM.
3. ENABLE CONDITION
Perform the diagnosis once at ignition switch ON.
cles.
Normality Judgment
8. FAIL SAFE
Barometric pressure sensor process: Fix the barometric pressure to 101 kPa (760 mmHg, 29.8 inHg).
Judgment Value
|Barometric pressure Intake manifold
pressure|
26.66 kPa (200
mmHg, 7.874 inHg)
|Intake manifold pressure at engine start
Intake manifold pressure|
< 1.33 kPa (9.99
mmHg, 0.393 inHg)
Judgment Value
pressure|
< 26.66 kPa (200
mmHg, 7.874 inHg)
GD(H4SO)-244
GENERAL DESCRIPTION
DT:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW
Detect the open/short circuit of the barometric pressure sensor.
3. ENABLE CONDITION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4SO)-245
GENERAL DESCRIPTION
DU:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH
3. ENABLE CONDITION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4SO)-246
GENERAL DESCRIPTION
FU(H4DOTC)-2
General Description
A: SPECIFICATION
Fuel tank
Location Under rear seat
Fuel pump
Type Impeller
2
, 79.8 123.3 psi)
Discharge rate
155 2 (40.9 US gal, 34.1 Imp gal)/h or more.
[12 V at 300 kPa (3.06 kg/cm
2
, 43.5 psi)]
Fuel filter In-tank type
FU(H4DOTC)-3
General Description
B: COMPONENT
1. INTAKE MANIFOLD
FU-03082
(8)
(9)
(9)
T2
T2
T5
T5
T2
(7)
(7)
(8)
T3
(17)
(18)
(16)
(15)
(11)
(11)
(21)
(10)
(10)
(22)
(11)
T3
(23)
(23)
(24)
(4)
(5)
(12)
(25)
(26)
(6)
T2
T2
B
B
A
A
(19)
(20)
(27)
(14)
(10)
(3)
(2)
(3)
(1)
(13)
T4
T4
T4 T4
T2
T2
T1
T2
T4 T1
T4
T4
T4
(11)
FU(H4DOTC)-4
General Description
(1) Pressure regulator (13) Fuel injector pipe LH (24) Solenoid valve bracket
(2) Fuel hose (14) Fuel injector pipe RH (25) Vacuum hose B
(3) Clamp (15) Solenoid valve bracket (26) Vacuum hose A
(4) Purge control solenoid valve 1 (16) Manifold absolute pressure sensor (27) Air control hose
(5) Vacuum hose D (17) Filter
(6) Vacuum hose C (18) Intake manifold Tightening torque:Nm (kgf-m, ft-lb)
(7) Intake manifold gasket (19) Wastegate control solenoid valve
ASSY
T1: 1.25 (0.13, 0.94)
(8) Guide pin T2: 6.4 (0.65, 4.7)
(9) Intake manifold (lower) (20) Vacuum hose T3: 8.3 (0.85, 6.1)
(10) Fuel injector (21) Fuel pipe protector LH T4: 19 (1.9, 14.0)
(11) Seal ring (22) Fuel pipe protector RH T5: 25 (2.5, 18.4)
(12) Purge control solenoid valve 2 (23) O-ring
(1) O-ring (2) Throttle body Tightening torque:Nm (kgf-m, ft-lb)
T: 8 (0.8, 5.9)
FU-03017
T
(1)
(2)
FU(H4DOTC)-5
General Description
(1) Crankshaft position sensor (4) Camshaft position sensor RH Tightening torque:Nm (kgf-m, ft-lb)
(2) Knock sensor T1: 6.4 (0.65, 4.7)
(3) Camshaft position sensor LH T2: 24 (2.4, 17.7)
FU-03083
(4)
(3)
(2)
(1)
T1
T1
T2
T1
FU(H4DOTC)-6
General Description
4. FUEL TANK
FU-03237
T4
T1
T4
T3
T3
T3
T2
T3
T3
T4
T1
(16)
(14)
(15)
(15)
(17)
(18)
(17)
(6)
(21)
(5)
(4)
(3)
(22)
(23)
(24)
(2)
(19)
(20)
(11)
(12)
(13)
(8)
(7)
(10)
(17)
(17)
(30)
(9)
(1)
T2
T3
(21)
(17)
(25)
(26)
(27)
(17)
(29)
(28)
(32)
(31)
(17)
(33)
(34)
FU(H4DOTC)-7
General Description
(1) Fuel tank (15) Clamp (28) Evaporation hose D
(2) Fuel tank band RH (16) Evaporation hose A (29) Evaporation pipe
(3) Fuel tank band LH (17) Clip (30) Evaporation hose E
(4) Delivery tube (18) Fuel tank protector LH (Rear) (31) Evaporation hose F
(5) Return tube (19) Stopper RH (32) Fuel sub level sensor filter
(6) Jet pump tube (20) Stopper LH (33) Fuel sub level sensor protector
(7) Fuel pump ASSY (21) Retainer (34) Clip
(8) Fuel pump upper plate (22) Heat shield cover
(9) Fuel pump gasket (23) Fuel tank protector RH (Front) Tightening torque:Nm (kgf-m, ft-lb)
(10) Fuel level sensor (24) Fuel tank protector LH (Front) T1: 4.4 (0.45, 3.2)
(11) Fuel sub level sensor (25) Evaporation hose B T2: 9 (0.9, 6.6)
(12) Fuel sub level sensor upper plate (26) Connector T3: 17.5 (1.78, 12.9)
(13) Fuel sub level sensor gasket (27) Evaporation hose C T4: 33 (3.4, 25)
(14) Fuel filler hose
FU(H4DOTC)-8
General Description
5. FUEL LINE
B
A
C
(27)
(24)
(29)
(23)
(23)
(23)
(23)
(22)
(23)
(39)
(28)
(30)
(26)
(25)
(38)
(38)
T2
T4
T1
T2
T1
T2
T6
T2
T6
T3
(21)
(19)
(17)
(16)
(1)
(1)
(1)
(32)
(33)
(1)
(34)
(31)
(20)
(18)
T2
T2
(33)
(1)
(43)
(23)
(42)
(40) (41)
T2
(23)
(37)
(36)
(31)
(23)
C
FU-03292
(1)
(5)
(1)
(3)
(4)
(2)
(8)
(13)
T5
(35)
T5
T2
(6)
(7)
(13)
(13)
T5
(35)
T5
D
D
B
A
(9)
(1)
(11)
(10)
(12)
(14)
(15)
(1)
(13)
(1)
T5
(13)
T2
FU(H4DOTC)-9
General Description
C: CAUTION
forming any work.
points.
the battery.
ing area.
(1) Clip (18) Drain filter (35) Fuel damper valve
(2) Fuel delivery hose A (19) Canister protector (36) Drain hose
(3) Evaporation hose A (20) Pressure control solenoid valve (37) Drain hose connector
(4) Fuel return hose A (21) Evaporation pipe A (38) Evaporation hose C
(5) Fuel return hose B (22) Evaporation pipe B (39) Evaporation hose D
(6) Fuel damper valve holder (23) Clip (40) Retainer
(7) Fuel damper valve bracket (24) Fuel filler pipe (41) Evaporation tube
(8) Fuel delivery hose B (25) Shut valve (42) Evaporation hose E
(9) Fuel pipe ASSY A (26) Gasket (43) Quick connector check cover
(10) Fuel delivery hose C (27) Filler ring
(11) Fuel return hose C (28) Fuel filler cap Tightening torque:Nm (kgf-m, ft-lb)
(12) Evaporation hose B (29) Fuel tank pressure sensor T1: 4.4 (0.45, 3.2)
(13) Clamp (30) Evaporation pipe protector T2: 7.5 (0.76, 5.5)
(14) Grommet (31) Connector A T3: 8 (0.8, 5.9)
(15) Fuel pipe ASSY B (32) Canister hose A T4: 17.6 (1.8, 13)
(16) Canister (33) Connector B T5: 1.25 (0.13, 0.94)
(17) Drain valve (34) Canister hose B T6: 1.0 (0.1, 0.7)
FU(H4DOTC)-10
General Description
D: PREPARATION TOOL
REMOVER
Used for disconnecting quick connector on the
fuel delivery hose side of the engine compart-
ment.
18371AA000 CONNECTOR
REMOVER
Used for disconnecting the quick connector on
the fuel return hose of the engine compartment.
hose.
This is a general tool made by the French com-
pany CAILLAU. (code) 54.0.000.205
18471AA000
FUEL PIPE
ADAPTER
Used for draining fuel.
ST42099AE000
ST18371AA000
ST18353AA000
ST18471AA000
FU(H4DOTC)-11
Throttle Body
2. Throttle Body
A: REMOVAL
1) Remove the collector cover.
3) Remove the intercooler. <Ref. to IN(H4DOTC)-
12, REMOVAL, Intercooler.>
4) Disconnect the connectors from the throttle posi-
tion sensor.
5) Remove the bolts which secure the air by-pass
pipe and PCV pipe to the intake manifold, and loos-
en the clamp which connects the throttle body and
duct.
6) Remove the duct from the throttle body.
throttle body.
8) Remove the bolts which secure the throttle body
to the intake manifold, and remove the throttle
body.
B: INSTALLATION
NOTE:
Use new O-rings.
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
IN-00203
FU-01157
FU-03020
FU-01158
FU-01159
FU(H4DOTC)-12
Intake Manifold
3. Intake Manifold
A: REMOVAL
<Ref. to FU(H4DOTC)-50, RELEASING OF FUEL
filler cap.
8) Drain approximately 3.0 2 (3.2 US qt, 2.6 Imp
qt) of coolant.
9) Remove the intake duct from the air cleaner
case.
12) Remove the coolant filler tank. <Ref. to
CO(H4DOTC)-29, REMOVAL, Coolant Filler Tank.>
13) Disconnect the emission hose (A) and the con-
nector (B) from the PCV hose assembly.
14) Remove the bolts which secure the air by-pass
pipe and PCV pipe to the intake manifold, and loos-
en the clamp which connects the throttle body and
duct.
15) Remove the duct from the throttle body.
throttle body.
IN-00203
FU-02340
(A)
FU-02339
(B)
FU-03020
FU-01158
FU(H4DOTC)-13
Intake Manifold
17) Disconnect the brake booster hose.
18) Fit the cut out in the ST with the protrusion on
the clamp to unlock, and disconnect the PCV hose
from the rocker cover.
19) Disconnect the engine harness connectors
from the bulk head harness connector.
20) Disconnect the connectors from the engine
coolant temperature sensor (A), oil pressure switch
(B) and crankshaft position sensor (C).
21) Disconnect the connector from power steering
pump switch.
23) Disconnect the connector from the secondary
air combination valve.
FU-02341
FU-03116
FU-02436
(A)
(B)
(C)
FU-00027
FU-03022
FU-01164
FU-03023
FU(H4DOTC)-14
Intake Manifold
24) Disconnect the connector from the camshaft
position sensor.
25) Disconnect the connector from the oil flow con-
26) Disconnect the connector from ignition coil.
27) Remove the engine harness fixed by clip (A)
from the rocker cover.
delivery hose.
CAUTION:
or cloth.
29) Disconnect the fuel return hose using the ST.
ST 18371AA000 CONNECTOR REMOVER
CAUTION:
or cloth.
(1) Attach ST to the fuel return pipe as shown in
the figure.
(2) Insert the front side of ST into the quick con-
nector.
FU-01165
ME-03094
IG-00092
FU-03025
(A)
(B) Fuel return hose
(C) Evaporation hose
FU-03095
(A)
(B)
(C)
ST
FU-03092
ST
FU-03113
ST
FU(H4DOTC)-15
Intake Manifold
(3) Insert the back side of ST into the quick con-
nector and push ST in the direction of arrow
mark to disconnect the fuel return hose.
30) Remove the clip and disconnect the evapora-
tion hose from the fuel pipe.
31) Remove the bolts which hold the tumble gener-
ator valve assembly onto the cylinder head.
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
2) Connect the fuel delivery hose, return hose, and
evaporation hose.
<Ref. to FU(H4DOTC)-71, INSTALLATION, Fuel
Delivery, Return and Evaporation Lines.>
NOTE:
If fuel hoses or clamps are damaged, replace them
with new parts.
3) Connect the connector to the oil flow control so-
lenoid valve.
FU-03114
ST
FU-03105
FU-03085
FU-03085
FU-03106
(A)
(B)
(C)
ME-03094
FU(H4DOTC)-16
Intake Manifold
4) Connect the connector to the engine coolant
temperature sensor (A), oil pressure switch (B) and
crankshaft position sensor (C).
5) Connect the connector to the knock sensor.
6) Connect the connector to the power steering
pump switch.
7) Connect the connectors to camshaft position
sensor.
8) Connect the connector to the secondary air com-
bination valve.
9) Connect the connector to the ignition coil.
10) Install the engine harness with clip (A) to the
rocker cover.
(A)
(B)
(C)
FU-00027
FU-01164
FU-03022
FU-01165
FU-03023
IG-00092
FU-03025
(A)
FU(H4DOTC)-17
Intake Manifold
11) Connect the engine harness connectors to the
bulkhead harness connectors.
12) Connect the brake booster hose.
13) Connect the PCV hose to the rocker cover and
lock it by fitting the clamp protrusion using ST.
NOTE:
Use a new clamp.
14) Connect the engine coolant hoses to throttle
body.
15) Install the duct to the throttle body.
16) Attach the bolts which secure the air by-pass
pipe and PCV pipe to the intake manifold.
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
17) Connect the emission hose (A) and the con-
nector (B) to the PCV hose assembly.
18) Install the coolant filler tank.
<Ref. to CO(H4DOTC)-29, INSTALLATION, Cool-
ant Filler Tank.>
19) Install the intercooler. <Ref. to IN(H4DOTC)-
12, INSTALLATION, Intercooler.>
20) Install the intake duct to the air cleaner case.
21) Install the fuse of fuel pump to the main fuse
box.
22) Connect the battery ground cable to the bat-
tery.
25) Fill engine coolant. <Ref. to CO(H4DOTC)-13,
26) Install the collector cover.
FU-02436
FU-02341
FU-03116
FU-01158
FU-03028
FU-02339
(B)
FU-02340
(A)
FU(H4DOTC)-18
Intake Manifold
C: DISASSEMBLY
1) Remove the engine ground terminal from the
fuel pipe protector LH and remove the fuel pipe pro-
tector LH from the intake manifold.
2) Remove the fuel pipe protector RH from the in-
take manifold.
3) Disconnect the evaporation hose and the con-
nector from the purge control solenoid valve 1, and
remove the purge control solenoid valve 1 from the
intake manifold.
4) Disconnect the filter assembly.
5) Remove the solenoid valve bracket assembly
from the intake manifold, and disconnect the con-
nector from the wastegate control solenoid valve,
manifold absolute pressure sensor and purge con-
trol solenoid valve 2.
6) Disconnect the evaporation hose of the purge
control solenoid valve 2 from the intake duct and
fuel pipe assembly.
7) Disconnect the connectors from the throttle posi-
tion sensor.
8) Remove the throttle body from the intake mani-
fold.
FU-03086
FU-03087
FU-03031
FU-03030
EC-00219
FU-01157
FU-01159
FU(H4DOTC)-19
Intake Manifold
9) Disconnect the connector from the fuel injector
and the tumble generator valve assembly.
10) Remove the PCV pipe (A), harness assembly
(B) and intake duct (C) from the intake manifold.
11) Remove the bolt which secures the fuel injector
pipe LH onto the front side of intake manifold, and
disconnect the pressure regulator vacuum hose
from the intake manifold.
RH side
LH side
13) Remove the fuel injector.
RH side
LH side
FU-03088
FU-03033
(C)
(A)
(B)
FU-03108
FU-03089
FU-03090
FU-03094
FU-03091
FU(H4DOTC)-20
Intake Manifold
15) Remove the bolt which secures fuel injector
pipe RH onto the lower side of the intake manifold.
16) Loosen the clamp which holds the fuel hose to
the fuel injector pipe, and then disconnect the fuel
hose from pipe.
17) Remove the fuel injector pipe.
18) Remove the tumble generator valve assembly
from the intake manifold.
D: ASSEMBLY
1) Install the tumble generator valve assembly onto
intake manifold.
NOTE:
Use new O-rings.
Tightening torque:
8.3 Nm (0.85 kgf-m, 6.1 ft-lb)
2) Install the fuel injector pipe.
3) Connect fuel hoses to fuel injector pipes on both
sides, and secure them with the clamps.
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
4) Tighten the bolts which secure the fuel injector
pipe RH to the lower side of the intake manifold.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-03109
FU-03110
FU-03111
FU-03039
FU-03039
FU-03111
FU-03110
FU(H4DOTC)-21
Intake Manifold
5) Tighten the bolts which secure fuel injector pipe
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6) Install the fuel injector.
RH side
LH side
7) Tighten the bolts which secure fuel injector pipe
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
LH side
RH side
8) Tighten the bolt which holds the fuel injector pipe
LH to the front side of the intake manifold, and con-
nect the pressure regulator vacuum hose to the in-
take manifold.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-03109
FU-03094
FU-03091
FU-03090
FU-03089
FU-03108
FU(H4DOTC)-22
Intake Manifold
9) Install PCV pipe (A), harness assembly (B) and
intake duct (C) to the intake manifold.
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
10) Connect the connector to the fuel injector and
the tumble generator valve assembly.
11) Install the throttle body to the intake manifold.
NOTE:
Use new O-rings.
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
12) Connect the connector to the throttle position
sensor.
13) Connect the evaporation hose to the purge
control solenoid valve 2.
NOTE:
ure.
FU-03033
(C)
(A)
(B)
FU-03088
FU-01159
(A) Purge control solenoid valve 1
(B) Purge control solenoid valve 2
(a) To intake manifold
(b) To intake duct
(c) To fuel pipe
FU-01157
EC-02201
(A)
(B)
(b)
(c)
(c) (a)
FU(H4DOTC)-23
Intake Manifold
14) Connect the connectors to the wastegate con-
trol solenoid valve, manifold absolute pressure
sensor and purge control solenoid valve 2, and in-
stall the solenoid valve bracket assembly to the in-
take manifold.
Tightening torque:
T1: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
T2: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
15) Connect the filter assembly.
16) Connect the evaporation hose and the connec-
tor to the purge control solenoid valve 1, and install
the purge control solenoid valve 1 to the intake
manifold.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
NOTE:
ure.
EC-02252
T2
T1
FU-03030
(A) Purge control solenoid valve 1
(B) Purge control solenoid valve 2
(b) To intake duct
(c) To fuel pipe
FU-03031
EC-02201
(A)
(B)
(b)
(c)
(c) (a)
FU(H4DOTC)-24
Intake Manifold
17) Install the fuel pipe protector RH to the intake
manifold.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
18) Install the fuel pipe protector LH to the intake
manifold, and install the engine ground terminal to
the fuel pipe protector LH.
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 that the connections are tight.
FU-03087
FU-03086
FU(H4DOTC)-25
Sensor
A: REMOVAL
4) Drain engine coolant. <Ref. to CO(H4DOTC)-
13, DRAINING OF ENGINE COOLANT, RE-
PLACEMENT, Engine Coolant.>
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
IN-00203
FU-00055
FU(H4DOTC)-26
A: REMOVAL
4) Remove the bolt which installs crankshaft posi-
tion sensor to cylinder block.
5) Remove the crankshaft position sensor, and
then disconnect the connector from it.
B: INSTALLATION
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203
FU-00056
FU-00057
FU-00058
T
FU(H4DOTC)-27
A: REMOVAL
3) Disconnect the connector from camshaft posi-
tion sensor RH.
4) Remove the camshaft position sensor RH from
the rear side of the cylinder head.
5) Remove the cam shaft position sensor LH in the
same way as RH.
B: INSTALLATION
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203
FU-01185
FU(H4DOTC)-28
Knock Sensor
7. Knock Sensor
A: REMOVAL
block.
B: INSTALLATION
1) Install the knock sensor to the cylinder block.
NOTE:
The portion of the knock sensor cord that is pulled
out must be positioned at a 60 angle relative to the
engine rear.
Tightening torque:
24 Nm (2.4 kgf-m, 17.7 ft-lb)
3) Install the intercooler.
<Ref. to IN(H4DOTC)-12, INSTALLATION, Inter-
cooler.>
4) Connect the battery ground cable to the battery.
IN-00203
FU-01164
FU-00519
(A) Front side
FU-00413
(A)
60
FU-01164
IN-00203
FU(H4DOTC)-29
A: SPECIFICATION
body.
Refer to Throttle Body for removal and installation
procedure. <Ref. to FU(H4DOTC)-11, REMOVAL,
Throttle Body.> <Ref. to FU(H4DOTC)-11, IN-
STALLATION, Throttle Body.>
FU(H4DOTC)-30
9. Mass Air Flow and Intake Air
Temperature Sensor
A: REMOVAL
2) Disconnect the connector from the mass air flow
and intake air temperature sensor.
ature sensor.
B: INSTALLATION
Tightening torque:
1 Nm (0.1 kgf-m, 0.7 ft-lb)
IN-00203
FU-01187
FU(H4DOTC)-31
10.Manifold Absolute Pressure
Sensor
A: REMOVAL
3) Disconnect the connector from manifold abso-
lute pressure sensor (A), and remove the filter as-
sembly (B) from intake manifold.
from the solenoid valve bracket.
B: INSTALLATION
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203
(A)
FU-01188
(B)
FU(H4DOTC)-32
Fuel Injector
11.Fuel Injector
A: REMOVAL
1. RH SIDE
filler cap.
FU(H4DOTC)-12, REMOVAL, Intake Manifold.>
6) Remove the fuel pipe protector RH from the in-
take manifold.
2. LH SIDE
filler cap.
6) Remove the engine ground terminal from the
fuel pipe protector LH and remove the fuel pipe pro-
tector LH from the intake manifold.
IN-00203
FU-03087
FU-03089
FU-03094
IN-00203
FU-03086
FU(H4DOTC)-33
Fuel Injector
FU-03034
FU-03090
FU-03091
FU(H4DOTC)-34
Fuel Injector
B: INSTALLATION
1. RH SIDE
NOTE:
Use new O-rings.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
2. LH SIDE
NOTE:
Use new O-rings.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
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-03089
FU-03087
FU-03090
FU-03034
FU-03086
FU(H4DOTC)-35
Tumble Generator Valve Assembly
12.Tumble Generator Valve
Assembly
A: REMOVAL
1) Release the fuel pressure. <Ref. to
FU(H4DOTC)-50, RELEASING OF FUEL PRES-
SURE, PROCEDURE, Fuel.>
filler cap.
<Ref. to FU(H4DOTC)-12, REMOVAL, Intake Man-
ifold.>
6) Disconnect the connector from the tumble gen-
erator valve assembly.
<Ref. to FU(H4DOTC)-32, REMOVAL, Fuel Injec-
tor.>
8) Remove the tumble generator valve body from
intake manifold.
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
8.3 Nm (0.85 kgf-m, 6.1 ft-lb)
IN-00203
FU-03093
FU-03039
FU-03039
FU(H4DOTC)-36
Tumble Generator Valve Actuator
Actuator
A: SPECIFICATION
The tumble generator valve assembly cannot be
disassembled.
Refer to Tumble Generator Valve Assembly for
removal and installation procedure. <Ref. to
FU(H4DOTC)-35, REMOVAL, Tumble Generator
Valve Assembly.> <Ref. to FU(H4DOTC)-35, IN-
STALLATION, Tumble Generator Valve Assem-
bly.>
FU(H4DOTC)-37
Tumble Generator Valve Position Sensor
Position Sensor
A: SPECIFICATION
The tumble generator valve assembly cannot be
disassembled.
Refer to Tumble Generator Valve Assembly for
removal and installation procedure. <Ref. to
FU(H4DOTC)-35, REMOVAL, Tumble Generator
Valve Assembly.> <Ref. to FU(H4DOTC)-35, IN-
STALLATION, Tumble Generator Valve Assem-
bly.>
FU(H4DOTC)-38
Oil Flow Control Solenoid Valve
15.Oil Flow Control Solenoid
Valve
A: REMOVAL
Oil flow control solenoid valve is a unit with cam-
shaft cap.
Refer to Camshaft for removal procedure. <Ref.
to ME(H4DOTC)-53, REMOVAL, Camshaft.>
B: INSTALLATION
Refer to Camshaft for installation procedure.
<Ref. to ME(H4DOTC)-54, INSTALLATION, Cam-
shaft.>
C: DISASSEMBLY
1) Remove the 2 mounting bolts and remove the oil
return cover and gasket.
2) Remove the mounting bolt and remove the oil
flow control solenoid valve.
D: ASSEMBLY
1) Install the oil flow control solenoid valve.
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
2) Apply liquid gasket to the two bolts which secure
the oil return cover.
Liquid gasket:
equivalent
3) Attach the oil return cover and gasket.
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
NOTE:
Use a new gasket.
(A) Oil flow control solenoid valve
(B) Oil return cover
(C) Gasket
(D) Camshaft cap
FU-03158
(A)
(D)
(C)
(B)
(A) Oil flow control solenoid valve
(B) Oil return cover
(C) Gasket
(D) Camshaft cap
FU-03158
(A)
(D)
(C)
(B)
FU(H4DOTC)-39
Wastegate Control Solenoid Valve
16.Wastegate Control Solenoid
Valve
A: REMOVAL
3) Disconnect the connector from the wastegate
control solenoid valve (A).
4) Disconnect pressure hose (B) from the waste-
gate control solenoid valve.
5) Remove the wastegate control solenoid valve
from the bracket
B: INSTALLATION
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203
FU-01192
(A)
(B)
FU(H4DOTC)-40
A: REMOVAL
IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.>
4) Disconnect the connector from front oxygen (A/
F) sensor.
5) Remove the front right side wheel.
8) Apply spray-type lubricant or equivalent to the
threaded portion of front oxygen (A/F) sensor, and
leave it for one minute or more.
CAUTION:
When removing the oxygen (A/F) sensor, wait
until exhaust pipe cools, otherwise it will dam-
age the exhaust pipe.
IN-00203
FU-03235
FU-00783
FU-00080
FU(H4DOTC)-41
B: INSTALLATION
ply the anti-seize compound only to the threaded
portion of front oxygen (A/F) sensor. This facilitates
the next removal.
CAUTION:
equivalent
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
3) Install the service hole cover.
5) Install the front right side wheel.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
sensor.
7) Install the air cleaner case. <Ref. to IN(H4DOTC)-
8, INSTALLATION, Air Cleaner Case.>
FU-00080
FU-00783
FU-03235
IN-00203
FU(H4DOTC)-42
Rear Oxygen Sensor
A: REMOVAL
4) Disconnect the connector from the rear oxygen
sensor.
5) Apply spray-type lubricant or equivalent to the
threaded portion of rear oxygen sensor, and leave
it for one minute or more.
CAUTION:
When removing the rear oxygen sensor, wait
B: INSTALLATION
1) Before installing rear oxygen (A/F) sensor, apply
the anti-seize compound only to the threaded por-
tion of rear oxygen (A/F) sensor. This facilitates the
next removal.
CAUTION:
equivalent
Tightening torque:
21 Nm (2.1 kgf-m, 15.5 ft-lb)
3) Connect the connector to rear oxygen sensor.
IN-00203
FU-01194
FU-01194
IN-00203
FU(H4DOTC)-43
SI-DRIVE (SUBARU Intelligent Drive) Selector
19.SI-DRIVE
(SUBARU Intelligent Drive)
Selector
A: REMOVAL
2) Remove the console box. <Ref. to EI-54, RE-
MOVAL, Console Box.>
3) Disconnect the connectors from the SI-DRIVE
selector.
4) Remove the screws securing the upper side of
the SI-DRIVE selector to the console box.
5) Remove the screws which secure the cup holder
to the console box, then remove the SI-DRIVE se-
lector.
B: INSTALLATION
C: INSPECTION
Measure the resistance between SI-DRIVE selec-
tor terminals.
IN-00203
AT-03718
AT-03719
Switch position Terminal No. Standard
Sport (when turning
the SI-DRIVE selector
to the left)
2 and 3
Less than 10
Intelligent
(when pushing the SI-
DRIVE selector)
0.8 1.2 k
Sport Sharp
(when turning the SI-
DRIVE selector to the
right)
2.14 3.2 k
FU-03123
2 3 4 1 5
FU(H4DOTC)-44
SI-DRIVE (SUBARU Intelligent Drive) S# Switch
20.SI-DRIVE
(SUBARU Intelligent Drive)
S# Switch
A: REMOVAL
2) Remove the airbag module. <Ref. to AB-14, RE-
MOVAL, Drivers Airbag Module.>
WARNING:
Always refer to Airbag System before per-
forming service on the airbag modules. <Ref. to
AB-4, CAUTION, General Description.>
3) Remove the screw which holds SI-DRIVE S#
switch to the steering wheel, and disconnect the
connector from the SI-DRIVE S# switch.
B: INSTALLATION
C: INSPECTION
Measure the resistance between SI-DRIVE S#
switch terminals.
IN-00203
FU-03122
Switch position Terminal No. Standard value
ON (When the SI-
DRIVE S# switch is
pressed)
3 and 4
Less than 10
OFF 1 M or more
2 3 4 1
FU-03121
FU(H4DOTC)-45
A: REMOVAL
side.
<Ref. to EI-61, REMOVAL, Lower Inner Trim.>
to the bracket.
the ECM.
B: INSTALLATION
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 (0.8 kgf-m, 5.5 ft-lb)
IN-00203
FU-00896
FU-02612
(A)
FU(H4DOTC)-46
Main Relay
22.Main Relay
A: REMOVAL
AL, Glove Box.>
B: INSTALLATION
IN-00203
FU-02092
(A)
FU-02093
FU(H4DOTC)-47
Fuel Pump Relay
23.Fuel Pump Relay
A: REMOVAL
AL, Glove Box.>
B: INSTALLATION
IN-00203
FU-02092
(A)
FU-02094
FU(H4DOTC)-48
Relay
A: REMOVAL
AL, Glove Box.>
control relay.
B: INSTALLATION
IN-00203
FU-02092
(A)
FU-02095
FU(H4DOTC)-49
Fuel Pump Control Unit
25.Fuel Pump Control Unit
A: REMOVAL
2) Remove the rear quarter trim of the left side.
(Wagon model) <Ref. to EI-63, REMOVAL, Rear
Quarter Trim.>
3) Peel the trunk side trim of the left side. (Sedan
model)
4) Remove the fuel pump control unit.
WAGON MODEL
SEDAN MODEL
5) Disconnect the connector from fuel pump control
unit.
B: INSTALLATION
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
IN-00203
FU-03220
FU-03231
FU(H4DOTC)-50
Fuel
26.Fuel
A: PROCEDURE
WARNING:
working area.
CAUTION:
box.
onds.
LECT MONITOR)
WARNING:
working area.
CAUTION:
NOTE:
If the fuel pump cannot be actuated, refer to
DRAINING FUEL (THROUGH THE FUEL FILLER
HOSE) <Ref. to FU(H4DOTC)-51, DRAINING
FUEL (THROUGH THE FUEL FILLER HOSE),
PROCEDURE, Fuel.>.
Be careful not to allow the battery to go flat.
1) Release the fuel pressure. <Ref. to FU(H4DOTC)-
DURE, Fuel.>
delivery hose.
CAUTION:
or cloth.
4) Connect the gasoline proof hose to ST, and put
the hose end into the container.
5) Actuate the fuel pump and drain the fuel using
Subaru Select Monitor <Ref. to EN(H4DOTC)(diag)-
60, FUEL PUMP CONTROL (ON/OFF DRIVE), OP-
ERATION, System Operation Check Mode.>.
CAUTION:
FU-01122
FU-03095
(A)
(B)
(C)
ST
FU(H4DOTC)-51
Fuel
FILLER HOSE)
WARNING:
working area.
CAUTION:
Fuel may remain in the fuel filler pipe. Per-
form the work after draining the fuel from the
fuel filler pipe through the fill opening using the
gasoline proof pump and the gasoline proof
hose (10 or less).
<Ref. to EX(H4DOTC)-13, REMOVAL, Rear Ex-
haust Pipe.> <Ref. to EX(H4DOTC)-15, REMOV-
AL, Muffler.>
filler cap.
filler pipe.
CAUTION:
or cloth.
7) Set a container under the vehicle and insert the
gasoline proof hose (10 or less) into the fuel filler
hose to drain the fuel.
CAUTION:
(A)
FU-02394
(B)
FU(H4DOTC)-52
Fuel Tank
27.Fuel Tank
A: REMOVAL
WARNING:
working area.
CAUTION:
3) Drain fuel from fuel tank.
<Ref. to FU(H4DOTC)-50, DRAINING FUEL
(WITH SUBARU SELECT MONITOR), PROCE-
DURE, Fuel.>
sensor.
service hole cover.
sensor.
10) Disconnect the quick connector of fuel delivery
(B) and return hose (C). <Ref. to FU(H4DOTC)-69,
REMOVAL, Fuel Delivery, Return and Evaporation
Lines.>
Quarter Trim.>
FU-02387
FU-02388
FU-02389
(B)
(A)
FU-01126
(B)
(A)
(A)
FU-01127
(A)
(B)
(C)
FU-02390
FU(H4DOTC)-53
Fuel Tank
FU(H4DOTC)-69, REMOVAL, Fuel Delivery, Re-
turn and Evaporation Lines.>
haust Pipe.>
wheel speed sensor.
cable clamp.
FU-02391
FU-01128
FU-00462
FU-02894
FU-02895
FU-02896
FU(H4DOTC)-54
Fuel Tank
WARNING:
mission jack.
tion hose (B).
WARNING:
Fuel may remain in the fuel tank. Be careful
not to let the fuel tank fall off when removing as
it is bad balance on either side.
FU-01132
FU-01133
FU-03100
FU-02392
FU-02393
(A)
FU-02394
(B)
FU-03293
FU(H4DOTC)-55
Fuel Tank
B: INSTALLATION
WARNING:
en the clamp.
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
(1) Hose
(2) Clip or clamp
(3) Pipe
FU-03293
(A)
FU-02394
(B)
( 1 )
( 2 ) ( 3 )
FU-00104
L
L/2
FU-02393
FU-02392
FU(H4DOTC)-56
Fuel Tank
CAUTION:
mission jack.
Tightening torque:
T1: 125 Nm (12.7 kgf-m, 92.2 ft-lb)
T2: 175 Nm (17.8 kgf-m, 129 ft-lb)
Tightening torque:
62 Nm (6.3 kgf-m, 46 ft-lb)
clamp.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
speed sensor.
11) Install the rear exhaust pipe. <Ref. to
EX(H4DOTC)-13, INSTALLATION, Rear Exhaust
Pipe.>
FU-01150
T1
T1
T1
T1
FU-03101
T2
T2
FU-01132
FU-02895
FU-02896
FU-02894
FU(H4DOTC)-57
Fuel Tank
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
pipe. <Ref. to FU(H4DOTC)-71, INSTALLATION,
Fuel Delivery, Return and Evaporation Lines.>
Tightening torque:
T1:1 Nm (0.1 kgf-m, 0.7 ft-lb)
T2: 7.5 Nm (0.7 kgf-m, 5.5 ft-lb)
Trim.>
Trim.>
sor.
22) Connect the quick connector of fuel delivery (B)
and return hose (C). <Ref. to FU(H4DOTC)-71, IN-
STALLATION, Fuel Delivery, Return and Evapora-
tion Lines.>
NOTE:
When connecting, be careful not to reverse the de-
livery side and return side.
sensor.
FU-01128
FU-02391
FU-02868
T2
T1
(A) Bolt
(B) Grommet
FU-01127
(A)
(B)
(C)
FU-01126
(B)
(A)
(A)
FU-02389
(B)
(A)
FU(H4DOTC)-58
Fuel Tank
C: INSPECTION
cracks or is damaged in any other way.
FU-02388
FU-02387
FU(H4DOTC)-59
Fuel Filler Pipe
28.Fuel Filler Pipe
A: REMOVAL
WARNING:
working area.
CAUTION:
filler cap.
7) Drain fuel from fuel tank. <Ref. to FU(H4DOTC)-
50, DRAINING FUEL (WITH SUBARU SELECT
MONITOR), PROCEDURE, Fuel.>
MOVAL, Mud Guard.>
the vehicle.
IN-00203
FU-00095
FU-02395
(A)
FU-02396
(B)
FU-02397
(B)
FU(H4DOTC)-60
Fuel Filler Pipe
B: INSTALLATION
of apron.
NOTE:
en the clamp.
Tightening torque:
2.5 Nm (0.3 kgf-m, 1.8 ft-lb)
FU-00103
(A)
(C)
(B)
(1) Hose
(2) Clip or clamp
(3) Pipe
(A)
FU-02396
(B)
FU-02397
(B)
( 1 )
( 2 ) ( 3 )
FU-00104
L
L/2
FU(H4DOTC)-61
Fuel Filler Pipe
et on the body.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
LATION, Mud Guard.>
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
tery.
C: INSPECTION
1) Check that the fuel filler pipe does not have
holes, cracks or is damaged in any other way.
D: DISASSEMBLY
<Ref. to EC(H4DOTC)-17, REMOVAL, Shut Valve.>
FU-02395
IN-00203
FU-02398
FU-02399
FU-02400
FU(H4DOTC)-62
Fuel Filler Pipe
E: ASSEMBLY
1) Install the shut pipe to the fuel filler pipe. <Ref. to
EC(H4DOTC)-17, INSTALLATION, Shut Valve.>
Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
FU-02399
FU-02400
FU-02398
FU(H4DOTC)-63
Fuel Pump
29.Fuel Pump
A: REMOVAL
WARNING:
working area.
CAUTION:
When the fuel meter indication is higher than
two third of the total, perform the work after
draining the fuel not to spill the fuel.
NOTE:
2) Drain fuel. <Ref. to FU(H4DOTC)-50, DRAIN-
ING FUEL (WITH SUBARU SELECT MONITOR),
PROCEDURE, Fuel.>
the fuel delivery hose, return hose and jet pump
hose. <Ref. to FU(H4DOTC)-69, REMOVAL, Fuel
bly onto fuel tank.
tank.
B: INSTALLATION
NOTE:
Use a new gasket.
Install with the protrusion (A) of gasket aimed at
the front side of the vehicle.
Insert the protrusion (B) of gasket to the upper
plate. (3 places)
Align the protrusion (C) of fuel pump assembly
with the cutout on the upper plate.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.2 ft-lb)
FU-02387
FU-02388
(A) Delivery hose
(B) Return hose
(C) Jet pump hose
FU-01140
(A)
(B)
(C)
FU-02835
1
2
3
4
5 6
7
8
(C)
(B)
(B)
(B)
(A)
FU(H4DOTC)-64
Fuel Pump
C: INSPECTION
WARNING:
as possible.
Be sure to perform the ON/OFF operation on
the battery side.
FU-01330
2
4
6
1
3
5
FU(H4DOTC)-65
Fuel Level Sensor
A: REMOVAL
WARNING:
ing area.
CAUTION:
NOTE:
FU(H4DOTC)-63, REMOVAL, Fuel Pump.>
et.
3) Remove the fuel temperature sensor.
4) Remove the fuel level sensor.
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.2 ft-lb)
(A) Connector
FU-02401
(A)
(B)
(C)
FU(H4DOTC)-66
A: REMOVAL
WARNING:
ing area.
CAUTION:
1) Drain fuel. <Ref. to FU(H4DOTC)-50, DRAIN-
ING FUEL (WITH SUBARU SELECT MONITOR),
PROCEDURE, Fuel.>
service hole cover.
sensor.
the fuel delivery hose, return hose and jet pump
hose. <Ref. to FU(H4DOTC)-69, REMOVAL, Fuel
B: INSTALLATION
NOTE:
Use a new gasket.
Align the protrusion (A) of gasket to the position
shown in the following figure.
Align the protrusion (B) of fuel sub level sensor
with the cutout portion of fuel sub level sensor up-
per plate.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.2 ft-lb)
FU-01126
(B)
(A)
(A)
FU-01143
(A) Jet pump hose
(B) Delivery hose
(C) Return hose
FU-01144
(B)
(C)
(A)
FU-02836
1
6
5
2
4
3
(B)
(A)
FU-01146
FU(H4DOTC)-67
Fuel Filter
32.Fuel Filter
A: SPECIFICATION
Fuel filter forms a single unit with fuel pump.
Refer to Fuel Pump for removal and installation.
<Ref. to FU(H4DOTC)-63, REMOVAL, Fuel Pump.>
<Ref. to FU(H4DOTC)-63, INSTALLATION, Fuel
Pump.>
FU(H4DOTC)-68
Fuel Damper Valve
A: REMOVAL
WARNING:
ing area.
CAUTION:
or cloth.
DURE, Fuel.>
livery line (A) and the fuel return line (B).
B: INSTALLATION
CAUTION:
If fuel hoses or clamps are damaged, replace
them with new parts.
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
FU-03115
(A)
(B)
FU(H4DOTC)-69
Fuel Delivery, Return and Evaporation Lines
34.Fuel Delivery, Return and Evaporation Lines
A: REMOVAL
WARNING:
CAUTION:
2) Release the fuel pressure. <Ref. to FU(H4DOTC)-50, RELEASING OF FUEL PRESSURE, PROCE-
DURE, Fuel.>
5) Disconnect the fuel delivery pipes and hoses, and then disconnect the fuel return pipes and hoses, evap-
oration pipes and hoses.
FU-03107
FU(H4DOTC)-70
delivery hose.
CAUTION:
or cloth.
CAUTION:
or cloth.
(1) Attach ST to the fuel return pipe as shown in
the figure.
nector.
FU-03095
(A)
(B)
(C)
ST
FU-03092
ST
FU-03113
ST
FU-03114
ST
FU(H4DOTC)-71
8) Remove the clip and disconnect the evaporation
hose from the fuel pipe.
10) Remove the fuel tank. <Ref. to FU(H4DOTC)-
52, REMOVAL, Fuel Tank.>
covered with dust.
plastic bag etc.
(B) down.
(B).
B: INSTALLATION
CAUTION:
Make sure there are no damage or dust on con-
nections. If necessary, clean seal surface of
pipe.
NOTE:
Use a new retainer.
(A) Connector
(B) Retainer
(C) Pipe
FU-03105
FU-01333
FU-00124
( A )
( B )
( C )
(A) Seal surface
(B) Pipe
(A) Connector
(B) Retainer
(C) Pipe
FU-00125
( A )
( B )
FU-00126
( A )
( B )
( C )
FU(H4DOTC)-72
CAUTION:
securely.
Make sure the two retainer poles are engaged
in their mating positions in the connector.
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).
fied.
specified.
2: 2.51.5 mm (0.0980.059 in)
L: 22.52.5 mm (0.8860.098 in)
CAUTION:
Fuel evaporation hose:
L = 17.52.5 mm (0.6890.098 in)
C: INSPECTION
(A) Connector
(B) Retainer
(C) Pipe
(1) Type A
(2) Type B
(3) Pipe
(4) Clamp
(5) Hose
FU-00127
( A )
( B )
( C )
(3) (4) (5)
L
(1)
(2)
FU-00128
(1) Hose
(2) Clip
(3) Pipe
FU-00129
(1)
(2)
L/2
L
(3)
FU(H4DOTC)-73
A: INSPECTION
NOTE:
Fill fuel fully to prevent the problem.
securely.
3) Clogged fuel filter Replace the fuel pump.
6) Clogged or bent air breather tube or pipe. Clean, correct or replace the air breather tube or pipe.
4) Clogged air breather tube or air vent tube
tube.
1)
pipe
Retighten.
2) Problem in tightness of the fuel saucer gasket air Correct or replace the gasket.
5. Noise
FU(H4DOTC)-74
EC(H4DOTC)-2
General Description
A: COMPONENT
1. SECONDARY AIR PUMP
(1) Secondary air pump (4) Bushing Tightening torque:Nm (kgf-m, ft-lb)
(2) Clip (5) Secondary air pump cover T1: 6.4 (0.65, 4.7)
(3) Secondary air pump bracket T2: 19 (1.9, 14.0)
EC-02191
(1)
(3)
(4)
(4)
(4)
(5)
(2)
T1
T1
T1
T2
EC(H4DOTC)-3
General Description
2. SECONDARY AIR COMBINATION VALVE
B: CAUTION
forming any work.
points.
the battery.
(1) Gasket (8) Secondary air pipe RH (13) Secondary air pipe LH
(2) Gasket (9) Secondary air combination valve
RH
(14) Gasket
(3) Gasket
(4) Clamp (10) Air duct A Tightening torque:Nm (kgf-m, ft-lb)
(5) Clamp (11) Air duct B T1: 6.4 (0.65, 4.7)
(6) Clamp (12) Secondary air combination valve
LH
T2: 9 (0.9, 6.6)
(7) Clamp T3: 19 (1.9, 14.0)
EC-02204
(3)
(1)
(2)
(9)
(6)
(7)
(5)
(4)
(12)
T3
T2
T2
T1
T2
a
a
(11)
(10)
(8)
T2
(13)
(14)
EC(H4DOTC)-4
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
hose.
This is a general tool made by the French
company CAILLAU. (code) 54.0.000.205
ST18353AA000
EC(H4DOTC)-5
A: REMOVAL
1) Remove the center exhaust pipe.
<Ref. to EX(H4DOTC)-9, REMOVAL, Center Ex-
haust Pipe.>
2) Disconnect the front catalytic converter (A) from
the rear catalytic converter (B).
B: INSTALLATION
NOTE:
Use a new gasket.
C: INSPECTION
leaks.
(A)
(B)
EC-00076
EC(H4DOTC)-6
A: REMOVAL
haust Pipe.>
2) Disconnect the rear catalytic converter (B) from
the front catalytic converter (A).
B: INSTALLATION
NOTE:
Use a new gasket.
C: INSPECTION
leaks.
(A)
(B)
EC-00076
EC(H4DOTC)-7
Canister
4. Canister
A: REMOVAL
7) Remove clip (C).
B: INSTALLATION
NOTE:
the pipe.
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
C: INSPECTION
cracked or loose.
EC-02079
(A)
(A)
(C)
(B)
EC-02080
EC-02080
EC(H4DOTC)-8
A: REMOVAL
1. PURGE CONTROL SOLENOID VALVE 1
3) Remove the bolts that attach the purge control
solenoid valve 1 to the intake manifold. Then dis-
connect the connector from the purge control sole-
noid valve 1.
4) Disconnect the evaporation hose from the intake
manifold and fuel pipe assembly.
3) Remove the solenoid valve bracket assembly
from intake manifold.
4) Disconnect the connector from purge control so-
lenoid valve 2.
5) Disconnect the evaporation hose from the intake
duct and fuel pipe assembly.
6) Remove the purge control solenoid valve 2 from
the solenoid valve bracket assembly.
IN-00203
EC-02200
IN-00203
EC-00219
EC-00220
EC(H4DOTC)-9
B: INSTALLATION
NOTE:
ure.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(A) Purge Control Solenoid Valve 1
(B) Purge Control Solenoid Valve 2
(b) To intake duct
(c) To fuel pipe
EC-02201
(A)
(B)
(b)
(c)
(c) (a)
EC-02200
EC(H4DOTC)-10
NOTE:
ure.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
T1: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
T2: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
C: INSPECTION
(A) Purge Control Solenoid Valve 1
(B) Purge Control Solenoid Valve 2
(b) To intake duct
(c) To fuel pipe
EC-02201
(A)
(B)
(b)
(c)
(c) (a)
EC-00220
EC-02252
T2
T1
EC(H4DOTC)-11
Fuel Level Sensor
A: REMOVAL
For removal procedure, refer to FU(H4DOTC)
section. <Ref. to FU(H4DOTC)-65, REMOVAL,
Fuel Level Sensor.>
B: INSTALLATION
For installation procedure, refer to FU(H4DOTC)
section. <Ref. to FU(H4DOTC)-65, INSTALLA-
TION, Fuel Level Sensor.>
EC(H4DOTC)-12
A: REMOVAL
FU(H4DOTC)-65, REMOVAL, Fuel Level Sensor.>
B: INSTALLATION
FU(H4DOTC)-65, INSTALLATION, Fuel Level
Sensor.>
(A) Fuel temperature sensor
EC-02083
(A)
EC-02083
(A)
EC(H4DOTC)-13
A: REMOVAL
For removal procedure, refer to FU(H4DOTC)
section. <Ref. to FU(H4DOTC)-66, REMOVAL,
Fuel Sub Level Sensor.>
B: INSTALLATION
For installation procedure, refer to FU(F4DOTC)
section. <Ref. to FU(H4DOTC)-66, INSTALLA-
TION, Fuel Sub Level Sensor.>
EC(H4DOTC)-14
9. Fuel Tank Pressure Sensor
A: REMOVAL
WARNING:
working area.
3) Open the fuel flap lid, and remove the fuel filler
cap.
pressure sensor.
pressure sensor.
with the bracket.
B: INSTALLATION
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
C: INSPECTION
IN-00203
EC-02084
EC-02084
EC(H4DOTC)-15
Valve
A: REMOVAL
to the fuel tank.
7) Remove the pressure control solenoid valve and
bracket as a unit.
from the bracket.
B: INSTALLATION
Tightening torque:
7.35 Nm (0.7 kgf-m, 5.4 ft-lb)
C: INSPECTION
IN-00203
(C)
(B)
EC-02086
(B)
(A)
EC-02087
EC(H4DOTC)-16
Drain Filter
11.Drain Filter
A: SPECIFICATION
move the drain filter from canister. Refer to Canis-
ter for removal and installation procedure. <Ref. to
EC(H4DOTC)-7, REMOVAL, Canister.> <Ref. to
EC(H4DOTC)-7, INSTALLATION, Canister.>
EC(H4DOTC)-17
Shut Valve
12.Shut Valve
A: REMOVAL
WARNING:
working area.
CAUTION:
1) Remove the fuel filler pipe.
<Ref. to FU(H4DOTC)-59, REMOVAL, Fuel Filler
Pipe.>
valve.
B: INSTALLATION
Tightening torque:
4.5 Nm (0.46 kgf-m, 3.3 ft-lb)
C: INSPECTION
EC-02088
EC-02089
EC-02089
EC(H4DOTC)-18
Drain Valve
13.Drain Valve
A: SPECIFICATION
move the drain valve from canister.
Refer to Canister for removal and installation pro-
cedure. <Ref. to EC(H4DOTC)-7, REMOVAL, Can-
ister.> <Ref. to EC(H4DOTC)-7, INSTALLATION,
Canister.>
EC(H4DOTC)-19
PCV Hose Assembly
14.PCV Hose Assembly
A: REMOVAL
CAUTION:
Do not remove unless the PCV hose, diagnos-
tics connector and PCV valve are damaged.
ifold.>
2) Fit the depression in the ST with the protrusion
on the clamp to unlock.
3) Remove the PCV hose assembly.
B: INSTALLATION
NOTE:
Use a new clamp.
1) Install the PCV hose assembly, then lock by fit-
ting the ST on the clamp protrusion.
<Ref. to FU(H4DOTC)-15, INSTALLATION, Intake
Manifold.>
EC-02090
EC-02090
EC(H4DOTC)-20
Secondary Air Pump
15.Secondary Air Pump
A: REMOVAL
3) Disconnect the connector (A) from secondary air
pump, and remove the harness.
4) Disconnect the hose (B) from secondary air
pump.
5) Remove the bolt (C) which secures the second-
ary air pump to the body.
B: INSTALLATION
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
C: INSPECTION
IN-00203
EC-02193
(A)
(B)
EC-02194
(C)
EC-02195
T
EC(H4DOTC)-21
Secondary Air Combination Valve
16.Secondary Air Combination
Valve
A: REMOVAL
1. SECONDARY AIR COMBINATION
VALVE LH
4) Disconnect the connector from the secondary air
combination valve LH.
5) Disconnect the air duct A.
6) Remove the secondary air pipe LH.
7) Remove the secondary air combination valve
LH.
VALVE RH
5) Disconnect the connector from the secondary air
combination valve RH.
6) Disconnect the air duct A.
7) Remove the secondary air pipe RH.
8) Remove the secondary air combination valve
RH.
(A) Secondary air combination valve LH
(B) Clamp
(C) Air duct A
(D) Gasket
(E) Clamp
(F) Air duct B
(G) Secondary air pipe LH
(H) Gasket
IN-00203
EC-02209
(A)
(D)
(G)
(E)
(B)
(F)
a
a
(H)
(C)
b
b
(A) Secondary air combination valve RH
(B) Clamp
(C) Air duct A
(D) Gasket
(E) Secondary air pipe RH
(F) Gasket
IN-00203
EC-02213
(B)
(C)
(E)
(F)
(D)
(A)
EC(H4DOTC)-22
Secondary Air Combination Valve
B: INSTALLATION
VALVE LH
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, 14.0 ft-lb)
VALVE RH
NOTE:
Use a new gasket.
Tightening torque:
T1: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
T2: 9 Nm (0.9 kgf-m, 6.6 ft-lb)
C: INSPECTION
Check the air duct and pipe for looseness.
(A) Secondary air combination valve LH
(B) Clamp
(C) Air duct A
(D) Gasket
(E) Clamp
(F) Air duct B
(G) Secondary air pipe LH
(H) Gasket
EC-02210
(A)
(D)
(G)
(E)
(B)
(F)
T1
T2
a
a
T1
(H)
(C)
b
b
(A) Secondary air combination valve RH
(B) Clamp
(C) Air duct A
(D) Gasket
(E) Secondary air pipe RH
(F) Gasket
EC-02214
(B)
(C)
(E)
(F)
(D)
(A)
T1
T2
T2
IN(H4DOTC)-2
General Description
INTAKE (INDUCTION)
A: COMPONENT
1. AIR CLEANER
perature sensor
(7) Air cleaner case (front) Tightening torque:Nm (kgf-m, ft-lb)
(8) Air intake duct T1: 1 (0.1, 0.7)
(2) Air cleaner case (rear) (9) Clip T2: 2.5 (0.25, 1.8)
(3) Clip (10) Resonator chamber T3: 6 (0.6, 4.4)
(4) Air intake boot (11) Cushion T4: 7.5 (0.76, 5.5)
(5) Clamp (12) Spacer
(6) Air cleaner element (13) Cushion
T3
(6)
(8)
(7)
(4)
(3)
(3)
(2)
(1)
T1
T2 (5)
(5)
T2
(9)
(11)
(12)
T4
(13)
(10)
IN-02209
IN(H4DOTC)-3
General Description
INTAKE (INDUCTION)
2. INTAKE DUCT
(1) PCV hose ASSY A (8) PCV pipe (15) PCV hose ASSY B
(2) Intake manifold (9) Vacuum hose (16) Solenoid valve bracket
(3) Solenoid valve bracket ASSY (10) Air by-pass pipe
(4) Intake duct (11) Clamp Tightening torque:Nm (kgf-m, ft-lb)
(5) Engine harness ASSY (12) Vacuum hose T1: 6.4 (0.65, 4.7)
(6) Vacuum hose (13) Brake booster hose T2: 19 (1.9, 14.0)
(7) Vacuum hose (14) Clamp
T2
(2)
(9)
(8)
(6)
(12)
(13)
(7)
(5)
(3)
(4)
T2
T1
T1
T2
(14)
(14)
(16)
T1
(1)
(15)
(2)
(10)
(11)
IN-02224
IN(H4DOTC)-4
General Description
INTAKE (INDUCTION)
3. INTERCOOLER
(1) Intercooler (3) Air by-pass valve Tightening torque:Nm (kgf-m, ft-lb)
(2) O-ring T1: 6.5 (0.66, 4.8)
T2: 16 (1.6, 11.8)
IN-02075
T2
(1)
(2)
(3)
T1
IN(H4DOTC)-5
General Description
INTAKE (INDUCTION)
4. TURBOCHARGER
(1) Oil inlet pipe (9) Clip Tightening torque:Nm (kgf-m, ft-lb)
(2) Metal gasket (10) Oil outlet hose T1: 4.9 (0.5, 3.6)
(3) Turbocharger (11) Turbocharger bracket RH T2: 5 (0.5, 3.7)
(4) Water pipe (12) Turbocharger bracket LH T3: 7.8 (0.8, 5.8)
(5) Clamp T4: 16 (1.6, 11.8)
(6) Engine coolant hose T5: 20 (2.0, 14.8)
(7) Gasket T6: 23 (2.3, 17.0)
(8) Oil outlet pipe T7: 33 (3.4, 24.6)
IN-02234
T4
T1
(3)
(8)
(4)
(5)
(9)
(9)
(6)
(12)
(2)
(2)
(2)
(7)
(2)
(11)
(10)
T7
T2
T5
T6
(1)
(2)
T3
IN(H4DOTC)-6
General Description
INTAKE (INDUCTION)
B: CAUTION
forming any work.
points.
the battery.
IN(H4DOTC)-7
Air Cleaner Element
INTAKE (INDUCTION)
A: REMOVAL
2) Remove the air intake duct. <Ref. to IN(H4DOTC)-
3) Disconnect the connector (A) from mass air flow
4) Remove the clip (B) from the air cleaner case.
B: INSTALLATION
CAUTION:
C: INSPECTION
Replace if excessively damaged or dirty.
IN-00203
(A)
(B)
(B)
IN-02254
IN-02255
IN(H4DOTC)-8
Air Cleaner Case
INTAKE (INDUCTION)
3. Air Cleaner Case
A: REMOVAL
3) Remove the air intake duct. <Ref. to IN(H4DOTC)-
4) Disconnect the connector (A) from mass air flow
5) Loosen the clamp (B) which connects the air in-
take boot and intake duct.
6) Remove the clip (C) from the air cleaner case.
7) Remove the air cleaner case (rear) and air in-
take boot.
9) Remove the bolts (A) and nuts (B) which secure
the air cleaner case (front) to the body.
B: INSTALLATION
NOTE:
When installing the air cleaner case (rear), align the
protrusion of the air cleaner case (rear) to the hole
on the air cleaner case (front) to install.
Tightening torque:
Bolt (A)
6 Nm (0.6 kgf-m, 4.4 ft-lb)
NUT (B)
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
IN-00203
(A)
(B)
(C)
(C)
(B)
IN-02210
(B)
(A)
IN-02211
IN-00220
(B)
(A)
IN-02211
IN(H4DOTC)-9
Air Intake Duct
INTAKE (INDUCTION)
4. Air Intake Duct
A: REMOVAL
B: INSTALLATION
C: INSPECTION
2) Inspect that no foreign objects in the air intake
duct.
IN-00217
IN(H4DOTC)-10
Resonator Chamber
INTAKE (INDUCTION)
A: REMOVAL
er Case for removal procedure. <Ref. to
B: INSTALLATION
er Case for installation procedure. <Ref. to
IN(H4DOTC)-8, INSTALLATION, Air Cleaner Case.>
C: INSPECTION
IN(H4DOTC)-11
Intake Duct
INTAKE (INDUCTION)
6. Intake Duct
A: REMOVAL
4) Remove the sensor, engine harness and fuel
pipe attached to the intake manifold. <Ref. to
FU(H4DOTC)-18, DISASSEMBLY, Intake Mani-
fold.>
5) Remove the intake duct from intake manifold.
B: INSTALLATION
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
IN-00203
IN-02222
IN-02222
IN(H4DOTC)-12
Intercooler
INTAKE (INDUCTION)
7. Intercooler
A: REMOVAL
2) Loosen the clamp and remove the air by-pass
pipe (A) from the air by-pass valve.
3) Loosen the clamp, and then remove the intake
duct (B) from the intercooler.
4) Remove the bolts which secure the intake duct
to the turbocharger.
5) Remove the bolts which secure the intercooler to
the bracket, and remove the intercooler.
B: INSTALLATION
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
C: DISASSEMBLY
1) Remove the air by-pass valve from intercooler.
IN-00222
(B)
(A)
IN-02238
IN-02077
IN-02238
IN-02077
IN-02094
IN(H4DOTC)-13
Intercooler
INTAKE (INDUCTION)
D: ASSEMBLY
NOTE:
Use new O-rings.
Be careful not to pinch the O-ring.
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
IN-02094
IN(H4DOTC)-14
Turbocharger
INTAKE (INDUCTION)
8. Turbocharger
A: REMOVAL
5) Remove the center exhaust pipe. <Ref. to
EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>
7) Separate the turbocharger joint pipe from turbo-
charger.
8) Disconnect the engine coolant hose which is
connected to coolant filler tank.
9) Loosen the clamp which secures turbocharger to
intake duct.
10) Remove the bolts which secure oil inlet pipe
bracket to turbocharger.
11) Remove the oil inlet pipe from the turbocharg-
er.
12) Disconnect the engine coolant hose from the
water pipe, and remove the turbocharger bracket
RH.
13) Disconnect the oil outlet hose from the oil outlet
pipe.
14) Take out the turbocharger from engine com-
partment.
IN-00203
IN-00019
IN-00074
IN-00022
IN-02225
IN-00024
IN(H4DOTC)-15
Turbocharger
INTAKE (INDUCTION)
B: INSTALLATION
1) Connect the oil outlet hose to the oil outlet pipe.
2) Install the turbocharger to intake duct.
Tightening torque:
3 Nm (0.3 kgf-m, 2.2 ft-lb)
3) Install the oil inlet pipe to the turbocharger.
Tightening torque:
T1: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
T2: 20 Nm (2.0 kgf-m, 14.5 ft-lb)
4) Install the turbocharger bracket RH, and connect
the engine coolant hose to the water pipe.
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
5) Install the joint pipe to turbocharger.
NOTE:
Replace the gasket with a new part.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
6) Connect the engine coolant hose which is con-
nected to the coolant filler tank.
8) Install the center exhaust pipe. <Ref. to
EX(H4DOTC)-10, INSTALLATION, Center Exhaust
Pipe.>
12) Connect the ground cable to battery.
IN-00024
IN-00074
IN-02256
T1
T2
IN-02225
IN-00019
IN-00203
IN(H4DOTC)-16
Air By-pass Valve
INTAKE (INDUCTION)
9. Air By-pass Valve
A: REMOVAL
2) Disconnect the air by-pass hose (A) from the air
by-pass valve.
3) Remove the air by-pass valve (B) from the inter-
cooler.
B: INSTALLATION
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
(A) Air by-pass hose
(B) Air by-pass valve
IN-00231
(A)
(B)
IN-00231
(A)
(B)
ME(H4DOTC)-2
General Description
MECHANICAL
A: SPECIFICATION
NOTE:
OS: Oversize US: Undersize
Engine
Model 2.5 L
Belt driven, double overhead camshaft,
4-valve/cylinder
Bore Stroke mm (in) 99.5 79.0 (3.92 3.11)
Piston displacement cm
3
(cu in) 2,457 (149.94)
(at 200 300 rpm)
kPa (kg/cm
2
, psi) 981 1,177 (10 12, 142 171)
Intake valve timing
Open
Max.
retard
ATDC 5
Min.
advance
BTDC 35
Close
Max.
retard
ABDC 65
Min.
advance
ABDC 25
Open BBDC 55
Close ATDC 5
Intake 0.200.02 (0.00790.0008)
Exhaust 0.350.02 (0.01380.0008)
Idling speed [at neutral position on MT, or P
or N position on AT]
rpm
No load 750100
A/C ON
800100 (MT model)
825100 (AT model)
Ignition order 1 3 2 4
Ignition timing BTDC/rpm
MT model 1210/750
AT model 1710/750
ME(H4DOTC)-3
General Description
MECHANICAL
Belt tension
adjuster
Protrusion of adjuster rod mm (in) 5.2 6.2 (0.205 0.244)
Belt tensioner
Spacer O.D. mm (in) 17.955 17.975 (0.7069 0.7077)
Tensioner bushing I.D. mm (in) 18.0 18.08 (0.7087 0.7118)
Clearance between spacer and
bushing
mm (in) Standard 0.025 0.125 (0.0010 0.0049)
Side clearance of spacer mm (in) Standard 0.20 0.55 (0.0079 0.0217)
Camshaft
Bending limit mm (in) 0.020 (0.0079) or less
Cam lobe height mm (in)
Intake Standard 46.55 46.65 (1.833 1.837)
Journal O.D. mm (in) Standard
Front 37.946 37.963 (1.4939 1.4946)
Center
rear
29.946 29.963 (1.1790 1.1796)
Journal clearance mm (in) Standard 0.037 0.072 (0.0015 0.0028)
Cylinder head
Surface warpage limit mm (in) 0.035 (0.0014)
Valve seat
Seating angle 90
Intake Standard 0.6 1.4 (0.024 0.055)
Valve guide
Inner diameter mm (in) 6.000 6.012 (0.2362 0.2367)
Protrusion above head mm (in) 15.8 16.2 (0.622 0.638)
Valve
Intake Standard 1.0 1.4 (0.039 0.055)
Intake 5.955 5.970 (0.2344 0.2350)
Exhaust 5.945 5.960 (0.2341 0.2346)
Valve stem gap mm (in) Standard
Intake 0.030 0.057 (0.0012 0.0022)
Exhaust 0.040 0.067 (0.0016 0.0026)
Intake 104.4 (4.110)
Exhaust 104.65 (4.1201)
Valve spring
Squareness 2.5, 2.1 mm (0.083 in) or less
Tension/spring height N (kgf, lb)/mm (in)
Set
205 235
(20.9 24.0, 46.1 52.8)/36.0 (1.417)
Lift
426 490
(43.4 50.0, 95.8 110)/26.5 (1.043)
Valve lifter
Outer diameter mm (in) Standard 34.959 34.975 (1.3763 1.3770)
Inner diameter (cylinder head) mm (in) Standard 34.994 35.016 (1.3777 1.3786)
Valve lifter clearance mm (in) Standard 0.019 0.057 (0.0007 0.0022)
Cylinder block
Surface warpage limit
(Mating surface with cylinder head)
mm (in) 0.025 (0.0098)
Cylinder inner diameter mm (in) Standard
A 99.505 99.515 (3.9175 3.9179)
B 99.495 99.505 (3.9171 3.9175)
Taper mm (in) Standard 0.015 (0.0006)
ME(H4DOTC)-4
General Description
MECHANICAL
Piston Outer diameter mm (in)
Standard
A 99.505 99.515 (3.9175 3.9179)
B 99.495 99.505 (3.9171 3.9175)
0.25 (0.0098) OS 99.745 99.765 (3.9270 3.9278)
0.50 (0.0197) OS 99.995 100.015 (3.9368 3.9376)
Piston pin
Standard clearance between piston
and piston pin
mm (in) Standard 0.004 0.008 (0.0002 0.0003)
Degree of fit
Piston pin must be fitted into position
with thumb at 20C (68F).
Piston ring
Connecting rod
Bend or twist per 100 mm (3.94 in) in
length
mm (in) Limit 0.1 (0.0039)
Bearing of
large end
Bearing size
mm (in)
Standard 1.490 1.502 (0.0587 0.0591)
0.03 (0.0012) US 1.504 1.512 (0.0592 0.0595)
0.05 (0.0020) US 1.514 1.522 (0.0596 0.0599)
0.25 (0.0098) US 1.614 1.622 (0.0635 0.0639)
Bushing of
small end
Clearance between piston pin and
bushing
mm (in) Standard 0 0.022 (0 0.0009)
Crankshaft
Bending limit mm (in) 0.035 (0.0014)
Crank pin
Crank journal
Crank pin outer diameter mm (in)
Standard 51.984 52.000 (2.0466 2.0472)
0.03 (0.0012) US 51.954 51.970 (2.0454 2.0461)
0.05 (0.0020) US 51.934 51.950 (2.0447 2.0453)
0.25 (0.0098) US 51.734 51.750 (2.0368 2.0374)
Crank journal outer
diameter
mm (in)
Standard 59.992 60.008 (2.3619 2.3625)
0.03 (0.0012) US 59.962 59.978 (2.3607 2.3613)
0.05 (0.0020) US 59.942 59.958 (2.3599 2.3605)
0.25 (0.0098) US 59.742 59.758 (2.3520 2.3527)
Oil clearance mm (in) 0.010 0.030 (0.0004 0.0012)
Main bearing
Bearing size
mm (in)
#1, #3
Standard 1.998 2.011 (0.0787 0.0792)
0.03 (0.0012) US 2.017 2.020 (0.0794 0.0795)
0.05 (0.0020) US 2.027 2.030 (0.0798 0.0799)
0.25 (0.0098) US 2.127 2.130 (0.0837 0.0839)
#2, #4, #5
Standard 2.000 2.013 (0.0787 0.0793)
0.03 (0.0012) US 2.019 2.022 (0.0795 0.0796)
0.05 (0.0020) US 2.029 2.032 (0.0799 0.0800)
0.25 (0.0098) US 2.129 2.132 (0.0838 0.0839)
ME(H4DOTC)-5
General Description
MECHANICAL
B: COMPONENT
1. TIMING BELT
(1) Timing belt cover No. 2 (RH) (13) Belt idler No. 2 Tightening torque:Nm (kgf-m, ft-lb)
(2) Timing belt guide (MT model) (14) Belt idler T1: 5 (0.5, 3.7)
(3) Crank sprocket (15) Timing belt cover (LH) T2: 9.75 (1.0, 7.2)
(4) Timing belt cover No. 2 (LH) (16) Front belt cover T3: 24.5 (2.5, 18.1)
(5) Tensioner bracket (17) Timing belt cover (RH) T4: 39 (4.0, 28.8)
(6) Automatic belt tension adjuster
ASSY
(18) Crank pulley T5: <Ref. to ME(H4DOTC)-51,
INSTALLATION, Cam
Sprocket.>
(19) Timing belt guide (MT model)
(7) Belt idler (20) O-ring
(8) Exhaust cam sprocket (RH) (21) Actuator cover T6: <Ref. to ME(H4DOTC)-40,
(9) Intake cam sprocket (RH)
(10) Intake cam sprocket (LH) T7: 6.4 (0.65, 4.7)
(11) Exhaust cam sprocket (LH) T8: 3.4 (0.3, 2.5)
(12) Timing belt T9: 25 (2.5, 18.4)
ME-03308
T5
T1
T6
(7)
(6)
(10)
(18)
(5)
(14)
(2)
(3)
T2
(4)
(1) (19)
(19)
T7
T4
T3
T9
T4
T5
T4
T5
T1
T7
(11)
(15)
(17)
(19)
(9)
(8)
(13)
(14)
(12)
(16)
T1
T1
T7
T1
T1
T5
(20)
(20)
T1
T8
T8
T1
(21)
(21)
ME(H4DOTC)-6
General Description
MECHANICAL
ME-03090
T7
(1)
T3
T3
T5
T5
T5
T5
T1
(3)
(7)
(6)
(9)
(8)
(10)
(12)
(28)
(31)
(13)
(25)
(21)
(20)
(6)
(16)
(17)
(18)
(9)
(8)
(19)
(15)
(14)
(29)
(11)
(5)
(4)
(22)
T7
T7
(14)
(29)
(12)
(27)
(27)
(26)
(27)
(31)
(30)
T2
T2
T2
T6
T1
(11)
(2)
T6
T2
T2
T6
(30)
T6
(24)
(23)
T4
(32)
ME(H4DOTC)-7
General Description
MECHANICAL
(1) Rocker cover (RH) (18) Camshaft cap (Front LH) Tightening torque:Nm (kgf-m, ft-lb)
(2) Rocker cover gasket (RH) (19) Intake camshaft cap (Rear LH) T1: <Ref. to ME(H4DOTC)-60,
INSTALLATION, Cylinder
Head.>
(3) Camshaft cap (Front RH) (20) Exhaust camshaft cap (Rear LH)
(4) Intake camshaft cap (Rear RH) (21) Rocker cover gasket (LH)
(5) Intake camshaft (RH) (22) Rocker cover (LH) T2: 8 (0.8, 5.9)
(6) Oil flow control solenoid valve (23) Oil filler cap T3: <Ref. to ME(H4DOTC)-54,
(7) Exhaust camshaft cap (Rear RH) (24) Oil filler duct
(8) Gasket (25) O-ring T4: 6.4 (0.65, 4.7)
(9) Oil return cover (26) Oil pipe (LH) T5: <Ref. to ME(H4DOTC)-54,
(10) Exhaust camshaft (RH) (27) Gasket
(11) Cylinder head bolt (28) Oil pipe (RH) T6: 29 (3.0, 21.4)
(12) Oil seal (29) Stud bolt T7: <Ref. to ME(H4DOTC)-54,
(13) Cylinder head (RH) (30) Union screw with filter
(with protrusion)
(14) Cylinder head gasket
(15) Cylinder head (LH) (31) Union screw without filter
(without protrusion)
(16) Intake camshaft (LH)
(17) Exhaust camshaft (LH) (32) Gasket
ME(H4DOTC)-8
General Description
MECHANICAL
(1) Exhaust valve (6) Valve spring (10) Exhaust valve oil seal
(2) Intake valve (7) Retainer (11) Intake valve guide
(3) Cylinder head (8) Retainer key (12) Exhaust valve guide
(4) Valve spring seat (9) Valve lifter (13) Plug
(5) Intake valve oil seal
ME-03157
(3)
(1)
(2)
(11) (4) (5) (6) (7) (8) (9)
(11)
(12)
(12)
(10)
(4)
(4)
(5) (6)
(6)
(7)
(7)
(8)
(8)
(9)
(9)
(10)
(4)
(6)
(7)
(8)
(9)
(13)
(13)
ME(H4DOTC)-9
General Description
MECHANICAL
4. CYLINDER BLOCK
ME-03309
T7
T2
T2
T2
T5
T4
T5
T4
T2
T6
T6
T4
(9)
(6)
(10)
(10)
(11)
(12)
(13)
(25)
(26)
(4)
(4)
(4)
(3)
(3)
(3)
(2)
(1)
(5)
(10)
T4
(10)
T6
T2
(19)
T9
(17)
(16)
(24)
T2
(15)
(27)
T10
(30)
(29)
T2
T2
(8)
(7)
T2
(14)
(28)
T3
(18)
(10)
T2
(30)
(29)
T2
(23)
(31)
T1
T8
(19)
(20)
(21)
(22)
T11
(32)
ME(H4DOTC)-10
General Description
MECHANICAL
(1) Oil pressure switch (17) Connector Tightening torque:Nm (kgf-m, ft-lb)
(2) Cylinder block (RH) (18) Oil strainer T1: 5 (0.5, 3.7)
(3) Service hole plug (19) Gasket T2: 6.4 (0.65, 4.7)
(4) Gasket (20) Oil pan T3: 10 (1.0, 7.2)
(5) Oil separator cover (21) Drain plug T4: 25 (2.5, 18.4)
(6) Water by-pass pipe (22) Drain plug gasket T5: <Ref. to ME(H4DOTC)-72,
INSTALLATION, Cylinder
Block.>
(7) Oil pump (23) Oil level gauge guide
(8) Front oil seal (24) Oil filter
(9) Rear oil seal (25) Gasket T6: 70 (7.1, 51.6)
(10) O-ring (26) Water pump hose T7: First 12 (1.2, 8.9)
Second 12 (1.2, 8.9)
(11) Service hole cover (27) Nipple
(12) Cylinder block (LH) (28) Seal T8: 44 (4.5, 32.5)
(13) Water pump (29) Washer T9: 54 (5.5, 40)
(14) Baffle plate (30) Seal washer T10: 69 (7.0, 50.9)
(15) Oil cooler (31) O-ring T11: 16 (1.6, 11.6)
(16) Water by-pass pipe (32) Engine rear hanger
ME(H4DOTC)-11
General Description
MECHANICAL
(1) Flywheel (MT model) (9) Piston pin (17) Crankshaft bearing #1, #3
(2) Ball bearing (MT model) (10) Snap ring (18) Crankshaft bearing #2, #4
(3) Reinforcement (AT model) (11) Connecting rod bolt (19) Crankshaft bearing #5
(4) Drive plate (AT model) (12) Connecting rod
(5) Top ring (13) Connecting rod bearing Tightening torque:Nm (kgf-m, ft-lb)
(6) Second ring (14) Connecting rod cap T1: 52 (5.3, 38.4)
(7) Oil ring (15) Crankshaft T2: 72 (7.3, 53.1)
(8) Piston (16) Woodruff key
ME-02437
T1
(5)
(6)
(7)
(10) (8)
(10)
(12)
(13)
(13)
(16)
(13)
(12)
(19)
(18)
(17)
(17)
(18)
(10)
(10)
(7)
(6)
(5)
(9)
(8)
(13)
(15)
(14)
(11)
(14)
(9)
T1
(11)
(1)
T2
(2)
(4)
(3)
T2
ME(H4DOTC)-12
General Description
MECHANICAL
6. ENGINE MOUNTING
C: CAUTION
forming any work.
points.
the battery.
and bearings.
assembly.
Be careful not to let oil, grease or engine coolant
contact the timing belt, clutch disc and flywheel.
making rechecks.
ready use.
jacks, etc.
T1: 35 (3.6, 25.8)
T2: 75 (7.6, 55.3)
(1)
T2
T1
T1
T2
ME-02090
ME(H4DOTC)-13
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
498267600 CYLINDER HEAD
TABLE
ADAPTER RH
(499817100).
ADAPTER LH
(499817100).
STOPPER
Used for removing and installing flywheel and
drive plate.
ST-498267600
ST-498457000
ST-498457100
ST-498497100
ME(H4DOTC)-14
General Description
MECHANICAL
498747300 PISTON GUIDE Used for installing the cup to the wheel cylinder
piston. (2.5 L model)
GUIDE
Used for press-fitting of intake and exhaust
valve guide oil seals.
499017100 PISTON PIN GUIDE Used for installing piston pin, piston and con-
necting rod.
499037100 CONNECTING ROD
BUSHING
REMOVER AND
INSTALLER
bushing.
REMOVER ASSY
ST-498747300
ST-498857100
ST-499017100
ST-499037100
ST-499097700
ME(H4DOTC)-15
General Description
MECHANICAL
499207400 CAM SPROCKET
WRENCH
Used for removing and installing exhaust cam
sprocket.
WRENCH
Used for removing and installing intake cam
sprocket.
SEAL INSTALLER
SEAL GUIDE (499597100).
SEAL GUIDE
REMOVER
ST-499207400
ST-499977500
ST-499587200
ST-499597100
ST-499718000
ME(H4DOTC)-16
General Description
MECHANICAL
18251AA020 VALVE GUIDE
ADJUSTER
Used for installing intake and exhaust valve
guides.
REMOVER
REAMER
499817100 ENGINE STAND Stand used for engine disassembly and
assembly.
ADAPTER RH (498457000) & LH (498457100).
WRENCH
ST18251AA020
ST-499767200
ST-499767400
ST-499817100
ST-499977100
ME(H4DOTC)-17
General Description
MECHANICAL
SOCKET
499587100 OIL SEAL
INSTALLER
Used for installing oil pump oil seal.
499587600 OIL SEAL
INSTALLER
Used for installing camshaft oil seal for DOHC
engine.
499597200 OIL SEAL GUIDE Used for installing camshaft oil seal for DOHC
engine.
Used together with the OIL SEAL INSTALLER
(499587600).
assembly to engine.
ST-499987500
ST-499587100
ST-499587600
ST-499597200
ST-498277200
ME(H4DOTC)-18
General Description
MECHANICAL
2. GENERAL TOOL
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
Camshaft
Cylinder head
REMOVER
Used for disconnecting quick connector of the
engine compartment.
18371AA000 CONNECTOR
REMOVER
Used for disconnecting the quick connector on
the fuel return hose of the engine compartment.
MONITOR III KIT
TOOL NAME REMARKS
Timing light Used for measuring ignition timing.
Vacuum gauge Used for measuring intake manifold vacuum.
ST42099AE000
ST18371AA000
ST1B021XU0
ME(H4DOTC)-19
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
ment.
switch to OFF.
DURE, Fuel.>
5) Remove all the spark plugs.
<Ref. to IG(H4DOTC)-4, REMOVAL, Spark Plug.>
spark plug hole.
NOTE:
9) Crank the engine by the starter motor, and read
the maximum value on the gauge when the needle
of gauge is steady.
10) Perform at least two measurements per cylin-
der, and make sure that the values are correct.
Compression (Fully open throttle):
Standard:
981 1,177 kPa (10 12 kgf/cm
2
, 142
171 psi)
Difference between cylinders:
49 kPa (0.5 kgf/cm
2
, 7 psi), or less
ME-03009
ME(H4DOTC)-20
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
lowing item:
properly.
not illuminate.
Monitor. <Ref. to EN(H4DOTC)(diag)-36, READ
CURRENT DATA FOR ENGINE (NORMAL
MODE), OPERATION, Subaru Select Monitor.>
and etc. are OFF)
Idle speed [No load and gears in neutral, P or
N range]:
750100 rpm
Idle speed [A/C ON and gears in neutral, P or
N range]:
800100 rpm (MT model)
825100 rpm (AT model)
NOTE:
General On-board Diagnosis Table under Engine
Control System. <Ref. to EN(H4DOTC)(diag)-2,
Basic Diagnostic Procedure.>
ME(H4DOTC)-21
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION:
careful not to burn yourself at measurement.
1. METHOD WITH SUBARU SELECT MON-
ITOR
following item:
not illuminate.
3) Read the ignition timing using Subaru Select Mon-
itor. <Ref. to EN(H4DOTC)(diag)-36, READ CUR-
1210/750 (MT Model)
1710/750 (AT Model)
system. Refer to Engine Control System. <Ref. to
EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
2. METHOD WITH TIMING LIGHT
following item:
not illuminate.
OFF.
5) Disconnect the connectors of the mass air flow
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 the air cleaner cover,
element, and mass air flow and intake air tempera-
ture sensor.
9) Start the engine, turn the timing light to the crank
pulley, and check the ignition timing by means of
crank pulley indicator.
1210/750 (MT Model)
1710/750 (AT Model)
EN(H4DOTC)(diag)-2, Basic Diagnostic Proce-
dure.>
ME(H4DOTC)-22
MECHANICAL
A: INSPECTION
3) Disconnect the brake vacuum hose from intake
manifold, and then install the vacuum gauge.
uum gauge indication.
By observing the gauge needle movement, the in-
ternal condition of the engine can be diagnosed as
described below.
(MT model)
(AT model)
ME-00801
Leakage around intake manifold gasket, or disconnected or
damaged vacuum hose
position.
tion.
Sticky valve
range.
Defective ignition system or throttle chamber idle adjustment
ME(H4DOTC)-23
Engine Oil Pressure
MECHANICAL
A: INSPECTION
3) Remove the oil pressure switch. <Ref. to
LU(H4DOTC)-20, REMOVAL, Oil Pressure Switch.>
4) Connect the oil pressure gauge hose to cylinder
block.
Oil pressure:
Standard
98 kPa (1.0 kgf/cm
2
, 14 psi) or more
(at 600 rpm)
294 kPa (3.0 kgf/cm
2
, 43 psi) or more
(at 5,000 rpm)
If the oil pressure is out of specification, check oil
pump, oil filter and lubrication line. <Ref. to
LU(H4DOTC)-24, INSPECTION, Engine Lubrica-
tion System Trouble in General.>
sure switch. <Ref. to LU(H4DOTC)-24, INSPEC-
TION, Engine Lubrication System Trouble in
General.>
NOTE:
Standard value is based on an engine oil tempera-
ture of 80C (176F).
pressure switch. <Ref. to LU(H4DOTC)-20, IN-
STALLATION, Oil Pressure Switch.>
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
IN-00203
IN-00203
ME-00009
ME(H4DOTC)-24
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
CAUTION:
or cloth.
NOTE:
If the fuel pressure is out of specification, check or
replace the pressure regulator and pressure regu-
lator vacuum hose.
DURE, Fuel.>
filler cap.
4) Disconnect the fuel delivery hose from fuel
damper valve, and connect fuel pressure gauge.
5) Install the fuse of fuel pump to the main fuse box.
7) Measure the fuel pressure while disconnecting
pressure regulator vacuum hose from intake mani-
fold.
NOTE:
to 0.2 kgf/cm
2
Fuel pressure:
Standard
284 314 kPa (2.9 3.2 kgf/cm
2
, 41 46 psi)
8) After connecting the pressure regulator vacuum
hose, measure the fuel pressure.
NOTE:
to 0.2 kgf/cm
2
Fuel pressure:
Standard
230 260 kPa
(2.35 2.65 kgf/cm
2
, 33 38 psi)
ME-03092
FU-01122
ME(H4DOTC)-25
Valve Clearance
MECHANICAL
8. Valve Clearance
A: INSPECTION
NOTE:
Inspection and adjustment of valve clearance
should be performed while engine is cold.
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
(2) Disconnect the connector of ignition coil.
(3) Remove the ignition coil.
(4) Place a suitable container under the vehicle.
cover (RH).
cover (RH).
(1) Disconnect the battery cable, and then re-
move the battery and battery carrier.
(2) Remove the secondary air pump. <Ref. to
EC(H4DOTC)-20, REMOVAL, Secondary Air
Pump.>
(3) Disconnect the connector of ignition coil.
(5) Place a suitable container under the vehicle.
cover (LH).
cover (LH).
12) Turn the crank pulley clockwise until the round
mark and arrow mark on the camshaft sprocket are
set to position shown in the figure.
NOTE:
Turn the crankshaft using socket wrench.
13) Measure the #1 cylinder intake valve and #3
cylinder exhaust valve clearance by using thick-
ness gauge (A).
NOTE:
zontal as possible with respect to the valve lifter.
Measure the exhaust valve clearances while lift-
ing-up the vehicle.
If the measured value is not within specification,
take notes of the value in order to adjust the valve
clearance later on.
Valve clearance:
Intake
0.200.02 mm (0.00790.0008 in)
Exhaust
0.350.02 mm (0.01380.0008 in)
to ME(H4DOTC)-26, ADJUSTMENT, Valve Clear-
ance.>
IN-00203
ME-03171
ME-00019
( A)
ME(H4DOTC)-26
Valve Clearance
MECHANICAL
15) Further turn the crank pulley clockwise and
then measure the valve clearances again.
(1) Set the round mark and arrow mark on cam
sprocket to the position shown in the figure, and
measure the #2 cylinder exhaust valve and #3
cylinder intake valve clearances.
measure the #2 cylinder intake valve and #4
cylinder exhaust valve clearances.
measure the #1 cylinder exhaust valve and #4
cylinder intake valve clearances.
B: ADJUSTMENT
NOTE:
1) Measure all the valve clearances. <Ref. to
ME(H4DOTC)-25, INSPECTION, Valve Clearance.>
NOTE:
Record each valve clearance after measurement.
2) Remove the camshaft. <Ref. to ME(H4DOTC)-
53, REMOVAL, Camshaft.>
3) Remove the valve lifter.
4) Measure the thickness of valve lifter using mi-
crometer.
5) Select a valve lifter of suitable thickness from the
following table using the measured valve clearance
and valve lifter thickness.
ME-03172
ME-03173
ME-03174
Unit: (mm)
Intake valve: S = (V + T) 0.20
Exhaust valve: S= (V + T) 0.35
S: Valve lifter thickness required
V: Measured valve clearance
T: Valve lifter thickness to be used
ME-00024
ME-00025
ME(H4DOTC)-27
Valve Clearance
MECHANICAL
6) Inspect all valves for valve clearance again at
this time. If the valve clearance is not correct, re-
peat the procedure over again from the first step.
Part No. Thickness mm (in)
13228 AB102 4.68 (0.1843)
13228 AB112 4.69 (0.1846)
13228 AB122 4.70 (0.1850)
13228 AB132 4.71 (0.1854)
13228 AB142 4.72 (0.1858)
13228 AB152 4.73 (0.1862)
13228 AB162 4.74 (0.1866)
13228 AB172 4.75 (0.1870)
13228 AB182 4.76 (0.1874)
13228 AB192 4.77 (0.1878)
13228 AB202 4.78 (0.1882)
13228 AB212 4.79 (0.1886)
13228 AB222 4.80 (0.1890)
13228 AB232 4.81 (0.1894)
13228 AB242 4.82 (0.1898)
13228 AB252 4.83 (0.1902)
13228 AB262 4.84 (0.1906)
13228 AB272 4.85 (0.1909)
13228 AB282 4.86 (0.1913)
13228 AB292 4.87 (0.1917)
13228 AB302 4.88 (0.1921)
13228 AB312 4.89 (0.1925)
13228 AB322 4.90 (0.1929)
13228 AB332 4.91 (0.1933)
13228 AB342 4.92 (0.1937)
13228 AB352 4.93 (0.1941)
13228 AB362 4.94 (0.1945)
13228 AB372 4.95 (0.1949)
13228 AB382 4.96 (0.1953)
13228 AB392 4.97 (0.1957)
13228 AB402 4.98 (0.1961)
13228 AB412 4.99 (0.1965)
13228 AB422 5.00 (0.1969)
13228 AB432 5.01 (0.1972)
13228 AB442 5.02 (0.1976)
13228 AB452 5.03 (0.1980)
13228 AB462 5.04 (0.1984)
13228 AB472 5.05 (0.1988)
13228 AB482 5.06 (0.1992)
13228 AB492 5.07 (0.1996)
13228 AB502 5.08 (0.2000)
13228 AB512 5.09 (0.2004)
13228 AB522 5.10 (0.2008)
13228 AB532 5.11 (0.2012)
13228 AB542 5.12 (0.2016)
13228 AB552 5.13 (0.2020)
13228 AB562 5.14 (0.2024)
13228 AB572 5.15 (0.2028)
13228 AB582 5.16 (0.2031)
13228 AB592 5.17 (0.2035)
13228 AB602 5.18 (0.2039)
13228 AB612 5.19 (0.2043)
13228 AB622 5.20 (0.2047)
13228 AB632 5.21 (0.2051)
13228 AB642 5.22 (0.2055)
13228 AB652 5.23 (0.2059)
13228 AB662 5.24 (0.2063)
13228 AB672 5.25 (0.2067)
13228 AB682 5.26 (0.2071)
13228 AB692 5.27 (0.2075)
13228 AB702 4.38 (0.1724)
13228 AB712 4.40 (0.1732)
13228 AB722 4.42 (0.1740)
13228 AB732 4.44 (0.1748)
13228 AB742 4.46 (0.1756)
13228 AB752 4.48 (0.1764)
13228 AB762 4.50 (0.1771)
13228 AB772 4.52 (0.1780)
13228 AB782 4.54 (0.1787)
13228 AB792 4.56 (0.1795)
13228 AB802 4.58 (0.1803)
13228 AB812 4.60 (0.1811)
13228 AB822 4.62 (0.1819)
13228 AB832 4.64 (0.1827)
13228 AB842 4.66 (0.1835)
13228 AB852 5.29 (0.2083)
13228 AB862 5.31 (0.2091)
13228 AB872 5.33 (0.2098)
13228 AB882 5.35 (0.2106)
13228 AB892 5.37 (0.2114)
13228 AB902 5.39 (0.2122)
13228 AB912 5.41 (0.2123)
13228 AB922 5.43 (0.2138)
13228 AB932 5.45 (0.2146)
13228 AB942 5.47 (0.2154)
13228 AB952 5.49 (0.2161)
13228 AB962 5.51 (0.2169)
13228 AB972 5.53 (0.2177)
13228 AB982 5.55 (0.2185)
13228 AB992 5.57 (0.2193)
13228 AC002 5.59 (0.2201)
13228 AC012 5.61 (0.2209)
13228 AC022 5.63 (0.2217)
13228 AC032 5.65 (0.2224)
ME(H4DOTC)-28
Engine Assembly
MECHANICAL
9. Engine Assembly
A: REMOVAL
front hood stay.
4) Collect the refrigerant from A/C system. <Ref. to
AC-21, Refrigerant Recovery Procedure.>
6) Disconnect the battery cable, and remove the
battery from the vehicle.
filler cap.
<Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake
Duct.> <Ref. to IN(H4DOTC)-8, REMOVAL, Air
Cleaner Case.>
10) Remove the radiator from vehicle. <Ref. to
CO(H4DOTC)-19, REMOVAL, Radiator.>
11) Remove the coolant filler tank.
<Ref. to CO(H4DOTC)-29, REMOVAL, Coolant
Filler Tank.>
12) Disconnect the A/C pressure hoses from A/C
compressor. <Ref. to AC-39, REMOVAL, Hose and
Tube.>
13) Disconnect the following connectors and ca-
bles.
FU-02436
ME-00028
ME-03081
ME-03082
ME(H4DOTC)-29
Engine Assembly
MECHANICAL
15) Remove the power steering pump from the
bracket.
(1) Loosen the lock bolt and slider bolt, and re-
move the front side belt. <Ref. to ME(H4DOTC)-
37, FRONT SIDE BELT, REMOVAL, V-belt.>
(2) Disconnect the power steering pump switch
connector.
(3) Remove the power steering pump from the
engine. <Ref. to PS-46, REMOVAL, Oil Pump.>
(4) Place the power steering pump on the right
side wheel apron.
<Ref. to EX(H4DOTC)-6, REMOVAL, Front Ex-
haust Pipe.> <Ref. to EX(H4DOTC)-9, REMOVAL,
Center Exhaust Pipe.>
18) Remove the bolts and nuts which hold the low-
er side of transmission to the engine.
AT model
MT model
FU-02341
ME-00035
ME-03083
AT-03238
MT-00077
LU-00223
ME(H4DOTC)-30
Engine Assembly
MECHANICAL
plate. (AT model)
(4) Remove other bolts while rotating the crank-
delivery hose.
CAUTION:
or cloth.
CAUTION:
or cloth.
(1) Attach the ST to the fuel return pipe as
nector.
ME-00044
LU-00221
FU-03095
(A)
(B)
(C)
ST
FU-03092
ST
FU-03113
ST
FU-03114
ST
ME(H4DOTC)-31
Engine Assembly
MECHANICAL
24) Remove the clip and disconnect the evapora-
tion hose from the fuel pipe.
wire ropes.
CAUTION:
weight.
27) Separation of engine and transmission.
CAUTION:
overlooked.
REMOVAL, Starter.>
(2) Set the ST to torque converter clutch case.
(AT model)
(3) Remove the bolts which hold the upper side
of the transmission to the engine.
AT model
MT model
(A) Transmission
(B) Garage jack
FU-03105
LU-00222
ME-00215
(B)
(A)
ST
ME-00049
ME-00491
MT-01524
ME(H4DOTC)-32
Engine Assembly
MECHANICAL
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
compartment.
NOTE:
B: INSTALLATION
1) Install the front cushion rubbers to engine.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
2) Apply a small amount of grease to splines of
main shaft. (MT model)
NOTE:
mission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
AT model
MT model
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
8) Remove the ST from the torque converter clutch
case. (AT model)
NOTE:
Be careful not to drop the ST into the torque con-
verter clutch case when removing the ST.
ME-00491
MT-01524
LU-00222
LU-00224
T2
T1
ME(H4DOTC)-33
Engine Assembly
MECHANICAL
(AT model)
NOTE:
Be careful not to drop bolts into the torque convert-
er clutch housing.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
(3) Fit the plug to service hole.
(1) Install the power steering pump.
Tightening torque:
Refer to COMPONENT of Power Steering
section for the tightening torque. <Ref. to PS-
4, COMPONENT, General Description.>
(2) Connect the power steering pump switch
connector.
(3) Install and adjust the front side belt. <Ref. to
ME(H4DOTC)-38, FRONT SIDE BELT, IN-
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
AT model
MT model
NOTE:
Tightening torque:
75 Nm (7.6 kgf-m, 55.3 ft-lb)
<Ref. to EX(H4DOTC)-10, INSTALLATION, Center
Exhaust Pipe.> <Ref. to EX(H4DOTC)-7, INSTAL-
LATION, Front Exhaust Pipe.>
ME-00044
ME-00037
ME-00035
AT-03238
MT-00077
ME-02651
(B) (A) (B) (A)
ME(H4DOTC)-34
Engine Assembly
MECHANICAL
(1) Fuel delivery hose, return hose and evapo-
ration hose
(4) Pressure regulator hose
18) Connect the following connectors and termi-
nals.
20) Install the air cleaner case and air intake duct.
<Ref. to IN(H4DOTC)-8, INSTALLATION, Air Clean-
er Case.> <Ref. to IN(H4DOTC)-9, INSTALLATION,
Air Intake Duct.>
21) Install the A/C pressure hoses. <Ref. to AC-39,
INSTALLATION, Hose and Tube.>
22) Install the radiator. <Ref. to CO(H4DOTC)-20,
INSTALLATION, Radiator.>
23) Install the coolant filler tank. <Ref. to
CO(H4DOTC)-29, INSTALLATION, Coolant Filler
Tank.>
cables.
Procedure.>
sary. (AT model) <Ref. to 5AT-28, INSPECTION,
Automatic Transmission Fluid.>
hood.
C: INSPECTION
1) Check that pipes, hoses, connectors and clamps
are installed firmly.
2) Check that the engine coolant is at specified lev-
el.
3) Check that the ATF is at specified level. (AT
model)
4) Start the engine and check for exhaust gas, en-
gine coolant, leaks of fuel, etc. Also check for noise
and vibrations.
ME(H4DOTC)-35
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine unit. <Ref. to ME(H4DOTC)-
28, REMOVAL, Engine Assembly.>
sembly.
B: INSTALLATION
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
exist.
ME(H4DOTC)-36
MECHANICAL
A: PROCEDURE
1) After removing the engine from body, secure it to
ST in the following procedure.
RH
LH
ST3 499817100 ENGINE STAND
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 pre-
viously in order to do that particular procedure.
ME-00057
ST3
ST2
ST1
ME(H4DOTC)-37
V-belt
MECHANICAL
12.V-belt
A: REMOVAL
NOTE:
1. FRONT SIDE BELT
IN(H4DOTC)-9, REMOVAL, Air Intake Duct.>.
3) Remove the collector cover bracket.
2. REAR SIDE BELT
1) Remove the front side belts. <Ref. to
ME(H4DOTC)-37, FRONT SIDE BELT, REMOV-
AL, V-belt.>
ME-03084
(A)
(C)
(B)
ME-00059
(A)
(B)
ME-00060
ME-00061
ME(H4DOTC)-38
V-belt
MECHANICAL
B: INSTALLATION
NOTE:
Wipe off any oil or water on the belt and pulley.
1. FRONT SIDE BELT
1) Install the front side belt (C), and tighten the slid-
er bolt (B) so as to obtain the specified belt tension.
Tightening torque:
Lock bolt (A):
25 Nm (2.5 kgf-m, 18.4 ft-lb)
Slider bolt (B):
8 Nm (0.8 kgf-m, 5.9 ft-lb)
4) Install the collector cover bracket.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
5) Install the air intake duct. <Ref. to IN(H4DOTC)-
9, INSTALLATION, Air Intake Duct.>
2. REAR SIDE BELT
1) Install the belt tensioner.
2) Install the rear side belt, and tighten the slider
bolt (B) so as to obtain the specified belt tension.
Tightening torque:
Lock nut (A):
23.0 Nm (2.35 kgf-m, 17.0 ft-lb)
4) Install the front side belt. <Ref. to ME(H4DOTC)-
38, FRONT SIDE BELT, INSTALLATION, V-belt.>
(A)
(C)
(B)
ME-00059
ME-03084
(A)
(B)
ME-00060
ME(H4DOTC)-39
V-belt
MECHANICAL
C: INSPECTION
1) Replace the belts, if crack, fraying or wear is
found.
or idler pulley installing position.
(A)
640 780 N (65 80 kgf, 144 175 lbf)
At inspection:
490 640 N (50 65 kgf, 110 144 lbf)
(B)
650 750 N (66 76 kgf, 146 169 lbf)
At inspection:
350 450 N (36 46 kgf, 78 101 lbf)
Belt tension (when not using a 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)
(A) Front side belt
(B) Rear side belt
C/P Crank pulley
GEN Generator
I/P Idler pulley
C/P
P/S
A/C
GEN
(A)
(B)
I/P
PM-00154
(A) Front side belt
(B) Rear side belt
(C) 98 N (10 kgf, 22 lbf)
C/P Crank pulley
GEN Generator
I/P Idler pulley
C/P
P/S
A/C
GEN
(A) (B)
(C)
I/P
PM-00002
ME(H4DOTC)-40
Crank Pulley
MECHANICAL
13.Crank Pulley
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
shaft, use ST.
B: INSTALLATION
2) Install the pulley bolt. To lock the crankshaft, use
ST.
pressed air.
and thread.
Tightening torque:
180 Nm (18.3 kgf-m, 132.7 ft-lb)
3) Check that the tightening angle of the crank pul-
ley bolt is 65 or more. Perform the following proce-
dure when less than 65.
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
pressed air.
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.
4) Install the V-belts. <Ref. to ME(H4DOTC)-38,
INSTALLATION, V-belt.>
C: INSPECTION
1) Check the V-belt is not worn or otherwise dam-
aged.
2) Check the tension of the belt. <Ref. to
ME(H4DOTC)-39, INSPECTION, V-belt.>
ME-00063
ST
ME-00063
ST
ME(H4DOTC)-41
Timing Belt Cover
MECHANICAL
14.Timing Belt Cover
A: REMOVAL
NOTE:
1) Remove the secondary air pump. <Ref. to
EC(H4DOTC)-20, REMOVAL, Secondary Air Pump.>
REMOVAL, V-belt.>
<Ref. to ME(H4DOTC)-40, REMOVAL, Crank Pul-
ley.>
4) Remove the timing belt cover (LH) (A).
5) Remove the timing belt cover (RH) (B).
6) Remove the front timing belt cover (C).
B: INSTALLATION
1) Install the front timing belt cover (C).
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
2) Install the timing belt cover (RH) (B).
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
3) Install the timing belt cover (LH) (A).
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
4) Install the crank pulley. <Ref. to ME(H4DOTC)-
40, INSTALLATION, Crank Pulley.>
6) Install the secondary air pump. <Ref. to
EC(H4DOTC)-20, INSTALLATION, Secondary Air
Pump.>
C: INSPECTION
Check the cover for damage.
ME-00064
(A)
(C)
(B)
ME-00064
(A)
(C)
(B)
ME(H4DOTC)-42
Timing Belt
MECHANICAL
15.Timing Belt
A: REMOVAL
NOTE:
when replacing a single part. For operation proce-
dures, refer to Timing Belt in the PM section.
<Ref. to PM-17, Timing Belt.>
1. TIMING BELT
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4DOTC)-
<Ref. to ME(H4DOTC)-41, REMOVAL, Timing Belt
Cover.>
ME-00065
ME-03124
ME-00728
ME-00729
ME(H4DOTC)-43
Timing Belt
MECHANICAL
5) If the alignment mark or arrow mark (which indi-
cates 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), in-
take cam sprocket (RH) and exhaust cam
sprocket (RH) with notches of timing belt cover
and cylinder block.
(2) Using white paint, put alignment and/or ar-
row marks on timing belts in relation to the cam
sprockets.
Z
1
: 54.5 teeth
Z
2
: 51 teeth
Z
3
: 28 teeth
6) Remove the belt idler (A).
ME-00069
ST
ME-00070
ME-03175
ME-03176
Z3
Z1 Z2
Z3
(A)
(B)
(C)
ME-03129
ME(H4DOTC)-44
Timing Belt
MECHANICAL
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.
1) Remove the belt idler (B) and (C).
2) Remove the belt idler No. 2.
3) Remove the automatic belt tension adjuster as-
sembly.
B: INSTALLATION
adjuster assembly.
CAUTION:
(1,000 kgf, 2,205 lbf).
cylinder. However, do not press the adjuster
Do not release the press pressure until stop-
per 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 165 N (16.8 kgf, 37.1 lbf) or more
until the adjuster rod is aligned with the stopper
pin hole in the cylinder.
(3) With a 2 mm (0.08 in) dia. stopper pin or a
2 mm (0.08 in) (nominal) dia. hex wrench insert-
ed into the stopper pin hole in cylinder, secure
the adjuster rod.
(A)
(B)
(C)
ME-03129
ME-00075
ME-03130
ME-00077
ME-00078
ME(H4DOTC)-45
Timing Belt
MECHANICAL
2) Install the automatic belt tension adjuster as-
sembly.
Tightening torque:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
3) Install the belt idler No. 2.
Tightening torque:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
4) Install the belt idlers.
Tightening torque:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
2. TIMING BELT
adjuster assembly. <Ref. to ME(H4DOTC)-44, AU-
TOMATIC BELT TENSION ADJUSTER ASSEM-
BLY AND BELT IDLER, INSTALLATION, Timing
Belt.>
2) Align the mark (A) on crank sprocket with the
mark on oil pump cover at cylinder block.
3) Align single line mark (A) on the exhaust cam
sprocket (RH) with notch (B) on timing belt cover.
4) Align single line mark (A) on the intake cam
sprocket (RH) with notch (B) on timing belt cover.
(Make sure that the double lines (C) on intake and
exhaust camshaft sprockets are aligned.)
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).
ME-03131
ME-00075
ME-00080
(A)
ME-00081
ME-00082
(A)
(B)
ME-03133
(B)
(C)
(A)
ME-00084
(B)
(A)
ME(H4DOTC)-46
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 the intake and exhaust cam sprockets are
aligned.
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.
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.)
When the camshafts are rotated to install the
timing belts, #2 intake and #4 exhaust cam of
camshafts (LH) are held to push their corre-
sponding valves down. (Under this condition,
these valves are held lifted.) Right-side cam-
shafts are held so that their cams do not push
valves down.
Camshafts (LH) must be rotated from the
zero-lift position to the position where the tim-
ing belt is to be installed with the smallest pos-
sible angle, in order to prevent mutual
interference of intake and exhaust valve heads.
Do not allow the camshafts to rotate in the di-
rection shown in the upper figure. Doing this
may cause both the intake and exhaust valves
to lift simultaneously, resulting in mutual inter-
ference of heads.
(A) Intake camshaft
(B) Exhaust camshaft
ME-03135
(A)
(B)
(C)
ME-00086
(A)
(B)
(A) Direction of rotation
(B) Timing belt installation position
(A)
(A)
(A)
(A)
(B)
(B)
GGGGG NG NNG NNG NNNNNNNNNNNNNNG NNGGGGGGGGGGGGGGGGGGG
OK OOOOOOOOOOOOOOOOOOOOOKKKKKKKKKKKKK OK OOKKKK
ME-03177
ME(H4DOTC)-47
Timing Belt
MECHANICAL
8) Install the 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:
If the timing belt slips by 3 or more teeth, the valve and piston may hit each other.
Make sure that the direction of belt rotation is correct.
(1) Arrow mark (4) 54.5 tooth length (6) 28 tooth length
(2) Timing belt (5) 51 tooth length (7) Install it in the end
(3) 28 tooth length
ME-03137
(1) (2)
(5)
(6)
(4)
(D)
(A)
(C)
(B)
(E)
(3)
RH-IN
RH-EX LH-EX
LH-IN
(7)
ME(H4DOTC)-48
Timing Belt
MECHANICAL
9) Install the belt idlers.
Tightening torque:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
NOTE:
Make sure that the marks on the timing belt and
sprockets are aligned.
10) After ensuring that the marks on the timing belt
and sprockets are aligned, remove the stopper pin
from tensioner adjuster.
11) Install the timing belt guide. (MT model)
NOTE:
Clean the threaded portion of timing belt cover
before attaching bolts.
Apply liquid gasket to the threaded portion of
cam sprocket. (when reusing bolts)
Liquid gasket:
equivalent
(1) Temporarily tighten the bolts mounting the
timing belt guide.
(2) Check and adjust the clearance between
timing belt and timing belt guide using a thick-
ness gauge.
Clearance:
1.00.5 mm (0.0390.020 in)
ME-00090
ME-00245
ME-00230
ME-00091
ME-03138
ME-00731
ME-00732
ME(H4DOTC)-49
Timing Belt
MECHANICAL
(3) Tighten the bolts mounting the timing belt
guide.
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
<Ref. to ME(H4DOTC)-41, INSTALLATION, Tim-
ing Belt Cover.>
<Ref. to ME(H4DOTC)-40, 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 timing belt.
2) Check the condition on the back surface of the
timing belt. If cracks are found, replace the timing
belt.
CAUTION:
Be careful not to let oil, grease or coolant
contact the timing 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-00095
ME-03124
ME-00728
ME-00729
ME-00099
h
ME(H4DOTC)-50
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 neces-
sary, replace the automatic belt tension adjuster
assembly.
NOTE:
Slight traces of oil on the oil seal of the rod does not
indicate a problem.
2) Check that the adjuster rod does not move when
a pressure of 165 N (16.8 kgf, 37.1 lbf) is applied to
it. This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 165 N (16.8 kgf, 37.1 lbf), 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 165 N (16.8 kgf, 37.1 lbf) to
it. Check the adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new part.
CAUTION:
(1,000 kgf, 2,205 lbf).
cylinder. However, do not press the adjuster
4) Measure the amount of rod protrusion H from
the end surface of body. If it is not within specified
range, replace with new part.
Amount of rod protrusion H:
5.2 6.2 mm (0.205 0.244 in)
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 ad-
juster assembly with a new part if faulty.
2) Check the belt tension pulley for smooth rota-
tion. 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 pul-
ley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
ME-00100
H
ME(H4DOTC)-51
Cam Sprocket
MECHANICAL
16.Cam Sprocket
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
ley.>
Cover.>
<Ref. to ME(H4DOTC)-42, REMOVAL, Timing
Belt.>
5) Remove the actuator cover of the intake cam
sprocket.
6) Fasten the cam sprocket and remove from the
cam shaft using ST.
ST 499207400 CAM SPROCKET WRENCH
B: INSTALLATION
1) Fasten the cam sprocket and install to the cam
shaft using ST.
NOTE:
Do not confuse the cam sprockets (LH) and (RH)
during installation.
Tightening torque:
Tighten to 30 Nm (3.1 kgf-m, 22.1 ft-lb) of
torque, and then tighten further by 45.
Tightening torque:
Tighten to 30 Nm (3.1 kgf-m, 22.1 ft-lb) of
torque, and then tighten further by 45.
2) Attach the actuator cover of the intake cam
sprocket.
NOTE:
Use new O-rings.
Tightening torque:
3.4 Nm (0.3 kgf-m, 2.5 ft-lb)
3) Install the timing belt. <Ref. to ME(H4DOTC)-44,
4) Install the timing belt cover. <Ref. to ME(H4DOTC)-
41, INSTALLATION, Timing Belt Cover.>
C: INSPECTION
and scratches.
sprocket and key.
ME-03282
ST
ME-03283
ST
ME-03282
ST
ME-03283
ST
ME(H4DOTC)-52
Crank Sprocket
MECHANICAL
17.Crank Sprocket
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
ley.>
Cover.>
<Ref. to ME(H4DOTC)-42, REMOVAL, Timing
Belt.>
B: INSTALLATION
ing Belt.>
3) Install the timing belt cover. <Ref. to
ME(H4DOTC)-41, INSTALLATION, Timing Belt
Cover.>
C: INSPECTION
wear and scratches.
sprocket and key.
3) Check the crank sprocket protrusion used for
sensor for damage and contamination of foreign
matter.
ME-00103
ME-00103
ME(H4DOTC)-53
Camshaft
MECHANICAL
18.Camshaft
A: REMOVAL
NOTE:
ance for preparation. <Ref. to ME(H4DOTC)-25,
INSPECTION, Valve Clearance.>
REMOVAL, V-belt.>
Cover.>
4) Remove the timing belt. <Ref. to ME(H4DOTC)-
42, REMOVAL, Timing Belt.>
5) Remove the cam sprocket. <Ref. to ME(H4DOTC)-
6) Disconnect the oil flow control solenoid valve as-
sembly connector.
8) Remove the timing belt cover No. 2 (RH).
NOTE:
Do not damage or lose the seal rubber when re-
moving the timing belt covers.
11) Disconnect the PCV hose from the rocker cov-
er.
12) Remove the rocker cover and gasket.
13) Remove the oil pipe.
ME-03094
ME-00106
(A) Union screw with filter (with protrusion)
(B) Union screw without filter (without protrusion)
ME-00107
ME-00105
(A)
(B)
ME-03085
ME(H4DOTC)-54
Camshaft
MECHANICAL
14) Loosen the oil flow control solenoid valve as-
sembly and intake camshaft cap bolts equally, a lit-
tle at a time in alphabetical order shown in the
figure.
15) Loosen the exhaust camshaft cap bolts equal-
ly, a little at a time in alphabetical order shown in
the figure.
16) Remove the oil flow control solenoid valve as-
sembly, intake camshaft cap and camshaft.
17) Remove the exhaust camshaft caps and cam-
shaft.
NOTE:
Arrange camshaft caps in order so that they can be
installed in their original positions.
CAUTION:
Do not scratch the journal surface when remov-
ing the oil seal.
lated parts.
B: INSTALLATION
1) Install the camshaft.
Apply engine oil to the cylinder head at camshaft
journal 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
lobe.
NOTE:
Set the camshaft to the position shown in the fig-
ure.
When set at the position shown in the figure, it is
not necessary to rotate the camshaft (RH) when in-
stalling the timing belt, but it is necessary to rotate
the camshaft (LH) slightly.
Intake camshaft (LH):
Rotate 80 clockwise.
Exhaust camshaft (LH):
Rotate 45 counterclockwise.
ME-00771
(A)
(E)
(F)
(B)
(D)
(C)
ME-00772
(A)
(E)
(F)
(B)
(D)
(C)
A Cylinder head (LH)
B Cylinder head (RH)
(a) Intake camshaft
(b) Exhaust camshaft
ME-00111
11
11
77.5
77.5
(a)
(b)
(a)
(b)
A
B
ME(H4DOTC)-55
Camshaft
MECHANICAL
2) Install the camshaft cap and oil flow control sole-
noid valve assembly.
(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:
or equivalent
(2) Apply a thin coat of engine oil to the cap
bearing surface, and install the cap to the cam-
shaft according to the identification mark.
(3) Gradually tighten the camshaft cap and oil
control valve assembly in at least two stages in
alphabetical order 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, 14.8 ft-lb)
(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 camshaft oil seal
periphery and oil seal lips, then install the oil seal
on the camshaft using ST1 and ST2.
NOTE:
Use a new oil seal.
ST1 499587600 OIL SEAL INSTALLER
ST2 499597200 OIL SEAL GUIDE
4) Install the oil pipe.
NOTE:
Make sure not to mix up the union screws with filter
and without filter as their installation positions are
different.
Tightening torque:
29 Nm (3.0 kgf-m, 21.4 ft-lb)
5) Connect the oil flow control solenoid valve con-
nector.
6) Tighten the ignition coil.
7) Similarly, install the parts on right-hand side.
ME-00773
ME-02379
(G)
(C)
(A) (K)
(L)
T1
(F)
(E)
T2
T2
(B) (J)
(H)
(D) (I)
T1
(A) Union screw with filter (with protrusion)
(B) Union screw without filter (without protrusion)
ME-00116
ST1
ST2
(A)
(B)
ME-03085
ME-03094
ME(H4DOTC)-56
Camshaft
MECHANICAL
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
9) Install the timing belt cover No. 2 (RH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
10) Install the timing belt cover No. 2 (LH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
11) Install the cam sprocket.
<Ref. to ME(H4DOTC)-51, INSTALLATION, Cam
Sprocket.>
12) Install the timing belt. <Ref. to ME(H4DOTC)-
44, INSTALLATION, Timing Belt.>
ME(H4DOTC)-26, ADJUSTMENT, Valve Clear-
ance.>
cover.
NOTE:
Use a new gasket.
(2) Apply liquid gasket to the specified point of
the cylinder head. Apply extra amount of liquid
gasket around semicircular plugs 5 mm or more.
NOTE:
Liquid gasket:
or equivalent
(3) Install the rocker cover on cylinder head.
Ensure the gasket is properly positioned during
installation.
ME-00105
ME-00107
ME-00106
ME-02771
ME(H4DOTC)-57
Camshaft
MECHANICAL
(4) Temporarily tighten the rocker cover tight-
ening bolt in alphabetical sequence shown in
the figure, and then tighten to specified torque
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(5) Connect the PCV hose.
ing Belt Cover.>
Pulley.>
C: INSPECTION
1) Measure the bend, and repair or replace if nec-
essary.
Service limit:
0.020 mm (0.0079 in) or less
place if faulty.
3) Measure the outside diameter of camshaft jour-
nal. If the journal diameter is not within the standard
value, check the oil clearance.
4) Measurement of the camshaft journal oil clear-
ance
(1) Clean the bearing caps and camshaft jour-
nals.
(2) Place the camshafts on cylinder head.
(Without installing the valve lifter)
(3) Place a plastigauge across each camshaft
journals.
(4) Gradually tighten the cap in at least two
stages in alphabetical order shown in the figure,
and then tighten to specified torque. Do not turn
the camshaft.
Tightening torque:
T1: 9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
T2: 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(5) Remove the bearing caps.
(6) Measure the widest point of the plastigauge
on each journal. If oil clearance exceeds the
standard, 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)
(7) Completely remove the plastigauge.
Camshaft journal
Front Center, rear
Standard
mm (in)
37.946 37.963
(1.4939 1.4946)
29.946 29.963
(1.1790 1.1796)
ME-00777
(E)
(F)
(H)
(G)
(D),(L)
(A),(I)
(C),(K)
(B),(J)
ME-00118
ME-00774
(A)
(E)
(F)
(B)
(D)
(C)
T2
T1
ME-00119
ME(H4DOTC)-58
Camshaft
MECHANICAL
5) Check the cam face condition; remove the minor
faults by grinding with oil stone. Measure the cam
height H. If it exceeds the standard or offset wear
occurs, replace it.
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)
37.0 mm (1.457 in)
6) Measure the thrust clearance of camshaft with
setting the dial gauge at end of camshaft. If the
thrust clearance exceeds the standard or there is
offset wear, replace the caps and cylinder head as
a set. If necessary replace the camshaft.
Standard:
0.068 0.116 mm (0.0027 0.0047 in)
ME-00120
H
A
ME-00121
ME(H4DOTC)-59
Cylinder Head
MECHANICAL
19.Cylinder Head
A: REMOVAL
NOTE:
ance for preparation. <Ref. to ME(H4DOTC)-25,
INSPECTION, Valve Clearance.>
REMOVAL, V-belt.>
ley.>
Cover.>
<Ref. to ME(H4DOTC)-42, REMOVAL, Timing Belt.>
<Ref. to ME(H4DOTC)-51, REMOVAL, Cam Sprock-
et.>
ifold.>
7) Remove the secondary air combination valve.
<Ref. to EC(H4DOTC)-21, REMOVAL, Secondary
Air Combination Valve.>
8) Remove the bolt which installs the A/C compres-
sor bracket on cylinder head.
9) Remove the camshaft. <Ref. to ME(H4DOTC)-
53, REMOVAL, Camshaft.>
10) Remove the oil level gauge guide. (LH side)
11) Remove the cylinder head bolts in alphabetical
order shown in the figure.
NOTE:
Leave the bolts (A) and (D) engaged by three or
four threads to prevent the cylinder head from fall-
ing.
hammer, separate it from cylinder block. Remove
the bolts (A) and (D) to remove cylinder head.
CAUTION:
ME-00122
(B) (C)
(D)
(E)
(F)
(A)
ME-00122
(B) (C)
(D)
(E)
(F)
(A)
ME(H4DOTC)-60
Cylinder Head
MECHANICAL
B: INSTALLATION
block.
CAUTION:
NOTE:
(1) Apply a thin coat of engine oil to washer and
bolt thread.
(2) Tighten all bolts to 29 Nm (3.0 kgf-m, 21.4
ft-lb) in alphabetical order.
(3) Further tighten all bolts to 69 Nm (7.0 kgf-
m, 50.9 ft-lb) in alphabetical order.
(4) Loosen all the bolts by 180 in the reverse
order of installing, and loosen them further by
180.
(5) Tighten all bolts to 49 Nm (5.0 kgf-m, 36.1
ft-lb) in alphabetical order.
(6) Tighten all bolts by 80 to 90 in alphabetical
order.
(7) Tighten all bolts by 40 to 45 in alphabetical
order.
CAUTION:
Do not tighten the bolts 45.
(8) Further tighten the bolts (A) and (B) by 40 to
45.
CAUTION:
Make sure the total re-tightening angle of the
step (7) and (8) does not exceed 90.
3) Install the oil level gauge guide. (LH side)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
4) Install the camshaft. <Ref. to ME(H4DOTC)-54,
5) Install the bolt of A/C compressor bracket to the
cylinder head.
Tightening torque:
36 Nm (3.7 kgf-m, 26.6 ft-lb)
6) Install the secondary air combination valve.
<Ref. to EC(H4DOTC)-22, INSTALLATION, Sec-
ondary Air Combination Valve.>
Manifold.>
Sprocket.>
ing Belt.>
ance.>
cover.
NOTE:
Use a new gasket.
gasket around semicircular plugs 5 mm or
more.
NOTE:
Liquid gasket:
or equivalent
installation.
ME-00123
(B)
(C)
(D) (E)
(F) (A)
ME-02771
ME(H4DOTC)-61
Cylinder Head
MECHANICAL
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ing Belt Cover.>
Pulley.>
C: DISASSEMBLY
3) Using ST2, compress the valve spring and re-
move the valve spring retainer key. Remove each
valve and valve spring.
ST2 499718000 VALVE SPRING REMOVER
NOTE:
Pay careful attention not to damage the lips of in-
take valve oil seals and exhaust valve oil seals.
Keep all the removed parts in order for re-install-
ing in their original positions.
ME-00777
(E)
(F)
(H)
(G)
(D),(L)
(A),(I)
(C),(K)
(B),(J)
ME-00124
ST1
ST2
ME(H4DOTC)-62
Cylinder Head
MECHANICAL
D: ASSEMBLY
(1) Exhaust valve (6) Valve spring (10) Exhaust valve oil seal
(2) Intake valve (7) Retainer (11) Intake valve guide
(3) Cylinder head (8) Retainer key (12) Exhaust valve guide
(4) Valve spring seat (9) Valve lifter (13) Plug
(5) Intake valve oil seal
ME-03157
(3)
(1)
(2)
(11) (4) (5) (6) (7) (8) (9)
(11)
(12)
(12)
(10)
(4)
(4)
(5) (6)
(6)
(7)
(7)
(8)
(8)
(9)
(9)
(10)
(4)
(6)
(7)
(8)
(9)
(13)
(13)
ME(H4DOTC)-63
Cylinder Head
MECHANICAL
1) Install the valve spring and valve.
NOTE:
(2) Set the cylinder head on ST1.
NOTE:
(4) Set the ST2 on valve spring.
ST2 499718000 VALVE SPRING REMOVER
2) Apply oil to the surfaces of the valve lifter.
3) Install the valve lifter.
E: INSPECTION
1. CYLINDER HEAD
2) Measure the warping of the cylinder head sur-
face that mates with crankcase using a straight
edge (A) and thickness gauge (B).
If the warping exceeds the limit, correct the surface
by grinding it with a surface grinder.
Warping limit:
0.035 mm (0.0014 in)
Grinding limit:
0.3 mm (0.012 in)
127.5 mm (5.02 in)
NOTE:
cause warping. When reinstalling, pay special at-
tention to the torque so as to tighten evenly.
ME-00124
ST1
ST2
ME-00126
(A)
(B)
ME(H4DOTC)-64
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 re-
placed.
Valve seat width W:
Intake
Standard
0.6 1.4 mm (0.024 0.055 in)
Exhaust
Standard
1.2 1.8 mm (0.047 0.071 in)
3. VALVE GUIDE
valve stem. The clearance can be checked by mea-
suring respectively the outer diameter of valve
stem with a micrometer and the inner diameter of
valve guide with a caliper gauge.
stem:
Standard
Intake
0.030 0.057 mm (0.0012 0.0022 in)
Exhaust
0.040 0.067 mm (0.0016 0.0026 in)
2) If the clearance between valve guide and valve
stem exceeds the standard, replace the valve
guide or valve itself whichever shows greater
amount of wear or damaged and etc. See the fol-
lowing procedure for valve guide replacement.
6.000 6.012 mm (0.2362 0.2367 in)
Intake
5.955 5.970 mm (0.2344 0.2350 in)
Exhaust
5.945 5.960 mm (0.2341 0.2346 in)
ME-00127
W
ME-00287
ME-00128
ST1
ST2
ME(H4DOTC)-65
Cylinder Head
MECHANICAL
ST 18251AA020 VALVE GUIDE ADJUSTER
inder head.
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.
ST2 18251AA020 VALVE GUIDE ADJUSTER
15.8 16.2 mm (0.622 0.638 in)
NOTE:
stone.
remedy the ST.
move chips.
guide.
ME-00757
ST
L
ME-00130
ST1
ST2
ME-00294
ME(H4DOTC)-66
Cylinder Head
MECHANICAL
1) Inspect the flange and stem of valve, and re-
place the valve with a new part if damaged, worn,
deformed, or if H is outside of the specified limit.
Standard
Intake (A)
1.0 1.4 mm (0.039 0.055 in)
Exhaust (B)
1.3 1.7 mm (0.051 0.067 in)
seat surface, and lap the valve and seat surface.
Install a new valve oil seal after lapping.
NOTE:
Intake
104.4 mm (4.110 in)
Exhaust
104.65 mm (4.1201 in)
5. VALVE SPRING
ME-00758
H
H
(B)
(A)
Tension/spring
height
N (kgf, lbf)/mm (in)
Set
205 235 (20.9 24.0,
46.1 52.8)/36.0 (1.417)
Lift
426 490 (43.4 50.0,
95.8 110)/26.50 (1.041)
Squareness
2.5, 2.1 mm (0.083 in) or
less
ME-00132
ME(H4DOTC)-67
Cylinder Head
MECHANICAL
SEAL
part. See the procedure 2) and subsequent for re-
placement procedures.
When the lip is damaged.
When the spring is out of the specified position.
valve seat.
When replacing the valve guide.
NOTE:
mer, etc. or strike in.
The intake valve oil seal and exhaust valve oil
seal can be distinguished by colors.
Color of rubber part:
Intake [Gray]
Exhaust [Green]
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)
3) Measure the inner diameter of valve lifter mating
surface on cylinder head.
Inner diameter:
34.994 35.016 mm (1.3777 1.3786 in)
NOTE:
If difference between outer diameter of valve lifter
and inner diameter of its mating surface is not with-
in the standard or there is uneven wear, replace the
cylinder head.
Standard:
0.019 0.057 mm (0.0007 0.0022 in)
ME-00133
ST2
ME-00134
ME-00135
ME(H4DOTC)-68
Cylinder Block
MECHANICAL
20.Cylinder Block
A: REMOVAL
NOTE:
oil completely.
ifold.>
REMOVAL, V-belt.>
ley.>
Cover.>
<Ref. to ME(H4DOTC)-42, REMOVAL, Timing Belt.>
<Ref. to ME(H4DOTC)-51, REMOVAL, Cam Sprock-
et.>
<Ref. to ME(H4DOTC)-52, REMOVAL, Crank
Sprocket.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the cylinder head.
<Ref. to ME(H4DOTC)-59, REMOVAL, Cylinder
Head.>
10) Remove the clutch disc and cover. (MT model)
<Ref. to CL-13, REMOVAL, Clutch Disc and Cov-
er.>
11) Remove the flywheel. (MT model)
<Ref. to CL-16, REMOVAL, Flywheel.>
12) Remove the drive plate. (AT model)
Using the ST, lock the crankshaft.
13) Remove the oil separator cover.
14) Remove the water by-pass pipe for heater.
15) Remove the oil filter. <Ref. to LU(H4DOTC)-23,
REMOVAL, Engine Oil Filter.>
16) Remove the oil cooler. <Ref. to LU(H4DOTC)-
23, REMOVAL, Engine Oil Filter.>
17) Remove the water pump. <Ref. to CO(H4DOTC)-
cylinder block.
NOTE:
pump.
19) Remove the oil pump from cylinder block using
a flat tip screwdriver.
CAUTION:
(1) Set the part so that the cylinder block (LH) is
on the upper side.
(2) Remove the bolts which secure oil pan to
cylinder block.
(3) Insert an oil pan cutter blade between cylin-
der block-to-oil pan clearance and remove the
oil pan.
CAUTION:
22) Remove the oil strainer stay.
ME-00136
ST
LU-00015
ME-00138
ME(H4DOTC)-69
Cylinder Block
MECHANICAL
25) Remove the water pipe.
ME-00300
(1) Service hole plug (4) Piston pin (7) Seal washer
(2) Gasket (5) Service hole cover (8) Washer
(3) Snap ring (6) O-ring
ME-02889
(3)
(4)
(2)
(1)
(3)
(4)
(5)
(6)
(2)
(3)
(2)
(1)
(3)
(4)
(4)
(8)
(7)
(1)
ME(H4DOTC)-70
Cylinder Block
MECHANICAL
26) Remove the service hole plugs using a hexa-
gon wrench [14 mm].
tons to bottom dead center position, then remove
the piston snap ring through service hole of #1 and
#2 cylinders.
using ST.
NOTE:
30) Similarly remove the piston pins from #3 and #4
pistons.
31) Remove the cylinder block connecting bolt on
the RH side.
32) Loosen the cylinder block connecting bolt on
the LH side by 2-3 turns.
33) Set the part so that the cylinder block (LH) is on
the upper side, and remove the cylinder block con-
necting bolt.
ME-00140
ME-00141
ME-00142
ST
ME(H4DOTC)-71
Cylinder Block
MECHANICAL
34) Separate the cylinder block (LH) and (RH).
NOTE:
When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
ing rod.
NOTE:
combination. Press the bearing at the end opposite
to locking lip.
38) Draw out each piston from cylinder block using
NOTE:
(1) Cylinder block (4) Crankshaft bearing (6) Seal washer
(2) Rear oil seal (5) Piston (7) Washer
(3) Crankshaft
ME-02890
(2)
(3)
(4)
(4)
(5)
(6)
(5)
(1)
(1)
(7)
ME(H4DOTC)-72
Cylinder Block
MECHANICAL
B: INSTALLATION
(1) Crankshaft bearing (4) Rear oil seal (7) Washer
(2) Crankshaft (5) O-ring
(3) Cylinder block (6) Seal washer
ME-03186
(4)
(1)
(3)
(6)
(6)
(7)
(7)
(3)
(2)
(5)
(6)
(7)
ME(H4DOTC)-73
Cylinder Block
MECHANICAL
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 O-ring on the cylin-
der block (RH).
(LH).
NOTE:
Do not allow liquid gasket to jut into O-ring
grooves, oil passages, bearing grooves, etc.
Liquid gasket:
or equivalent
thread.
NOTE:
bolts on LH side (A D) in alphabetical sequence.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
bolts on RH side (E J) in alphabetical sequence.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
ME-00145
ME-00779
(A)
(B)
(D)
(C)
ME-00780
(J)
(H)
(G)
(E)
(F)
(I)
ME-00779
(A)
(B)
(D)
(C)
ME-00780
(J)
(H)
(G)
(E)
(F)
(I)
ME(H4DOTC)-74
Cylinder Block
MECHANICAL
(A), (C): Angle tightening
Tightening angle:
90
(B), (D): Torque tightening
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
Tightening angle:
90
11) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts on the LH side (A H) in alphabetical
order.
Tightening torque:
(A) (G): 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Use a new oil seal.
GUIDE
STALLER
13) Position the top ring gap at (A) or (B) in the fig-
ure.
14) Position the second ring gap at 180 on the re-
verse side the top ring gap.
ME-00779
(A)
(B)
(D)
(C)
ME-00780
(J)
(H)
(G)
(E)
(F)
(I)
ME-00147
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(A)
(A) Rear oil seal
(B) Flywheel attaching bolt
ME-00148
ST1
ST2
(B)
(A)
ME-00718
(A) (B)
ME-02087
(C)
25
ME(H4DOTC)-75
Cylinder Block
MECHANICAL
16) Align the upper rail spin stopper (E) to the side
hole (D) on the piston.
17) Position the expander gap at (F) in the figure on
the 180 opposite direction of (C).
18) Set the lower rail gap at position (G), located
120 clockwise from (C).
NOTE:
Make sure ring gaps do not face the same direc-
tion.
skirt area.
ME-02471
(E) (D)
ME-02088
(F)
ME-02089
120
(C) (G)
ME(H4DOTC)-76
Cylinder Block
MECHANICAL
Install the snap rings in the piston holes located op-
posite to the service holes in cylinder block before
positioning pistons in cylinders.
NOTE:
Use new snap rings.
(A) Front side
ME-00154
#4
#3
#2
#1
(A)
(1) Piston (4) Gasket Tightening torque:Nm (kgf-m, ft-lb)
(2) Piston pin (5) Service hole plug T: 70 (7.1, 51.6)
(3) Snap ring
ME-02442
(1)
(1)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
T
ME(H4DOTC)-77
Cylinder Block
MECHANICAL
20) Install the piston.
are on the upper side.
#1 and #2 connecting rods are set at bottom
dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to the pistons and
cylinders and insert pistons in their cylinders us-
ing ST2.
ST2 498747300 PISTON GUIDE
NOTE:
Face the piston front mark towards the front of the
engine.
21) Install the piston pin.
(1) Apply a coat of engine oil to ST3 before in-
sertion, and then insert it into the service hole to
align piston pin hole with connecting rod small
end.
ST3 499017100 PISTON PIN GUIDE
(3) Install the snap ring.
NOTE:
Use new snap rings.
(4) Apply liquid gasket to the threaded portion
of the service hole plug.
Liquid gasket:
equivalent
(A) Front mark
ME-00157
ST2
ST1
ME-00722
(A)
ME-00158
ST1
ST3
ME-00159
ME-00160
ME(H4DOTC)-78
Cylinder Block
MECHANICAL
(5) Install the service hole plug and gasket.
NOTE:
Use a new gasket.
are on the upper side. Following the same pro-
cedures as used for #1 and #2 cylinders, install
the pistons and piston pins.
(7) Install the service hole cover.
NOTE:
Use new O-rings.
ME-00140
(1) Piston (5) Service hole plug Tightening torque:Nm (kgf-m, ft-lb)
(2) Piston pin (6) Service hole cover T1: 6.4 (0.65, 4.7)
(3) Snap ring (7) O-ring T2: 70 (7.1, 51.6)
(4) Gasket
(2)
(3)
(1)
(2)
(6)
(3)
(7)
(4)
(5)
ME-02440
T2
T1
(1)
ME(H4DOTC)-79
Cylinder Block
MECHANICAL
22) Install the water pipe.
NOTE:
Use new O-rings.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Use new O-rings.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
25) Install the oil strainer stay.
NOTE:
Tighten the oil strainer stay together with baffle
plate.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
pan, and install the oil pan.
NOTE:
Liquid gasket:
or equivalent
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
27) Apply liquid gasket to the mating surface of oil
separator cover and the threaded portion of bolt (A)
shown in the figure (when reusing the bolt), and
then install the oil separator cover.
NOTE:
Use new oil separator cover.
Liquid gasket:
Mating surface
THREE BOND 1217G (Part No.
K0877Y0100) or equivalent
Bolt thread (A) (when reusing the bolt)
equivalent
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
28) Install the flywheel. (MT model) <Ref. to CL-16,
INSTALLATION, Flywheel.>
29) Install the clutch disc and cover. (MT model)
<Ref. to CL-13, INSTALLATION, Clutch Disc and
Cover.>
30) Install the drive plate. (AT model)
To lock the crankshaft, use ST.
Tightening torque:
72 Nm (7.3 kgf-m, 53.1 ft-lb)
ME-00300
ME-00162
ME-03333
(A)
ME-00136
ST
ME(H4DOTC)-80
Cylinder Block
MECHANICAL
31) Install the oil pump.
(1) Using the ST, install the front oil seal.
NOTE:
(2) Apply liquid gasket to the matching surface
of oil pump.
NOTE:
Liquid gasket:
or equivalent
(3) Apply a coat of engine oil to the inside of oil
seal.
(4) Install the oil pump to cylinder block. Be
careful not to damage the oil seal during instal-
lation.
NOTE:
Make sure the oil seal lip is not folded.
Use new O-rings and oil seals.
Do not forget to install the O-ring.
(5) Apply liquid gasket to the three bolts thread
shown in figure. (when reusing bolts)
Liquid gasket:
equivalent
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
32) Install the water pump and gasket.
NOTE:
When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Use a new gasket.
Tightening torque:
First: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
Second: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
33) Install the water by-pass pipe for heater.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
34) Install the oil cooler. <Ref. to LU(H4DOTC)-22,
INSTALLATION, Engine Oil Cooler.>
35) Install the oil filter. <Ref. to LU(H4DOTC)-23,
INSTALLATION, Engine Oil Filter.>
(A) O-ring
ME-00164
ME-00165
(A)
ME-00312
LU-02103
T
ME-02463
(F)
(E)
(D)
(C)
(B)
(A)
ME(H4DOTC)-81
Cylinder Block
MECHANICAL
36) Install the cylinder head.
<Ref. to ME(H4DOTC)-60, INSTALLATION, Cylin-
der Head.>
37) Install the camshaft. <Ref. to ME(H4DOTC)-
54, INSTALLATION, Camshaft.>
38) Install the crank sprocket. <Ref. to
ME(H4DOTC)-52, INSTALLATION, Crank Sprock-
et.>
Sprocket.>
ing Belt.>
ance.>
cover.
NOTE:
Use a new gasket.
gasket around semicircular plugs 5 mm or
more.
NOTE:
Liquid gasket:
or equivalent
installation.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ing Belt Cover.>
Pulley.>
Manifold.>
46) Install the generator and A/C compressor with
their brackets.
Tightening torque:
36 Nm (3.7 kgf-m, 26.6 ft-lb)
ME-02771
ME-00777
(E)
(F)
(H)
(G)
(D),(L)
(A),(I)
(C),(K)
(B),(J)
ME(H4DOTC)-82
Cylinder Block
MECHANICAL
C: DISASSEMBLY
NOTE:
Keep the removed connecting rods, connecting rod
caps and bearings in order so that they are kept in
their original combinations/groups, and not mixed
together.
pander.
NOTE:
ME-02741
(2)
(2)
(6)
(5)
(4)
(3)
(1)
ME(H4DOTC)-83
Cylinder Block
MECHANICAL
D: ASSEMBLY
2) Position each connecting rod with the side mark
facing forward.
3) Tighten the connecting rod cap with connecting
rod bolt. Make sure the arrow mark on connecting
rod cap facing front during installation.
NOTE:
When tightening the connecting rod nuts, apply
oil on the threads.
Tightening torque:
52 Nm (5.3 kgf-m, 38.4 ft-lb)
4) Install the oil ring upper rail, expander and lower
rail by hand.
ring expander.
NOTE:
Assemble so that the piston ring mark R faces the
top side of the piston.
(1) Connecting rod bearing (5) Second ring Tightening torque:Nm (kgf-m, ft-lb)
(2) Connecting rod (6) Top ring T: 52 (5.3, 38.4)
(3) Connecting rod cap (7) Snap ring
(4) Oil ring (8) Side mark
ME-02985
(1)
(1)
(7)
(4)
(5)
(6)
(3)
T
(2)
(8)
ME(H4DOTC)-84
Cylinder Block
MECHANICAL
E: INSPECTION
1. CYLINDER BLOCK
edge, and correct by grinding if necessary.
Warping limit:
0.025 mm (0.00098 in)
Grinding limit:
0.1 mm (0.004 in)
201.0 mm (7.91 in)
NOTE:
ature of 20C (68F).
Standard diameter:
A: 99.505 99.515 mm (3.9175 3.9179 in)
B: 99.495 99.505 mm (3.9171 3.9175 in)
(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
(F) #4 cylinder bore size mark
ME-00170
#5
#4
#3
#2
#1
(A) (B)
(F)
(D)
A
B
A
B
5
4
5
4
(C) (E)
ME(H4DOTC)-85
Cylinder Block
MECHANICAL
2) Cylinder inner diameter measurement
NOTE:
ture of 20C (68F).
Taper:
Standard
0.015 mm (0.0006 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
or cylinder wear, select a suitable sized piston by
measuring the piston clearance.
4) Cylinder outer diameter measurement
NOTE:
ture of 20C (68F).
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)
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)
piston.
NOTE:
ture of 20C (68F).
Standard
0.010 0.010 mm (0.00039 0.00039 in)
6) Boring and honing
(1) If any of the measured value of taper, out-of-
roundness or cylinder-to-piston clearance is out
of standard or if there is any damage on the cyl-
inder wall, rebore it to replace with an oversize
piston.
CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same time,
der block.
NOTE:
rise. Thus, when measuring the cylinder diameter,
wait until it has cooled to room temperature.
100.005 mm (3.9372 in)
H1: 10 mm (0.39 in)
H2: 45 mm (1.77 in)
H3: 80 mm (3.15 in)
H4: 115 mm (4.53 in)
ME-00171
(A) (B)
H2
H1
H3
H4
ME-00172
H
ME(H4DOTC)-86
Cylinder Block
MECHANICAL
2) Check the piston ring groove for wear and dam-
Replace if faulty.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 0.008 mm (0.0002 0.0003 in)
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 re-
placed, replace the piston ring with a new part of
the same size as piston.
NOTE:
stalling the ring to piston, face this mark to the top
side.
lower rail. When installing oil ring on piston, be
careful of the direction of each rail.
ME-00173
ME-00174
ME-00175
(A)
(A) Upper rail
(B) Expander
(C) Lower rail
ME-02480
(A)
(B)
(C)
(A)
(B)
(C)
ME(H4DOTC)-87
Cylinder Block
MECHANICAL
inder using the piston, and measure the piston ring
gap with a thickness gauge.
gauge.
NOTE:
5. 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)
the crankshaft, and measure the thrust clearance
using a thickness gauge. If the thrust clearance ex-
ceeds the standard or uneven wear is found, re-
place the connecting rod.
Standard
0.070 0.330 mm (0.0028 0.0130 in)
Standard
mm (in)
Piston ring gap
Top ring
0.20 0.25
(0.0079 0.0098)
Second ring
0.37 0.52
(0.015 0.020)
Oil ring rail
0.20 0.50
(0.0079 0.0197)
Standard
mm (in)
Clearance between
piston ring and pis-
ton ring groove
Top ring
0.040 0.080
(0.0016 0.0031)
Second ring
0.030 0.070
(0.0012 0.0028)
ME-00177
ME-00178
(A) Thickness gauge
(B) Connecting rod
( A)
( A)
( B)
( B)
ME-00179
ME-00180
ME(H4DOTC)-88
Cylinder Block
MECHANICAL
size as necessary.
Standard
0.017 0.045 mm (0.0007 0.0018 in)
and replace with a new part if worn or damaged.
Standard
0 0.022 mm (0 0.0009 in)
with ST and press.
(2) Press the bushing with the ST after applying
oil on the periphery of new bushing.
ST 499037100 CONNECTING ROD BUSH-
ING REMOVER AND IN-
STALLER
BEARING
cracks through liquid penetrant testing, etc. If de-
fective, replace the crankshaft.
2) Measure warping of the crankshaft. If it exceeds
the limit, correct or replace it.
NOTE:
If a suitable V-block is not available, using just the
#1 and #5 crankshaft bearings on cylinder block,
position the crankshaft on cylinder block. Then,
measure the crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
Unit: mm (in)
Bearing
Bearing size
Outer diameter of
crank pin
Standard
1.490 1.502
(0.0587 0.0591)
51.984 52.000
(2.0466 2.0472)
0.03
(0.0012)
undersize
1.504 1.512
(0.0592 0.0595)
51.954 51.970
(2.0454 2.0461)
0.05
(0.0020)
undersize
1.514 1.522
(0.0596 0.0599)
51.934 51.950
(2.0447 2.0453)
0.25
(0.0098)
undersize
1.614 1.622
(0.0635 0.0639)
51.734 51.750
(2.0368 2.0374)
ME-00181
ME-00174
ME-00182
ST
ME-00183
ME(H4DOTC)-89
Cylinder Block
MECHANICAL
place or grind to correct the crankshaft as neces-
sary. 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)
To 51.750 mm (2.0374 in)
Crank journal:
Out-of-roundness
0.005 mm (0.0002 in)
Cylindricality
0.006 mm (0.0002 in)
To 59.758 mm (2.3527 in)
ME-00184
Unit: mm (in)
Crank journal diameter
#1, #3 #2, #4, #5
Standard
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
1.998 2.011
(0.0787 0.0792)
2.000 2.013
(0.0787 0.0793)
1.490 1.502
(0.0587 0.0591)
0.03 (0.0012)
undersize
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
2.017 2.020
(0.0794 0.0795)
2.019 2.022
(0.0795 0.0796)
1.504 1.512
(0.0592 0.0595)
0.05 (0.0020)
undersize
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
2.027 2.030
(0.0798 0.0799)
2.029 2.032
(0.0799 0.0800)
1.514 1.522
(0.0596 0.0599)
0.25 (0.0098)
undersize
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)
1.614 1.622
(0.0635 0.0639)
ME(H4DOTC)-90
Cylinder Block
MECHANICAL
center bearing by using thickness gauge. If clear-
ance exceeds the standard, replace the bearing.
Standard
0.030 0.115 mm (0.0012 0.0045 in)
an undersize one, and replace or grind to correct
the crankshaft as necessary.
Standard
0.010 0.030 mm (0.0004 0.0012 in)
ME-00313
ME(H4DOTC)-91
MECHANICAL
A: SPECIFICATION
Refer to Cylinder Head for removal and installa-
tion procedures of intake and exhaust valves. <Ref.
to ME(H4DOTC)-59, REMOVAL, Cylinder Head.>
<Ref. to ME(H4DOTC)-60, INSTALLATION, Cylin-
der Head.>
ME(H4DOTC)-92
Piston
MECHANICAL
22.Piston
A: SPECIFICATION
Refer to Cylinder Block for removal and installation
procedures of pistons. <Ref. to ME(H4DOTC)-68,
REMOVAL, Cylinder Block.> <Ref. to ME(H4DOTC)-
ME(H4DOTC)-93
Connecting Rod
MECHANICAL
23.Connecting Rod
A: SPECIFICATION
tion procedures of connecting rod.
<Ref. to ME(H4DOTC)-68, REMOVAL, Cylinder
Block.> <Ref. to ME(H4DOTC)-72, INSTALLA-
TION, Cylinder Block.>
ME(H4DOTC)-94
Crankshaft
MECHANICAL
24.Crankshaft
A: SPECIFICATION
procedures of crankshaft. <Ref. to ME(H4DOTC)-68,
REMOVAL, Cylinder Block.> <Ref. to ME(H4DOTC)-
ME(H4DOTC)-95
MECHANICAL
A: INSPECTION
NOTE:
The RANK shown in the chart shows the possibilities of the cause of trouble in order from Very often to
Rarely.
A Very often
B Sometimes
C Rarely
Symptom Problem parts etc. Possible cause RANK
Defective inhibitor switch or neutral switch C
Defective starter B
Battery Improper connection of terminal A
Run-down battery A
Seized camshaft C
not occur.
Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line C
Defective timing B
ME(H4DOTC)-96
MECHANICAL
3) Initial combustion occurs. Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line C
Defective timing B
combustion.
Defective timing B
ME(H4DOTC)-97
MECHANICAL
stall
Clogged fuel line C
Timing belt Defective timing C
ME(H4DOTC)-98
MECHANICAL
poor acceleration
Clogged fuel line B
Over-cooling C
4. Surging Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line B
ME(H4DOTC)-99
MECHANICAL
idle.
6. Dieseling (Run-on) Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
system
8. Knocking Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> A
Cooling system Overheating A
sumption
ket
B
Defective oil filter gasket B
ME(H4DOTC)-100
MECHANICAL
tion
ME(H4DOTC)-101
Engine Noise
MECHANICAL
26.Engine Noise
A: INSPECTION
NOTE*)
Therefore, perform the Clear Memory Mode <Ref. to EN(H4DOTC)(diag)-56, OPERATION, Clear Memory Mode.> and Inspec-
tion Mode <Ref. to EN(H4DOTC)(diag)-45, PROCEDURE, Inspection Mode.> after connecting the fuel injector connector.
speed increases.
Worn camshaft
Broken valve spring
Oil pressure is normal.
Loosened flywheel mounting bolt
Damaged engine mounting
High-pitched clank
condition.
Wrong spark plug
Improper gasoline
between 1,000 and 2,000 rpm.
(NOTE*)
and engine is warm
(NOTE*)
Unusually worn valve lifter
Worn cam sprocket
engine

a dry cloth

Loose V-belt
Hissing sound
Timing belt noise
Loose timing belt
Belt contacting with case/adjacent part
Valve noise Incorrect valve clearance
ME(H4DOTC)-102
Engine Noise
MECHANICAL
EX(H4DOTC)-2
General Description
EXHAUST
A: COMPONENT
1. FRONT EXHAUST PIPE
EX-02209
T1
T1
T4
T4
T3
T4
T4
T3
T1
T2
T1
(1)
(3)
(9)
(11)
(13)
(12)
(8)
(5)
(15)
(17)
(16)
(18)
(19)
(20)
(14)
(4)
(2)
A
A
(6)
(10)
T5
T2
T2
(7)
(7)
EX(H4DOTC)-3
General Description
EXHAUST
(1) Gasket (10) Front exhaust pipe lower cover (20) Exhaust manifold (LH)
(2) Exhaust manifold upper cover
(RH)
(11) Gasket
(12) Exhaust manifold upper cover
(LH)
(3) Exhaust manifold (RH) T1: 19 (1.9, 14.0)
(4) Exhaust manifold lower cover
(RH)
(13) Exhaust manifold outer cover (LH) T2: 25 (2.5, 18.4)
(14) Gasket T3: 40 (4.1, 29.5)
(5) Front exhaust pipe upper cover (15) Turbocharger joint pipe T4: 42.5 (4.3, 31.3)
(6) Front exhaust pipe upper insulator
(RH)
(16) Gasket T5: <Ref. to FU(H4DOTC)-41,
INSTALLATION, Front Oxygen
(A/F) Sensor.>
(17) Front oxygen (A/F) sensor
(7) Gasket (18) Front exhaust pipe upper insulator
(LH)
(8) Front exhaust pipe
(9) Front exhaust pipe lower insulator
(RH)
(19) Front exhaust pipe lower insulator
(LH)
EX(H4DOTC)-4
General Description
EXHAUST
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER
(1) Gasket (11) Rear exhaust pipe Tightening torque:Nm (kgf-m, ft-lb)
(2) Front catalytic converter (12) Chamber T1: 13 (1.3, 9.6)
(3) Center exhaust pipe (Front) (13) Cushion rubber T2: 18 (1.8, 13.3)
(4) Gasket (14) Spring T3: 30 (3.1, 22.1)
(5) Center pipe upper cover (Rear) (15) Bolt T4: 35 (3.6, 26.0)
(6) Clamp (16) Gasket T5: 42.5 (4.3, 31.3)
(7) Rear catalytic converter lower
cover
(17) Muffler (RH) T6: 48 (4.9, 35.4)
(18) Self-locking nut T7: <Ref. to FU(H4DOTC)-42,
INSTALLATION, Rear Oxygen
Sensor.>
(8) Rear oxygen sensor (19) Muffler (LH)
(9) Rear catalytic converter (20) Center exhaust pipe (Rear)
(10) Gasket (21) Bracket
EX-02220
A
(10)
(9)
A
T4
T5
(21)
T2
T7
(5)
(8)
(7)
(20)
(4)
T1
T1
(11)
(12)
(15)
(14)
(13)
(13)
(16)
(13)
(16)
(19)
(17)
(13)
(13)
T3
(6)
T3
T5
T5
(1)
(2)
(3)
(18)
T6
(18)
T6
(18)
T6
(18)
T6
EX(H4DOTC)-5
General Description
EXHAUST
B: CAUTION
forming any work.
points.
the battery.
EX(H4DOTC)-6
Front Exhaust Pipe
EXHAUST
A: REMOVAL
CAUTION:
ning.
<Ref. to FU(H4DOTC)-40, REMOVAL, Front Oxy-
gen (A/F) Sensor.>
5) Remove the exhaust manifold lower cover (RH)
and the exhaust manifold cover (LH).
6) Remove the bolts and nuts which hold front ex-
haust pipe assembly onto turbocharger joint pipe.
7) 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.
8) Remove the front exhaust pipe assembly.
9) Remove the covers from exhaust manifold and
front exhaust pipe.
10) Separate the front exhaust pipe from exhaust
manifolds.
IN-00203
EX-02059
EX-00018
EX-02206
EX-00005
EX-00245
EX(H4DOTC)-7
Front Exhaust Pipe
EXHAUST
B: INSTALLATION
1) Install the front exhaust pipe and the exhaust
manifold.
NOTE:
Use a new gasket.
Tightening torque:
42.5 Nm (4.3 kgf-m, 31.3 ft-lb)
2) Install the front exhaust pipe cover.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 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.
NOTE:
Use a new gasket.
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
5) Connect the exhaust manifold (RH) to turbo-
charger joint pipe.
NOTE:
Use a new gasket.
Tightening torque:
42.5 Nm (4.3 kgf-m, 31.3 ft-lb)
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)
<Ref. to FU(H4DOTC)-41, INSTALLATION, Front
Oxygen (A/F) Sensor.>
EX-00245
EX-02206
EX-00005
EX-00018
EX-02059
EX(H4DOTC)-8
Front Exhaust Pipe
EXHAUST
C: INSPECTION
leaks.
IN-00203
EX(H4DOTC)-9
Center Exhaust Pipe
EXHAUST
3. Center Exhaust Pipe
A: REMOVAL
CAUTION:
ning.
5) Remove the intercooler bracket.
8) Remove the bolts which install the lower side of
turbocharger lower cover.
10) Remove the turbocharger upper cover.
11) Remove the bolts which hold the turbocharger
lower cover and center exhaust pipe.
12) Separate the center exhaust pipe from turbo-
charger.
14) Disconnect the connector from the rear oxygen
sensor.
15) Separate the center exhaust pipe from rear ex-
haust pipe.
IN-00203
EX-00009
EX-00010
EX-00011
EX-00012
EX-00206
EX-02065
EX(H4DOTC)-10
Center Exhaust Pipe
EXHAUST
pipe bracket to transmission.
pipe to hanger bracket.
CAUTION:
Be careful not to pull down the center exhaust
pipe.
B: INSTALLATION
1) Install the center exhaust pipe and temporarily
tighten the bolt which holds center exhaust pipe to
hanger bracket.
2) Temporarily tighten the bolt which holds the cen-
ter pipe to transmission.
3) Connect the center exhaust pipe to turbocharg-
er.
NOTE:
Use a new gasket.
Tightening torque:
42.5 Nm (4.3 kgf-m, 31.3 ft-lb)
4) Install the center exhaust pipe to rear exhaust
pipe.
NOTE:
Use a new gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
EX-00208
EX-00209
EX-00016
EX-00012
EX-02065
EX-00206
EX(H4DOTC)-11
Center Exhaust Pipe
EXHAUST
bracket to transmission.
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
to hanger bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
9) Position the turbocharger lower cover, and tight-
en the bolts which hold the lower cover and center
exhaust pipe.
Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
10) Position the turbocharger upper cover, and
tighten the bolts which install the upper cover.
Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
12) Tighten the bolts which install the under side of
turbocharger lower cover.
Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
15) Install the intercooler bracket.
C: INSPECTION
leaks.
EX-00208
EX-00209
EX-00011
EX-00010
EX-00009
IN-00203
EX(H4DOTC)-12
Joint Pipe
EXHAUST
4. Joint Pipe
A: REMOVAL
CAUTION:
ning.
<Ref. to FU(H4DOTC)-40, REMOVAL, Front Oxy-
gen (A/F) Sensor.>
6) Remove the exhaust manifold lower cover (RH).
7) Remove the bolts and nuts which hold the front
exhaust manifold to joint pipe.
haust Pipe.>
9) Remove the turbocharger. <Ref. to IN(H4DOTC)-
14, REMOVAL, Turbocharger.>
10) Take off the joint pipe in the upward direction.
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
T: 42.5 Nm (4.3 kgf-m, 31.3 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
C: INSPECTION
leaks.
IN-00203
EX-02075
EX-00018
EX-00019
T
EX-02075
EX(H4DOTC)-13
Rear Exhaust Pipe
EXHAUST
A: REMOVAL
CAUTION:
ning.
3) Separate the rear exhaust pipe from center ex-
haust pipe.
4) Separate the rear exhaust pipe from both muf-
flers.
CAUTION:
pipe.
cushion rubber.
B: INSTALLATION
rubber.
NOTE:
installing.
3) Install the rear exhaust pipe to both mufflers.
NOTE:
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
4) Install the rear exhaust pipe to center exhaust
pipe.
NOTE:
Use a new gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
EX-02065
EX-00210
EX-00219
EX-00219
EX-00210
EX-02065
EX(H4DOTC)-14
Rear Exhaust Pipe
EXHAUST
C: INSPECTION
leaks.
EX(H4DOTC)-15
Muffler
EXHAUST
6. Muffler
A: REMOVAL
CAUTION:
ning.
3) Separate the muffler (RH) from the rear exhaust
pipe.
5) Remove the cushion rubber, and remove the
muffler.
CAUTION:
Be careful not to drop the muffler during remov-
al.
6) Perform the same procedures for the muffler
(LH).
B: INSTALLATION
NOTE:
installing.
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
C: INSPECTION
leaks.
EX-00210
EX-00211
EX-00210
EX(H4DOTC)-16
Muffler
EXHAUST
CO(H4DOTC)-2
General Description
COOLING
A: SPECIFICATION
Cooling system
Electric fan + Forced engine coolant
circulation system
Total engine coolant capacity 2 (US qt, Imp qt)
MT: approx. 7.3 (7.7, 6.4)
AT: approx. 7.2 (7.6, 6.3)
Water pump
Discharge
performance I
Discharge rate 2 (US gal, Imp gal) /min. 20 (5.3, 4.4)
Pump speed Discharge pressure 760 rpm 2.9 kPa (0.3 mAq)
Discharge
performance II
Pump speed Discharge pressure 3,000 rpm 49.0 kPa (5.0 mAq)
Discharge
performance III
Pump speed Discharge pressure 6,000 rpm 225.4 kPa (23.0 mAq)
Impeller diameter mm (in) 76 (2.99)
Pump pulley diameter mm (in) 60 (2.36)
Clearance
between impeller
and case
Standard mm (in) 0.5 1.5 (0.020 0.059)
Thermostat
Radiator fan
Motor input
Main fan W 120
Sub fan W 120
Fan diameter /
Blade
Main fan 320 mm (12.6 in)/5
Sub fan 320 mm (12.6 in)/7
Radiator
Type Down flow
Core dimensions
Width Height
Thickness
mm (in) 687.4 340 16 (27.06 13.39 0.63)
Pressure range in
which cap valve is
open
Coolant filler tank
side
kPa (kg/cm
2
, psi)
Above: 10815
(1.10.15, 162)
Below: 1.0 to 4.9
(0.01 0.05, 0.1 0.7)
Radiator side kPa (kg/cm
2
, psi)
Above only: 13714.7
(1.400.15, 202.1)
Reservoir tank Capacity 2 (US qt, Imp qt) 0.45 (0.48, 0.40)
CO(H4DOTC)-3
General Description
COOLING
Coolant SUBARU coolant 000016218
Phosphoric acid (non-amine)
type
Vehicle speed
A/C compressor
load
Increase: 94C
(201F) or less
Decrease: 91C
(196F) or less
Increase: 95 96C
(203 205F)
Decrease: 92 94C
(198 201F)
Increase: 97C
(207F) or more
Decrease: 95C
(203F) or more
Radiator fan operation Radiator fan operation Radiator fan operation
19 km/h (12 MPH) or less
10 km/h (6 MPH) or less
Low Low-Speed Low-Speed High-Speed
20 69 km/h (12 43 MPH)
11 64 km/h (7 40 MPH)
70 105 km/h (43 65 MPH)
65 103 km/h (40 64 MPH)
106 km/h (66 MPH) or more
104 km/h (65 MPH) or more
OFF OFF High-Speed High-Speed
CO(H4DOTC)-4
General Description
COOLING
B: COMPONENT
1. WATER PUMP
(2) Gasket (6) Thermostat cover T1: First 12 (1.2, 8.9)
(3) Heater by-pass hose (7) Coolant filler tank by-pass hose Second 12 (1.2, 8.9)
(4) Thermostat T2: 12 (1.2, 8.9)
CO-02279
(6)
(4)
(1)
(5)
(2)
T2
T1
T1
(3)
(7)
CO(H4DOTC)-5
General Description
COOLING
2. RADIATOR AND RADIATOR FAN
C
B
T5
T3
T3
T4
T4
(8)
(9)
(7)
(10)
(29)
(12)
(11)
(14)
(5)
(5)
(6)
(5)
(1)
(2)
(3)
(4)
(28)
(22)
(23)
(5)
(30)
(21)
(13)
(15)
(15)
(18)
(19)
(20)
B
C
T4
T4
(27)
(26)
(5)
(5)
(25)
(24)
T2
T2
T1
CO-02354
(17)
(16)
(15)
(15)
T4
CO(H4DOTC)-6
General Description
COOLING
C: CAUTION
forming any work.
points.
the battery.
(1) Radiator lower cushion (14) Radiator main fan ASSY (26) Coolant filler tank hose A
(2) Radiator (15) ATF hose clamp (AT model) (27) Coolant filler tank hose B
(3) Radiator upper cushion (16) ATF hose A (AT model) (28) Radiator lower bracket
(4) Radiator upper bracket (17) ATF hose B (AT model) (29) Over flow hose B
(5) Clamp (18) ATF pipe (AT model) (30) Heat shield cover (AT model)
(6) Radiator hose A (19) ATF hose C (AT model)
(7) Engine coolant reservoir tank cap (20) ATF hose D (AT model) Tightening torque:Nm (kgf-m, ft-lb)
(8) Over flow hose A (21) Radiator hose B T1: 3 (0.3, 2.2)
(9) Engine coolant reservoir tank (22) Radiator drain plug T2: 3.4 (0.35, 2.5)
(10) Over flow pipe (23) O-ring T3: 5 (0.5, 3.7)
(11) Radiator sub fan shroud (24) Engine coolant filler tank T4: 7.5 (0.76, 5.5)
(12) Radiator main fan shroud (25) Radiator cap
(Engine coolant filler tank cap)
T5: 12 (1.2, 8.9)
(13) Radiator sub fan ASSY
CO(H4DOTC)-7
General Description
COOLING
D: PREPARATION TOOL
WRENCH
WRENCH
sprocket.
WRENCH
sprocket.
ST-499977100
ST-499977500
ST-499207400
CO(H4DOTC)-8
Radiator Fan System
COOLING
A: WIRING DIAGRAM
CO-02317
B136
F108 F16 B361
F17
F16
1 2
1
7
B360
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
F108
2 3 8
10
1
9
4
11 12 13 14 15 16
5 6 7
17 18
F27
B136
F36 F35 B143
F17
B361
1
7
2 3 4 5 6
8 9 10 11 12 13 14
F109
3 4 1 2 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
5 6 7
F27
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
3 1 2
7 4 5 6
16 7
21
2
2
1
9
1
8
1
1
1
2
2
0
2
1
1
0
1
3
E E
M
1
2
M
F109 B360
10 1
SBF-6 MAIN SBF
No.3
No.22
No.26
1
8
2
9
B: C: E:
ECM
No.4
BATTERY
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
20 21 22
19
18
3 4 5
7
6
10 11
12
13
15
16
17
14
2
1
9 8
E
6
E
5
C
1
0
B
7
MAIN
FUSE BOX
(M/B)
B143 B:
F35 C:
F36 E:
MAIN FAN
MOTOR
SUB FAN MOTOR
MAIN FAN
RELAY
1
2
MAIN
FAN
RELAY
SUB
FAN
RELAY
THROUGH JOINT
CONNECTOR
RELAY
HOLDER
IGNITION SWITCH
CO(H4DOTC)-9
Radiator Fan System
COOLING
B: INSPECTION
Vehicle speed is 19 km/h (12 MPH) or less.
TROUBLE SYMPTOMS:
Radiator main fan and sub fan do not rotate under the above conditions.
Step Check Yes No
NOTE:
OFF in this order.
Mode for detail procedures. <Ref. to
EN(H4DOTC)(diag)-57, Compulsory Valve Op-
eration Check Mode.>
fans rotate at low speed?
3) Perform the compulsory operation check for
the radiator fan relay using Subaru Select Mon-
itor.
NOTE:
OFF in this order.
Mode for detail procedures. <Ref. to
fans rotate at high speed?
Radiator main fan
system is normal.
Go to step 27.
LAY.
2) Remove the sub fan relay from the relay
holder.
LAY.
CO(H4DOTC)-10
Radiator Fan System
COOLING
5 CHECK FUSE.
supply line.
6 CHECK FUSE.
supply line.
relay terminals.
Terminals
No. 10 No. 11:
more?
Go to step 8. Replace the sub
fan relay.
No. 13 of the sub fan relay.
relay terminals.
Terminals
No. 10 No. 11:
Is resistance less than 1 ? Go to step 9. Replace the sub
fan relay.
LAY TERMINAL AND SUB FAN MOTOR
CONNECTOR.
1) Disconnect the connector from the sub fan
motor.
the sub fan relay terminal and sub fan motor
connector.
(F16) No. 1 (F27) No. 11:
circuit of harness
between sub fan
relay terminal and
sub fan motor con-
nector.
10 CHECK HARNESS BETWEEN SUB FAN MO-
TOR CONNECTOR AND MAIN FAN RELAY 2
CONNECTOR.
holder.
sub fan motor connector and main fan relay 2
connector.
(F16) No. 2 (F27) No. 18:
circuit of the har-
ness between sub
fan motor connec-
tor and main fan
relay 2 connector.
Check for poor contact of sub fan motor connec-
tor.
Is there poor contact in the sub
fan motor connector?
Repair the poor
contact of sub fan
motor connector.
Go to step 12.
minal No. 1 of the sub fan motor, and the ground
() terminal to terminal No. 2.
Does the sub fan rotate? Go to step 13. Replace the sub
fan motor.
Measure the resistance of main fan relay 2.
Terminals
No. 21 No. 18:
fan relay 2.
Step Check Yes No
CO(H4DOTC)-11
Radiator Fan System
COOLING
TOR.
motor.
motor connector.
(F17) No. 1 (F27) No. 2:
circuit of the har-
ness between
main fan relay 2
terminal and main
fan motor connec-
tor.
15 CHECK MAIN FAN MOTOR AND GROUND
CIRCUIT.
Measure the resistance between main fan
motor connector and chassis ground.
circuit of the har-
ness between
main fan motor
connector and
chassis ground.
Check poor contact of main fan motor connec-
tor.
main fan motor connector?
Repair the poor
contact of main fan
motor connector.
Go to step 17.
17 CHECK MAIN FAN MOTOR.
minal No. 1 of the main fan motor, and the
ground () terminal to terminal No. 2.
Does the main fan rotate? Go to step 18. Replace the main
fan motor.
LAY AND ECM.
2) Measure the resistance between the sub
fan relay terminal and ECM connector.
(B136) No. 18 (F27) No. 12:
circuit of harness
between sub fan
relay terminal and
ECM.
connector?
Repair the poor
contact of the ECM
connector.
Check the DTC.
Repair the trouble
cause. <Ref. to
EN(H4DOTC)(diag
)-44, Read Diag-
nostic Trouble
Code (DTC).>
box.
fan relay 1 switch.
more?
fan relay 1.
1) Connect the main fan relay 1 coil side termi-
nal to the battery.
fan relay 1.
TOR.
motor.
motor connector.
(F17) No. 1 (F36) No. 6:
circuit of the har-
ness between
main fan relay 1
terminal and main
fan motor connec-
tor.
Step Check Yes No
CO(H4DOTC)-12
Radiator Fan System
COOLING
RELAY 1 AND ECM.
relay 1 terminal and ECM connector.
(B136) No. 29 (B143) No. 7:
circuit of the har-
ness between
main fan relay 1
terminal and ECM.
RELAY 2 AND ECM.
Measure the resistance between main fan relay
2 terminal and ECM connector.
(B136) No. 29 (F27) No. 22:
circuit of the har-
ness between
main fan relay 2
terminal and ECM.
25 CHECK FUSE.
2) Remove the fuse No. 4 and 26.
Is the fuse blown out? Replace the fuse. Go to step 26.
connector?
Repair the poor
contact of the ECM
connector.
Repair the power
supply circuit to the
main fuse box.
If the both fans do not rotate at high speed in the
condition of step 2, check whether the sub fan is
rotating.
Does the sub fan rotate? Go to step 20. Go to step 28.
28 CHECK GROUND CIRCUIT OF MAIN FAN
RELAY 2.
holder.
circuit of harness
between main fan
relay 2 and chassis
ground.
29 CHECK POWER SUPPLY TO MAIN FAN RE-
LAY 2.
2) Measure the voltage between main fan relay
2 terminal and chassis ground.
supply line.
2) Remove the main fan relay 2.
Terminals
(F27) No. 18 (F27) No. 19:
more?
fan relay 2.
1) Connect the battery to main fan relay 2 ter-
minals No. 20 and No. 22.
Terminals
(F27) No. 18 (F27) No. 19:
fan relay 2.
Step Check Yes No
CO(H4DOTC)-13
Engine Coolant
COOLING
3. Engine Coolant
A: REPLACEMENT
into container.
NOTE:
Remove the coolant filler tank cap so that engine
coolant will drain faster.
er neck.
system protective agent. <Ref. to
CO(H4DOTC)-2, SPECIFICATION, General
Description.>
3) Fill the engine coolant into coolant filler tank up
to the filler neck position.
mended engine coolant. <Ref. to
Description.>
Coolant level:
mended engine coolant. <Ref. to
Description.>
CAUTION:
Do not confuse the cap of coolant filler tank and
cap of radiator.
NOTE:
When pouring the engine coolant, the radiator side
cap must not be removed.
FULL level.
5) Close the coolant filler tank cap, and start the en-
gine. Race 5 to 6 times at 3,000 rpm or less, then
stop the engine. (Complete this operation within 40
seconds.)
6) Wait for one minute after the engine stops, then
open the coolant filler tank cap. If the engine cool-
ant level drops, add engine coolant into the coolant
filler tank up to the filler neck position.
8) Install the coolant filler tank cap and reservoir
tank cap properly.
LO.
10) Run the engine at 2,000 rpm or less until radia-
tor fan starts and stops.
NOTE:
12) Open the coolant filler tank cap. If the engine
coolant level drops, add engine coolant into the
coolant filler tank up to the filler neck position and
the reservoir tank to FULL level.
13) Install the coolant filler tank cap and reservoir
tank cap properly.
CO-00248
CO(H4DOTC)-14
Engine Coolant
COOLING
B: INSPECTION
1. RELATIONSHIP OF ENGINE COOLANT
TEMPERATURE
of engine coolant is shown in the diagram 1. Mea-
[Example]
(7F) (point B), and the freezing temperature is 20C
(4F) (point C).
Diagram 1
2. PROCEDURE TO ADJUST THE
CONCENTRATION OF THE COOLANT
temperature, find the proper engine coolant con-
centration in the diagram 1 and replace the neces-
sary amount of coolant with an undiluted solution of
engine coolant (concentration 50%).
[Example]
tical 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) undiluted engine coolant solution.
If a coolant concentration of 50% is needed, drain all
the coolant and refill with the undiluted solution only.
Diagram 2
CO-02172
60%
(1.054)
1.000
1.010
1.020
1.030
1.040
1.050
1.060
1.070
1.080
1.090
1.100
Freezing
temperature
Concentration
of coolant
S
p
e
c
i
f
i
c

g
r
a
v
i
t
y
o
f

c
o
o
l
a
n
t
Coolant temperature
B
A
C
-40
(-40) (-22) (-4) (14) (32) (50) (68) (86)
( F)
(104)
-30 -20 -10 0 10 20 30 40
(
7
7

F
)
50%
40%
30%
20%
2
5

C10%
C
CO-00012
10
0
1
2
3
(1.1,
0.9)
(2.1,
1.8)
(3.2,
2.6)
10%
15%
25%
20%
30%
35%
40%
45%
A
20 30 40 50
Q
u
a
n
t
i
t
y

o
f

c
o
o
l
a
n
t

t
o

b
e
d
r
a
i
n
e
d

(
U
S

q
t
,

I
m
p

q
t
)
of coolant
CO(H4DOTC)-15
Water Pump
COOLING
4. Water Pump
A: REMOVAL
2) Remove the radiator. <Ref. to CO(H4DOTC)-19,
REMOVAL, Radiator.>
REMOVAL, V-belt.>
5) Remove the timing belt. <Ref. to ME(H4DOTC)-
42, REMOVAL, Timing Belt.>
6) Remove the automatic belt tension adjuster (A).
7) Remove the belt idler (B).
8) Remove the belt idler No. 2 (C).
9) Remove the cam sprocket (LH) using ST. <Ref.
to ME(H4DOTC)-51, REMOVAL, Cam Sprocket.>
10) Remove the belt cover (LH) No. 2.
12) Disconnect the hose from water pump.
B: INSTALLATION
1) Install the water pump onto cylinder block (LH).
NOTE:
Use a new gasket.
When installing the water pump, tighten the bolts
in two stages in alphabetical sequence as shown in
figure.
Tightening torque:
First:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
Second:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
2) Install the hose to water pump.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
CO-00023
( A)
( B)
( C)
CO-00024
CO-00025
CO-00021
ME-02463
(F)
(E)
(D)
(C)
(B)
(A)
CO-00025
CO(H4DOTC)-16
Water Pump
COOLING
4) Install the belt cover No. 2 (LH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
5) Install the cam sprocket (LH) using ST. <Ref. to
ME(H4DOTC)-51, INSTALLATION, Cam Sprock-
et.>
6) Install the belt idler No. 2 (C).
Tightening torque:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
7) Install the belt idler (B).
Tightening torque:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
8) Install the automatic belt tension adjuster (A)
which has a tension rod held by a pin. <Ref. to
ME(H4DOTC)-44, AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER, IN-
STALLATION, Timing Belt.>
9) Install the timing belt. <Ref. to ME(H4DOTC)-45,
TIMING BELT, INSTALLATION, Timing Belt.>
12) Install the radiator. <Ref. to CO(H4DOTC)-20,
INSTALLATION, Radiator.>
C: INSPECTION
tion.
2) Check the water pump pulley for abnormalities.
3) Make sure the impeller is not deformed or dam-
aged.
4) Inspect the clearance between impeller and
pump case.
Clearance between impeller and pump case:
Standard
0.5 1.5 mm (0.020 0.059 in)
5) After water pump installation, check pulley shaft
for engine coolant leaks or noise. If leaks or noise
are noted, replace the water pump assembly.
CO-00024
CO-00023
( A)
( B)
( C)
CO-00293
CO(H4DOTC)-17
Thermostat
COOLING
5. Thermostat
A: REMOVAL
<Ref. to CO(H4DOTC)-13, DRAINING OF EN-
GINE COOLANT, REPLACEMENT, Engine Cool-
ant.>
stat cover.
the gasket and thermostat.
CO-00248
CO-02124
(B) Gasket
(C) Thermostat
CO-02336
(A)
(C)
(B)
CO(H4DOTC)-18
Thermostat
COOLING
B: INSTALLATION
NOTE:
Use a new gasket.
NOTE:
The thermostat must be installed with the jiggle pin
facing upward.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
cover.
C: INSPECTION
Inspection method
NOTE:
five minutes or more before measuring the valve
lift.
Starting temperature to open:
76 80C (169 176F)
Fully opens:
91C (196F)
Valve lift:
(B) Gasket
(C) Thermostat
(D) Jiggle pin
CO-02337
(A)
T
(B)
(C)
(D)
(A) Thermometer
(B) Thermostat
CO-00033
( A)
( B)
CO(H4DOTC)-19
Radiator
COOLING
6. Radiator
A: REMOVAL
CAUTION:
Wait until engine cools down before working on
the radiator because the radiator is pressur-
ized.
model)
<Ref. to CO(H4DOTC)-13, DRAINING OF EN-
GINE COOLANT, REPLACEMENT, Engine Cool-
ant.>
8) Disconnect the connectors of radiator main fan
(A) and sub fan motor (B).
stat cover.
10) Disconnect the ATF cooler hoses from ATF
pipes.
Plug the ATF pipe to prevent ATF from leaking. (AT
model)
IN(H4DOTC)-9, REMOVAL, Air Intake Duct.>
IN-00203
CO-02355
CO-00251
(A)
CO-00252
(B)
CO-02124
CO-00253
CO(H4DOTC)-20
Radiator
COOLING
14) Remove the reservoir tank. <Ref. to
CO(H4DOTC)-28, REMOVAL, Reservoir Tank.>
15) Disconnect the radiator inlet hose (A) from the
radiator.
16) Remove the hood stay holder (B).
17) Disconnect the two coolant filler tank hoses
from the radiator.
19) Move the radiator to the left while lifting it up-
ward.
B: INSTALLATION
1) Attach the radiator lower cushion to the hole on
the radiator lower bracket.
NOTE:
the bolts.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
4) Connect the two coolant filler tank hoses to the
radiator.
5) Connect the radiator inlet hose (A).
CO-00255
(A)
(B)
CO-00256
CO-00040
CO-00041
CO-00040
CO-00256
CO(H4DOTC)-21
Radiator
COOLING
6) Install the hood stay holder (B).
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
7) Install the reservoir tank. <Ref. to
CO(H4DOTC)-28, INSTALLATION, Reservoir
Tank.>
8) Connect the over flow hose.
9) Install the air intake duct.
<Ref. to IN(H4DOTC)-9, INSTALLATION, Air In-
take Duct.>
11) Connect the ATF cooler hoses. (AT model)
13) Connect the connectors to the radiator main
fan motor (A) and sub fan motor (B).
14) Install the heat shield cover to the radiator. (AT
model)
Tightening torque:
3 Nm (0.3 kgf-m, 2.2 ft-lb)
18) Fill engine coolant.
<Ref. to CO(H4DOTC)-13, FILLING OF ENGINE
CO-00255
(A)
(B)
CO-00253
CO-02124
CO-00251
(A)
CO-00252
(B)
CO-02355
IN-00203
CO(H4DOTC)-22
Radiator
COOLING
C: INSPECTION
1) Remove the coolant filler tank cap, fill the cool-
ant filler tank with engine coolant, then install the
tester to the installation position of the cap.
2) Apply a pressure of 122 kPa (1.2 kg/cm
2
, 18 psi)
CAUTION:
Inspection must be carried out at the side of
coolant filler tank, not at the side of radiator.
vance.
Be careful of the spurt of engine coolant
when removing the tester.
Be careful not to deform the filler neck of the
coolant filler tank when installing and removing
the tester.
CO-02244
CO(H4DOTC)-23
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
Remove the cap if it is opened under a pressure
less than the service limit value
Coolant filler tank side
Specification:
93 123 kPa
(0.95 1.25 kg/cm
2
, 14 18 psi)
Service limit:
83 kPa (0.85 kg/cm
2
, 12 psi)
Radiator side
Specification:
122 152 kPa
(1.24 1.55 kg/cm
2
, 18 22 psi)
Service limit:
112 kPa (1.14 kg/cm
2
, 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-00044
CO(H4DOTC)-24
COOLING
Motor
A: REMOVAL
6) Disconnect the main fan motor connector (A).
model)
8) Drain the coolant about 1 2 (1.06 US qt,
0.88 Imp qt). <Ref. to CO(H4DOTC)-13, DRAIN-
ING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>
tor main fan motor assembly. (AT model)
13) Remove the over flow pipe.
15) Remove the mounting bolts from radiator main
fan motor assembly.
radiator.
18) Remove the radiator main fan motor assembly
from vehicle.
IN-00203
CO-00251
(A)
CO-02355
CO-00258
CO-00259
CO-00255
(A)
(B)
CO(H4DOTC)-25
COOLING
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
Tightening torque:
3 Nm (0.3 kgf-m, 2.2 ft-lb)
C: DISASSEMBLY
nector onto the shroud.
motor.
shroud.
D: ASSEMBLY
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
CO-00255
(A)
(B)
CO-00259
CO-02355
CO-02142
CO-00050
CO-00050
CO-02142
CO(H4DOTC)-26
COOLING
Motor
A: REMOVAL
6) Disconnect the sub fan motor connector (B).
model)
8) Drain the coolant about 1 2 (1.06 US qt,
0.88 Imp qt). <Ref. to CO(H4DOTC)-13, DRAIN-
ING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>
tor sub fan motor assembly. (AT model)
13) Remove the over flow pipe.
15) Remove the mounting bolts from the radiator
sub fan motor assembly.
radiator.
18) Remove the radiator sub fan motor assembly
from the vehicle.
IN-00203
CO-00252
(B)
CO-02355
CO-00292
CO-00255
(A)
(B)
CO(H4DOTC)-27
COOLING
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
Tightening torque:
3 Nm (0.3 kgf-m, 2.2 ft-lb)
C: DISASSEMBLY
nector onto the shroud.
motor.
shroud.
D: ASSEMBLY
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
CO-00255
(A)
(B)
CO-00292
CO-02355
CO-02143
CO-00050
CO-00050
CO-02143
CO(H4DOTC)-28
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
2) Disconnect the over flow hose (A).
3) Pull out the reservoir tank to the arrow direction
while pushing the claw (B).
B: INSTALLATION
C: INSPECTION
FULL and LOW.
CO-00263
(B)
(A)
CO(H4DOTC)-29
Coolant Filler Tank
COOLING
11.Coolant Filler Tank
A: REMOVAL
WARNING:
2) Drain the coolant about 3.0 2 (3.2 US qt,
2.6 Imp qt). <Ref. to CO(H4DOTC)-13, DRAINING
OF ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
3) Disconnect the engine coolant hoses from cool-
ant filler tank.
4) Remove the bolts which install the coolant filler
tank.
5) Disconnect the engine coolant hose which con-
nects the under side of coolant filler tank.
6) Remove the coolant filler tank.
B: INSTALLATION
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
CO-00264
CO-00264
CO(H4DOTC)-30
COOLING
A: INSPECTION
Over-heating
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timing
Inspect and repair ignition control system. <Ref. to
EN(H4DOTC)(diag)-2, PROCEDURE, Basic Diagnos-
tic Procedure.>
h. Clogged or leaking radiator Clean, repair or replace.
i. Engine oil mixed in engine coolant
Replace the engine coolant. If it is ineffective, inspect
and repair the engine side.
j. Air/fuel mixture ratio too lean
EN(H4DOTC)(diag)-2, PROCEDURE, Basic Diagnos-
tic Procedure.>
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylin-
der
Adjust or replace.
m. Slipping clutch Correct or replace.
n. Dragging brake Adjust.
o. Defective radiator fan
Over-cooling
Engine coolant
leaks
a. Loosened or damaged connecting units on
hoses
Correct or replace.
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and cylinder
block
Correct or replace.
Noise
a. Timing belt problem Replace.
LU(H4DOTC)-2
General Description
LUBRICATION
A: SPECIFICATION
Oil pump
Number of teeth
Inner rotor 9
Outer rotor 10
Tip clearance between inner and outer rotors mm (in) 0.04 0.14 (0.0016 0.0055)
Side clearance between inner rotor and pump case mm (in) 0.02 0.07 (0.0008 0.0028)
Case clearance between outer rotor and
pump case
Standard mm (in) 0.10 0.175 (0.0039 0.0069)
Performance
(Oil temperature 80C
(176F))
600 rpm
Discharge
pressure
kPa (kg/cm
2
, psi) 98 (1.0, 14)
Discharge
rate
5,000 rpm
Discharge
pressure
kPa (kg/cm
2
, psi) 294 (3.0, 43)
Discharge
rate
2
, psi) 588 (6.0, 85)
Oil filter
Filtration area cm
2
(sq in)
Outer diameter:
68 mm (2.68 in)
800 (124)
Outer diameter:
65 mm (2.56 in)
470 (72.9)
2
, psi) 160 (1.63, 23.2)
Outer diameter width mm (in)
Outer diameter:
68 mm (2.68 in)
68 65 (2.68 2.56)
Outer diameter:
65 mm (2.56 in)
65 74.4 (2.56 2.93)
Oil pressure
switch
2
, psi) 14.7 (0.15, 2.1)
2
, psi) 981 (10, 142) or more
Engine oil
LU(H4DOTC)-3
General Description
LUBRICATION
Recommended oil:
The proper viscosity oil helps the engine maintain
its ideal temperature, and cranking speed in-
creased by reducing viscosity friction in hot condi-
tion.
CAUTION:
NOTE:
If the vehicle is used in regions with high tempera-
tures or in other severe environments, use oil with
the viscosities shown below. API standard: SM or
SL
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-
50
(2) Recommended
( C) -30 -20 -15 0 15 30 40
-22 -4 5 32 59 86 104
SAE (1)
( F)
10W-30, 10W-40 , 10W-50
5W-30 (2)
LU-02329
LU(H4DOTC)-4
General Description
LUBRICATION
B: COMPONENT
(1) Plug (16) Oil pressure switch (31) Seal
(2) Gasket (17) Oil filler duct (32) O-ring
(3) Relief valve spring (18) O-ring (33) Gasket
(4) Relief valve (19) Rocker cover (34) O-ring
(5) Front oil seal (20) Baffle plate
(6) Oil pump case (21) O-ring Tightening torque:Nm (kgf-m, ft-lb)
(7) Inner rotor (22) Oil strainer T1: 5 (0.5, 3.7)
(8) Outer rotor (23) Gasket T2: 5.4 (0.55, 4.0)
(9) Oil pump cover (24) Oil level gauge guide T3: 6.4 (0.65, 4.7)
(10) Oil filter (25) Oil pan T4: 10 (1.0, 7.0)
(11) Oil cooler connector (26) Oil level gauge T5: 25 (2.5, 18.4)
(12) Water by-pass pipe (27) Drain plug gasket T6: 44 (4.5, 32.5)
(13) Oil cooler (28) Drain plug T7: 54 (5.5, 40)
(14) O-ring (29) Gasket T8: 69 (7.0, 50.9)
(15) Oil pump ASSY (30) Oil filler cap
LU-02356
(15)
(14)
T5
T3
T2
T6
T3
(9)
(8)
(7)
(6)
(16)
(26)
(5)
(4)
(3)
(2)
(1)
(29)
(19)
T7
(11)
(12)
(10)
T3
(13)
T8
T6
(28)
(25)
(27)
(23)
T1
T3
(24)
(32)
T3
(20)
(31)
T4
(22)
(21)
T3
(18)
(17)
(30)
(33)
T3
(34)
LU(H4DOTC)-5
General Description
LUBRICATION
C: CAUTION
forming any work.
points.
the battery.
under cover, wipe it off with cloth to avoid emitting
LU(H4DOTC)-6
General Description
LUBRICATION
D: PREPARATION TOOL
1. SPECIAL TOOL
WRENCH
499587100 OIL SEAL
INSTALLER
Used for installing oil seal into oil pump.
WRENCH
WRENCH
ST-499977100
ST-499587100
ST18332AA000
ST18332AA010
LU(H4DOTC)-7
Oil Pressure System
LUBRICATION
A: WIRING DIAGRAM
LU-02357
E
i3
B38
B21
E2
1
7
E11
No.5
SBF-6 MAIN SBF
B72
3 1
B72
A
1
5
i10
1
7
i10
A
3
1 3
4 5 6
2 2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B38
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
A:
BATTERY
IGNITION
SWITCH
OIL PRESSURE
SWITCH
COMBINATION
METER
O
I
L

P
R
E
S
S
U
R
E

W
A
R
N
I
N
G

L
I
G
H
T
LU(H4DOTC)-8
Oil Pressure System
LUBRICATION
B: INSPECTION
Step Check Yes No
2) Check the warning light in the combination
meter.
nate?
the combination
4, INSPECTION,
Combination Meter
System.>
2 CHECK HARNESS CONNECTOR BETWEEN
COMBINATION METER AND OIL PRES-
SURE SWITCH.
switch.
4) Measure the voltage of harness between oil
pressure switch connector and chassis ground.
pressure switch.
Go to step 3.
meter.
Terminals
(i10) No. 3 No. 15:
and connector.
NOTE:
the following item:
Open circuit of
harness between
combination meter
and oil pressure
switch
Poor contact in
combination meter
connector
Poor contact in
oil pressure switch
connector
Poor contact of
coupling connector
Repair or replace
the combination
4, INSPECTION,
Combination Meter
System.>
LU(H4DOTC)-9
Engine Oil
LUBRICATION
3. Engine Oil
A: INSPECTION
oil.
4) Remove the oil level gauge again and check the
reading. If the engine oil level is below L line, add
oil to bring the level up to F line.
the level.
7) Just after driving or while the engine is warm, en-
gine oil level shows in the range between F line
and cutout portion. This is caused by thermal ex-
pansion of engine oil.
NOTE:
As the oil level gauge is used for daily inspection,
standard of upper and lower level of the oil level
gauge is set for the condition that engine is cold.
B: REPLACEMENT
engine oil.
plug.
NOTE:
engine oil.
CAUTION:
NOTE:
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
fill engine oil through the oil filler duct to the F line
on oil level gauge. Make sure that the vehicle is
Recommended oil:
mended oil. <Ref. to LU(H4DOTC)-2, SPECI-
FICATION, General Description.>
capacity. <Ref. to LU(H4DOTC)-2, SPECIFI-
(A) Oil level gauge
(C) Upper level
(D) Lower level
LU-00213
(C)
(B)
(A)
(E)
(D)
LU-02189
(A)
LU-02189
(A)
LU(H4DOTC)-10
Engine Oil
LUBRICATION
necessary, add engine oil up to the F line on oil
level gauge.
(A) Oil level gauge
(C) Upper level
(D) Lower level
LU-00213
(C)
(B)
(A)
(E)
(D)
LU(H4DOTC)-11
Oil Pump
LUBRICATION
4. Oil Pump
A: REMOVAL
6) Remove the bolts which install water pipe of oil
cooler to oil pump.
7) Remove the water pipe and hoses between oil
cooler and water pump.
9) Remove the radiator. <Ref. to CO(H4DOTC)-19,
REMOVAL, Radiator.>
10) Remove the crankshaft position sensor. <Ref.
to FU(H4DOTC)-26, REMOVAL, Crankshaft Posi-
tion Sensor.>
11) Remove the V-belts. <Ref. to ME(H4DOTC)-
37, REMOVAL, V-belt.>
13) Remove the crank pulley using ST. <Ref. to
ME(H4DOTC)-40, REMOVAL, Crank Pulley.>
14) Remove the water pump. <Ref. to
CO(H4DOTC)-15, REMOVAL, Water Pump.>
IN-00203
LU-00137
LU-00010
LU-00011
LU-00012
LU-00013
LU-00014
LU(H4DOTC)-12
Oil Pump
LUBRICATION
cylinder block.
NOTE:
pump.
18) Remove the oil pump by using flat tip screw-
driver.
CAUTION:
Be careful not to scratch mating surfaces of
B: INSTALLATION
Perform the following.
NOTE:
pump.
NOTE:
Liquid gasket:
or equivalent
3) Apply a coat of engine oil to the inside of oil seal.
LU-00015
LU-00016
(A) O-ring
LU-00021
ST
ME-00165
(A)
ME-00312
LU(H4DOTC)-13
Oil Pump
LUBRICATION
4) Install the oil pump to cylinder block. Be careful
not to damage the oil seal during installation.
NOTE:
Make sure the front oil seal lip is not folded.
Use new O-rings.
5) Apply liquid gasket to the three bolts thread
shown in figure. (when reuse the bolts)
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 reas-
sembly.
NOTE:
Before disassembling the oil pump, remove the re-
lief valve.
LU-02103
T
(A) Front oil seal
(B) Oil pump case
(C) Inner rotor
(D) Outer rotor
(E) Oil pump cover
(F) Relief valve
(H) Plug
(I) Gasket
LU-00020
(E)
(D)
(C)
(B)
(A)
(F)
(G)
(I)
(H)
LU(H4DOTC)-14
Oil Pump
LUBRICATION
D: ASSEMBLY
NOTE:
2) Apply a coat of engine oil to inner and outer ro-
tors.
3) Assemble the inner and outer rotors in their orig-
inal positions.
4) Assemble the oil relief valve and install relief
valve spring and plug.
NOTE:
Use a new gasket.
5) Install the oil pump cover.
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)
LU-00021
ST
(A) Front oil seal
(B) Oil pump case
(C) Inner rotor
(D) Outer rotor
(E) Oil pump cover
(F) Relief valve
(H) Plug
(I) Gasket
LU-02134
T1
T2
(G)
(F)
(I)
(H)
(A)
(B)
(C)
(D)
(E)
LU(H4DOTC)-15
Oil Pump
LUBRICATION
E: INSPECTION
1. TIP CLEARANCE
is out of specification, replace the rotors as a set.
Tip clearance:
Standard
0.04 0.14 mm (0.0016 0.0055 in)
2. CASE CLEARANCE
the oil pump case. If clearance is out of standard,
replace the oil pump case.
Case clearance:
Standard
0.10 0.175 mm (0.0039 0.0069 in)
3. SIDE CLEARANCE
Measure the clearance between the inner rotor and
the oil pump cover by checking the step between
the inner rotor and the oil pump cover as shown in
the following figure. If the clearance is out of spec-
ification, replace the rotors and the oil pump case.
Side clearance:
Standard
0.02 0.07 mm (0.0008 0.0028 in)
4. OIL RELIEF VALVE
Check the valve for assembly condition and dam-
age, and the relief valve spring for damage and de-
terioration. 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 lbf)
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-00023
LU-00024
LU-00025
LU(H4DOTC)-16
LUBRICATION
A: REMOVAL
6) Remove the air intake boot and air cleaner case
(rear).
7) Remove the intercooler.
er.>
wire ropes.
CAUTION:
When lifting up the vehicle, raise up wire ropes
at the same time.
14) Drain the engine oil.
15) Remove the front exhaust pipe.
<Ref. to EX(H4DOTC)-6, REMOVAL, Front Ex-
haust Pipe.>
IN-00203
LU-00220
LU-00221
LU-02366
CO-00040
LU-00222
LU(H4DOTC)-17
LUBRICATION
17) Remove the bolts which install oil pan on cylin-
der block with the engine raised up.
CAUTION:
of oil pan cutter.
B: INSTALLATION
NOTE:
Before installing the oil pan, clean the mating sur-
face of oil pan and engine block.
1) Make sure that the seals (A) are installed se-
curely on the baffle plate in a direction as shown in
the figure below.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
3) Install the oil strainer to the cylinder block.
NOTE:
Use new O-rings.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
4) Tighten the oil strainer stay together with the baf-
fle plate.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Use a new gasket.
Liquid gasket:
or equivalent
(A) Oil pan
(B) Oil strainer
(C) Baffle plate
(D) Cylinder block
LU-02023
(A)
(C)
(D)
(B)
LU-02334
(A) Gasket
LU-00052
(A)
LU-02353
(A)
LU(H4DOTC)-18
LUBRICATION
6) Tighten the bolts which install oil pan to cylinder
block.
Tightening torque:
T1: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
T2: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
T3: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
7) Lower the engine onto front crossmember.
8) Tighten the nuts which install front cushion rub-
ber onto front crossmember.
Tightening torque:
75 Nm (7.6 kgf-m, 55.3 ft-lb)
9) Install the front exhaust pipe. <Ref. to
EX(H4DOTC)-7, INSTALLATION, Front Exhaust
Pipe.>
CAUTION:
When lowering the vehicle, lower the lift up de-
vice and wire ropes at the same time.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
14) Install the radiator upper brackets.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
(A) Oil pan
(B) Oil strainer
(C) Baffle plate
(D) Cylinder block
T2
T2
T3
T1
(A)
(C)
(D)
(B)
T1
LU-02335
LU-02023
LU-00222
LU-00224
T2
T1
CO-00040
LU(H4DOTC)-19
LUBRICATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
17) Install the air intake boot and air cleaner case
(rear).
18) Connect the connector to the mass air flow and
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
22) Refill the engine oil. <Ref. to LU(H4DOTC)-9,
INSPECTION, Engine Oil.>
C: INSPECTION
Visually check that the oil pan, oil strainer, oil
strainer stay and baffle plate are not damaged.
LU-02366
LU-00220
IN-00203
LU(H4DOTC)-20
Oil Pressure Switch
LUBRICATION
A: REMOVAL
2) Remove the generator from the bracket. <Ref. to
SC(H4SO)-15, REMOVAL, Generator.>
B: INSTALLATION
threads.
Liquid gasket:
equivalent
2) Install the oil pressure switch to the cylinder
block.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
3) Connect the terminal to the oil pressure switch.
4) Install the generator to the bracket. <Ref. to
SC(H4SO)-15, INSTALLATION, Generator.>
C: INSPECTION
Check the oil pressure switch installation portion for
oil leakage and oil seepage.
LU-00036
LU-00037
LU-00038
LU-00037
LU-00036
LU(H4DOTC)-21
Engine Oil Cooler
LUBRICATION
7. Engine Oil Cooler
A: REMOVAL
4) Drain the engine oil.
5) Drain engine coolant.
6) Remove the bolts which install water pipe of oil
cooler to oil pump.
7) Remove the water by-pass pipe and hose be-
tween oil cooler and water pump.
8) Remove the engine oil filter. <Ref. to
LU(H4DOTC)-23, REMOVAL, Engine Oil Filter.>
9) Remove the oil cooler connector and remove the
oil cooler.
LU-00137
LU-00040
(A) Gasket
(B) Oil cooler
(C) Oil cooler connector
LU-02304
(C)
(B)
(A)
LU(H4DOTC)-22
Engine Oil Cooler
LUBRICATION
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
T: 54 Nm (5.5 kgf-m, 40 ft-lb)
C: INSPECTION
1) Check the coolant paths for clogs while spraying
compressed air.
2) Check the mating surfaces of cylinder block,
gasket groove and oil filter for damage.
(A) Gasket
(B) Oil cooler
(C) Oil cooler connector
LU-02305
(C)
(B)
(A)
T
LU(H4DOTC)-23
Engine Oil Filter
LUBRICATION
A: REMOVAL
3) Remove the clip.
the arrow.
5) Remove the oil filter using ST.
oil filter)
oil filter)
CAUTION:
B: INSTALLATION
CAUTION:
block or oil cooler.
(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 fil-
ter 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).
4) Return the service hole cover to the original po-
sition.
C: INSPECTION
NOTE:
sary.
2) Check the engine oil level. <Ref. to
LU(H4DOTC)-9, INSPECTION, Engine Oil.>
(A) Oil filter
LU-02190
LU-02191
LU-02192
(A)
LU(H4DOTC)-24
LUBRICATION
9. Engine Lubrication System Trouble in General
A: INSPECTION
Symptoms Possible cause Corrective action
ON.
failure
2) Low oil pressure
pump rotor and gear
Replace.
3) No oil pressure
Insufficient engine oil (degradation, etc.) Replace.
not turn on.
momentarily.
3) Low oil pressure
Check for the same
possible causes as
listed 1) 2).
SP(H4DOTC)-2
General Description
A: SPECIFICATION
Specifications for the turbo model are the same as
the SOHC model. <Ref. to SP(H4SO)-2, General
Description.>
IG(H4DOTC)-2
General Description
IGNITION
A: SPECIFICATION
B: COMPONENT
Item Specification
Ignition coil
Type FK0186/FK0334
Ignition system Independent ignition coil
Spark plug
Manufacturer and type NGK: SILFR6A
Thread size (diameter, pitch, length) mm 14, 1.25, 26.5
Electrode Iridium
(1) Spark plug Tightening torque:Nm (kgf-m, ft-lb)
(2) Ignition coil T1: 21 (2.1, 15.5)
T2: 16 (1.6, 11.8)
IG-00098
(1)
T1
T2
T1
(1)
(2)
(2)
T2
IG(H4DOTC)-3
General Description
IGNITION
C: CAUTION
forming any work.
points.
the battery.
IG(H4DOTC)-4
Spark Plug
IGNITION
2. Spark Plug
A: REMOVAL
Spark plug:
Refer to SPECIFICATION for the spark
plug. <Ref. to IG(H4DOTC)-2, SPECIFICA-
1. RH SIDE
3) Remove the air cleaner case.
<Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner
Case.>
NOTE:
Turn #3 ignition coil by 180 degrees to remove it.
2. LH SIDE
3) Disconnect the secondary air pump duct from
the secondary air pump. <Ref. to EC(H4DOTC)-20,
REMOVAL, Secondary Air Pump.>
4) Remove the bolts that attach the secondary air
pump duct to the rocker cover (LH), and raise the
secondary air pump duct.
NOTE:
Turn #4 ignition coil by 180 degrees to remove it.
IN-00203
IG-00092
IG-02067
IG-02068
IG(H4DOTC)-5
Spark Plug
IGNITION
B: INSTALLATION
1. RH SIDE
Tightening torque (Spark plug):
21 Nm (2.1 kgf-m, 15.5 ft-lb)
Tightening torque (Ignition coil):
16 Nm (1.6 kgf-m, 11.8 ft-lb)
2. LH SIDE
21 Nm (2.1 kgf-m, 15.5 ft-lb)
16 Nm (1.6 kgf-m, 11.8 ft-lb)
Tightening torque (secondary air pump duct):
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
C: INSPECTION
1) Normal:
2) Carbon fouled:
air cleaner.
3) Oil fouled:
bustion chamber through worn rings and excessive
clearance between valve guides and stems.
4) Overheating:
(A) Spark plug gap
(C) Crack
(D) Damage
(E) Damaged gasket
IG-02010
(A)
(B)
(E)
(C)
(D)
IG-00011
IG-00012
IG-00013
IG-00014
IG(H4DOTC)-6
Spark Plug
IGNITION
D: ADJUSTMENT
Clean up the spark plug using nylon brush or equiv-
alent. Clean and remove the carbon or oxide de-
posits. If deposits are too stubborn, replace the
spark plugs. After cleaning the spark plugs, mea-
sure the spark plug gap using a gap gauge.
NOTE:
Never use a plug cleaner.
Never use a metal brush because it makes insu-
lator worn.
Spark plug gap : L
0.7 0.8 mm (0.028 0.031 in)
IG-02035
L
IG(H4DOTC)-7
Ignition Coil
IGNITION
3. Ignition Coil
A: REMOVAL
Direct ignition type has been adopted. Refer to Re-
moving Spark Plugs for removal procedure. <Ref.
to IG(H4DOTC)-4, REMOVAL, Spark Plug.>
B: INSTALLATION
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
C: INSPECTION
For inspection procedure, refer to Diagnostics for
Engine Starting Failure. <Ref. to EN(H4DOTC)(di-
ag)-78, IGNITION CONTROL SYSTEM, Diagnos-
tics for Engine Starting Failure.>
IG(H4DOTC)-8
Ignition Coil
IGNITION
SC(H4DOTC)-2
General Description
A: SPECIFICATION
Specifications for the turbo model are included in
the SC(H4SO) section. <Ref. to SC(H4SO)-2, Gen-
eral Description.>
EN(H4DOTC)(diag)-2
A: PROCEDURE
1. ENGINE
Step Check Yes No
EN(H4DOTC)(diag)-3, CHECK, Check List for
Interview.>
Diagnostics for
Engine Start Fail-
ure. <Ref. to
EN(H4DOTC)(diag
)-71, Diagnostics
for Engine Starting
Failure.>
INDICATOR LIGHT.
light illuminate?
General Diagnos-
tic Table <Ref. to
EN(H4DOTC)(diag
)-372, General
Diagnostic Table.>
3 CHECK INDICATION OF DTC ON SCREEN.
general scan tool.
NOTE:
EN(H4SO)(diag)-43, Read Diagnostic Trouble
Code (DTC).>
General scan tool
Is DTC displayed on the Subaru
Select Monitor or general scan
tool?
Record the DTC.
Repair the trouble
cause. <Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).> Go
to step 4.
Repair the related
parts.
NOTE:
If DTC is not
shown on display
although the mal-
function indicator
light illuminates,
perform the diag-
nosis of malfunc-
circuit or combina-
tion meter. <Ref. to
EN(H4DOTC)(di-
ag)-62, Malfunc-
tion Indicator
Light.>
EN(H4DOTC)(diag)-56, Clear Memory Mode.>
EN(H4DOTC)(diag)-45, Inspection Mode.>
tool?
Inspect using
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
)-91, Diagnostic
Procedure with
Diagnostic Trouble
Code (DTC).>
Finish the diagno-
sis.
EN(H4DOTC)(diag)-3
A: CHECK
1. CHECK LIST NO. 1
NOTE:
Date of repair
Odometer reading
km
V.I.N. miles
Weather Fine
Cloudy
Rainy
Snowy
Various/Others:
Hot
Warm
Cool
Cold
Place Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others:
Warming-up
After warming-up
Any temperature
Others:
Engine speed rpm
At starting
While idling
At racing
While accelerating
While cruising
While decelerating
Rear wiper ON/ OFF
EN(H4DOTC)(diag)-4
2. CHECK LIST NO. 2
NOTE:
ABS warning light
b) Fuel level
What:
What:
What:
Where:
From where:
What kind:
From where:
What kind:
Rough idling
Poor acceleration
Back fire
After fire
Does not shift.
EN(H4DOTC)(diag)-5
General Description
A: CAUTION
CAUTION:
All the airbag system wiring harnesses and
connectors are colored yellow. Do not use elec-
trical test equipment on these circuits.
aged.
etc.
necting the connectors. <Ref. to EN(H4DOTC)(di-
more into the part.
CAUTION:
NOTE:
When replacing the ECM of the models with Immo-
OPERATION MANUAL.
sembly as the grounding point to chassis when
compartment.
drop them.
CAUTION:
ness.
matching.
above.
fuel pressure. <Ref. to FU(H4DOTC)-50, RELEAS-
ING OF FUEL PRESSURE, PROCEDURE, Fuel.>
(A) Stud bolt
EN-00069
(A)
FU-01170
EN(H4DOTC)(diag)-6
General Description
diagnosis function.
B: INSPECTION
1. BATTERY
of the electrolyte.
proper grounding.
2. ENGINE GROUND
C: NOTE
of the complex electronic control. Malfunction indi-
cator light in the combination meter indicates oc-
currence of a fault or trouble.
board computer.
2. ENGINE AND EMISSION CONTROL SYS-
TEM
The Multipoint Fuel Injection (MFI) system is a
system that supplies the optimum air-fuel mixture
to the engine for all the various operating condi-
tions through the use of the latest electronic tech-
nology.
With this system, the fuel which is pressurized at a
constant pressure is injected into the intake air pas-
sage of the cylinder head. The injection quantity of
fuel is controlled by an intermittent injection sys-
tem, where the electro-magnetic injection valve (fu-
el 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 en-
gine are converted into electronic signals, and this
enables additional system features with greatly im-
proved adaptability, making it easier to add com-
pensation features.
Reduced emission of harmful exhaust gases.
Increased engine output.
Superior startability and warm-up perfor-
mance in cold weather since compensation is
made for engine coolant and intake air tempera-
ture
FU-01170
EN(H4DOTC)(diag)-7
General Description
D: PREPARATION TOOL
MONITOR III KIT
SOCKET
ST1B021XU0
ST-499987500
EN(H4DOTC)(diag)-8
A: LOCATION
1. ENGINE
Control module
EN-03145
(1)
(2) (4)
(3)
(1)
EN-01147 EN-05065
(2)
EN-02975
(3)
AT-01877
(4)
EN(H4DOTC)(diag)-9
Sensor
(1) Manifold absolute pressure sen-
sor
(4) Knock sensor (7) Mass air flow and intake air tem-
perature sensor
(5) Intake camshaft position sensor
(2) Engine coolant temperature sen-
sor
(6) Crankshaft position sensor (8) Tumble generator valve ASSY
(3) Electronic throttle control
EN-05066
(6)
(3) (2) (7) (5) (8) (1) (5)
(4) (8)
EN(H4DOTC)(diag)-10
EN-01927
(1)
(2)
EN-00295
EN-01928
(3)
EN-02169
(4)
EN-01798
(5)
EN-02919
(6)
EN-02920
(7)
EN-05373
(8)
EN(H4DOTC)(diag)-11
(1) Front oxygen (A/F) sensor (3) Exhaust temperature sensor (5) Rear oxygen sensor
(2) Precatalytic converter (4) Front catalytic converter (6) Rear catalytic converter
(1)
(4)
(3)
(5)
(6)
(2)
EN-02922
(1)
EN-00303 EN-00304
(3)
(2)
(4)
EN-00305
(5)
EN-00306
(6)
EN-00307
EN(H4DOTC)(diag)-12
EN-03146
(1)
(4)
(2) (3)
EN-03147
(2)
(1)
EN-03003
(3)
EN-03132
(4)
EN(H4DOTC)(diag)-13
(1) Wastegate control solenoid valve (5) Intake oil flow control solenoid
valve
(8) Secondary air combination valve
LH
(2) Purge control solenoid valve 2
(3) Purge control solenoid valve 1 (6) Secondary air pump (9) Tumble generator valve ASSY
(4) Ignition coil (7) Secondary air combination valve
RH
EN-05068
(4) (8) (4) (5) (1) (2) (3) (9) (5)
(7) (9) (6)
EN(H4DOTC)(diag)-14
EN-01935
(1)
(2)
EN-05069
(3)
EN-05070
(4)
EN-05071
(5)
EN-04936
(6)
EN-04990
(7)
EN-04991
(8)
EN-04992
(9)
EN(H4DOTC)(diag)-15
(2) Canister
EN-03938
(1)
(2) (3) (4)
EN-02980
(1)
EN-02981
(4)
(3)
(2)
EN(H4DOTC)(diag)-16
(1) Starter (6) Radiator main fan relay 1 (10) Secondary air combination valve
relay 2
(2) Fuel pump (7) Radiator sub fan relay
(3) Main relay (8) Radiator main fan relay 2 (11) Secondary air pump relay
(4) Fuel pump relay (9) Secondary air combination valve
relay 1
(5) Electronic throttle control relay
EN-05721
(3)
(2)
(7) (8) (6) (1) (9) (10) (11)
(4) (5)
EN-05614
(1)
(2)
EN-02093
EN-03150
(3)
(4)
(5)
EN-05073
(6) (9) (11)
(8)
(7)
(10)
EN(H4DOTC)(diag)-17
Contents
Connector
No.
Terminal
No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
Crankshaft
position
sensor
Signal () B134 14 0 0
Shield B134 24 0 0
Rear oxygen
sensor
Signal B135 4 0 0 0.9
Shield B135 1 0 0
GND
(sensor)
B135 30 0 0
Front oxygen
(A/F) sensor
heater
Signal 1 B136 3 Waveform
Signal 2 B136 2 Waveform
Rear oxygen sensor heater
signal
B136 4 0 13 12 14 Waveform
Engine coolant
temperature
sensor
Signal B134 34 1.0 1.4 1.0 1.4 After engine is warmed-up.
GND
(sensor)
B134 29 0 0 After engine is warmed-up.
Air flow sensor
Signal B135 26 0.3 4.5
Shield B135 35 0 0
GND B135 34 0 0
Intake air temperature
sensor signal
B135 18 0.3 4.6 0.3 4.6
Wastegate control solenoid
valve
B137 27 0 or 10 13 0 or 12 14 Waveform
Starter switch B136 32 0 0 Cranking: 8 14
A/C switch B136 24
ON: 10 13
OFF: 0
ON: 12 14
OFF: 0

Neutral position switch
(AT / MT)
B136 31
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14

Delivery (test) mode
connector
B135 27 10 13 13 14 When connected: 0
EN-05288
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H4DOTC)(diag)-18
Knock sensor
Signal B134 15 2.8 2.8
Shield B134 25 0 0
Ignition switch OFF
: 10 13
Control module power
supply
B134 7 10 13 12 14
B135 2 10 13 12 14
Sensor power supply B134 19 5 5
Ignition control
#1 B137 18 0 12 14 Waveform
#2 B137 19 0 12 14 Waveform
#3 B137 20 0 12 14 Waveform
#4 B137 21 0 12 14 Waveform
Fuel injector
#1 B137 8 10 13 1 14 Waveform
#2 B137 9 10 13 1 14 Waveform
#3 B137 10 10 13 1 14 Waveform
#4 B137 11 10 13 1 14 Waveform
Fuel pump con-
trol unit
Signal 1 B135 33 10 13 12 14
Signal 2 B136 12 0 or 5 0 or 5 Waveform
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 12 14

ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 12 14

ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 12 14
Model with A/C only
Light ON: 1 or less
Light OFF: 10 14
Purge control solenoid valve 1 B137 29
ON: 1 or less
OFF: 10 13
ON: 1 or less
OFF: 12 14
Waveform
Purge control solenoid valve 2 B136 7
ON: 1 or less
OFF: 10 13
ON: 1 or less
OFF: 12 14
Waveform
Manifold
absolute
pressure
sensor
Signal B134 6 1.7 2.4 1.1 1.6

Power
supply
B134 19 5 5
GND
(sensor)
B134 29 0 0
Power steering oil pressure
switch
B134 33 10 13
ON: 0
OFF: 12 14

Front oxygen (A/F) sensor sig-
nal (+)
B135 9 2.8 3.2 2.8 3.2
Front oxygen (A/F) sensor sig-
nal ()
B135 8 2.4 2.7 2.4 2.7
Front oxygen (A/F) sensor
shield
B135 1 0 0
SSM communication line B136 16
1 or less 4 or
more
1 or less 4 or
more

Intake camshaft position sen-
sor (LH)
B134 21 0 or 5 0 or 5 Waveform
sor (RH)
B134 11 0 or 5 0 or 5 Waveform
sor ground
B134 22 0 0
Contents
Connector
No.
Terminal
No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
EN(H4DOTC)(diag)-19
Electric
throttle control
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 5 5
GND
(sensor)
B134 29 0 0
Electronic throttle control
motor (+)
motor ()
motor power supply
B136 1 10 13 12 14
motor relay
B136 21
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
turned to ON: ON
Intake AVCS
solenoid (LH)
Signal (+) B137 15
ON: 10 13
OFF: 0
ON: 12 14
OFF: 0

Signal () B137 14 0 0
Intake AVCS
solenoid (RH)
Signal (+) B137 17
ON: 10 13
OFF: 0
ON: 12 14
OFF: 0

Signal () B137 16 0 0
Accelerator
pedal position
sensor
Main sensor
signal
B135 23
Fully closed: 1
Fully opened: 3.3
Fully closed: 1
Fully opened: 3.3

Main power
supply
B135 21 5 5
GND
(main
sensor)
B135 29 0 0
Shield B136 6 0 0
Sub sensor
signal
B135 31
Fully closed: 1
Fully opened: 3.3
Fully closed: 1
Fully opened: 3.3

Sub power
supply
B135 22 5 5
GND
(sub
sensor)
B135 30 0 0
Starter relay B136 20
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
ON: cranking
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14

Clutch switch B136 25
When clutch pedal is
depressed: 0
When brake pedal is
released: 10 13
When clutch pedal
is depressed: 0
When brake pedal
is released
: 12 14

When brake pedal is
depressed: 0
When brake pedal is
released: 10 13
When brake pedal
is depressed: 0
When brake pedal
is released
: 12 14

Contents
Connector
No.
Terminal
No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
EN(H4DOTC)(diag)-20
When brake pedal is
depressed: 10 13
When brake pedal is
released: 0
When brake pedal
is depressed
: 12 14
When brake pedal
is released: 0

Cruise control command
switch
B135 24
When operating noth-
ing: 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
When operating
nothing: 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
ON: 0
OFF: 5

Fuel tank pressure sensor B135 32 2.3 2.7 2.3 2.7
Pressure control solenoid
valve
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

Ambient temperature: 25C
(77F)
Immobilizer
Signal 1 B136 26
Signal 2 B136 34
CAN communication (+) B136 27
CAN communication () B136 35
AT/MT identification B136 15 0 0
Blow-by leak diagnosis
signal
B134 30 0 0
At the time of open circuit
(fault): 5
Tumble generator valve posi-
tion sensor signal (RH)
B134 26
Fully closed: 0.4
1.2
Fully opened
: 2.8 4.6
Fully closed
: 0.4 1.2
Fully opened
: 2.8 4.6

Tumble generator valve posi-
tion sensor signal (LH)
B134 16
Fully closed: 0.4
1.2
Fully opened
: 2.8 4.6
Fully closed
: 0.4 1.2
Fully opened
: 2.8 4.6

Tumble generator valve RH
(closed)
B137 23 0 or 10 13 0 or 12 14
Tumble generator valve LH
(closed)
B137 13 0 or 10 13 0 or 12 14
Tumble generator valve RH
(open)
B137 22 0 or 10 13 0 or 12 14
Tumble generator valve LH
(open)
B137 12 0 or 10 13 0 or 12 14
Secondary air
pipe pressure
sensor
Signal B134 27 2.2 2.8 2.2 2.8
When secondary air is
inducted: 3.2 4.9
Power sup-
ply
B134 19 5.12 5.12
GND
(sensor)
B134 29 0 0
Contents
Connector
No.
Terminal
No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
EN(H4DOTC)(diag)-21
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

Secondary air pump relay B136 8
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14

Self-shutoff control B136 23 10 13 12 14
GND (ignition system)
B137 26 0 0
B137 6 0 0
Ground (engine 1) B134 5 0 0
Ground (body) B136 6 0 0
Contents
Connector
No.
Terminal
No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
EN(H4DOTC)(diag)-22
EN-05322
ONE CRANK ROTATION
5V
10ms
0
EN-05359
ONE CAM ROTATION
ONE CAM ROTATION
LH
5V
50ms
0
RH
0
EN(H4DOTC)(diag)-23
MT 1
5
4 11 13 2 3
AT
1
12
C25
C16
C6
B21
B29
B22
B30
B31
B27
B23
MT
M
T
M
T
M
T
M
T
M
T
A
T
A
T
C32
B5
B19
B17
C12
C31
B33
C20
AT
12
EN-05714
M/B FUSE No.13
STARTER MOTOR
IGNITION
SWITCH
CLUTCH
SWITCH
F/B FUSE No.21
F/B FUSE No.12
M/B FUSE No.11
INHIBITOR
RELAY
STARTER
RELAY
TCM
NEUTRAL
SWITCH
FUEL
PUMP
RELAY
FUEL PUMP
CONTROL UNIT
FUEL
TEMPERA-
TURE
SENSOR
F/B FUSE No.4
DATA LINK
CONNECTOR
CLUTCH
SWITCH
TEST MODE
CONNECTOR
JOINT
CONNECTOR
JOINT
CONNECTOR
A
C
C
E
L
E
R
A
T
O
R

P
E
D
A
L

P
O
S
I
T
I
O
N

S
E
N
S
O
R
EN(H4DOTC)(diag)-24
D29
C23
C21
C1
SBF-5
SBF-7
A22
D18
B2
A7
A11
7 6
A21
5
C7
D19
D20
D21
D26
D6
C11
A30
A33
C22
I/F
I/F
EN-05715
MAIN
RELAY
ELECTRONIC
THROTTLE
CONTROL
RELAY
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
INTAKE CAMSHAFT
POSITION SENSOR LH
INTAKE CAMSHAFT
POSITION SENSOR RH
POWER STEERING
OIL PRESSURE
SWITCH
F/B FUSE No.7
F/B FUSE No.5
IGNITION COIL
No.1
IGNITION COIL
No.2
IGNITION COIL
No.3
IGNITION COIL
No.4
PCV
HOSE ASSY
COMBINATION METER
MALFUNCTION
INDICATOR LIGHT
M
I
C
R
O

C
O
M
P
U
T
E
R
C
A
N
T
R
A
N
S
C
E
I
V
E
R
&

R
E
C
E
I
V
E
R
TACHO-
METER
SPEEDO-
METER
ENGINE
COOLANT
TEMPER-
ATURE
GAUGE
POWER
SUPPLY CIRCUIT
B
O
D
Y

I
N
T
E
G
R
A
T
E
D

U
N
I
T

(
C
A
N

C
O
M
M
U
N
I
C
A
T
I
O
N
)
EN(H4DOTC)(diag)-25
A18
D11
D10
D9
D8
D27
B18
A34
A29
A6
A19
D4
A28
D5
B34
B26
B35
7
4
8
7 3
9
EN-05716
FUEL INJECTOR
No.1
FUEL INJECTOR
No.2
FUEL INJECTOR
No.3
FUEL INJECTOR
No.4
WASTEGATE
SOLENOID VALVE
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
ENGINE
COOLANT
TEMPERATURE
SENSOR
ELECTRONIC
THROTTLE
CONTROL
M
A
S
S

A
I
R

F
L
O
W

&

I
N
T
A
K
E

A
I
R

T
E
M
P
E
R
A
T
U
R
E

S
E
N
S
O
R
EN(H4DOTC)(diag)-26
2
C8
C3
B1
C2
B8
B9
C4
C19
B4
A27
9 8
6
C30
A13
A14
A25
A24
D17
D16
D15
D14
D22
D23
A26
D12
D13
A16
A15
8 9
10
7
EN-05717
FRONT
OXYGEN
(A/F)
SENSOR RH
REAR
OXYGEN
SENSOR RH
SECONDARY
AIR COMBINATION
VALVE RELAY 2
SECONDARY
AIR COMBINATION
VALVE RELAY 2
SECONDARY
AIR PUMP VALVE
RELAY
RELAY
HOLDER
FUSE10A
RELAY
HOLDER
FUSE60A
SECONDARY
AIR COMBINATION
VALVE RH
SECONDARY
AIR COMBINATION
VALVE LH
SECONDARY
AIR PUMP
TUMBLE
GENERATOR
VALVE ASSY LH
TUMBLE
GENERATOR
VALVE ASSY RH
OIL FLOW
CONTROL
SOLENOID VALVE LH
OIL FLOW
CONTROL
SOLENOID VALVE RH
CRANKSHAFT
POSITION SENSOR
KNOCK SENSOR
EN(H4DOTC)(diag)-27
C24
C33
C9
D7
D3
D1
D2
A5
C15
C26
B28
B12
B24
C35
C18
C29
C27
C34
B20
B32
C28
C17
10
MT
13 11 7
EN-05718
FUEL TANK
PRESSURE SENSOR
PRESSURE CONTROL
SOLENOID VALVE
DRAIN VALVE
STOP LIGHT SWITCH
BRAKE SWITCH
SUB FAN RELAY
MAIN FAN RELAY
A/C CONTROL MODULE
A/C PRESSURE SWITCH
A/C RELAY
ENGINE GROUND
(IMMOBILIZER)
(CAN COMMUNICATION)
EN(H4DOTC)(diag)-28
Engine Load
17.6 35.64 (%): Idling
13.2 26.73 (%): 2,500 rpm racing
EN(H4DOTC)(diag)-29
Data Link Connector
A: NOTE
CAUTION:
1 2 3 4 5 7 6 8
9 10 11 12 13 15 14 16
EN-04893
1 Power supply 9 Blank
2 Blank 10 Blank
3 Blank 11 Blank
4 Ground 12 Blank
5 Ground 13 Blank
6 CAN communication (+) 14 CAN communication ()
EN(H4DOTC)(diag)-30
General Scan Tool
A: OPERATION
by SAE J1978.
freeze frame data.
data
DTC
(4) MODE $04: Clear/Reset emission-related
diagnostic information
test results for intermittently monitored systems
test results for continuously monitored systems
Read out the data according to repair procedures.
(For detailed operation procedure, refer to the gen-
eral scan tool instruction manual.)
NOTE:
For details concerning DTC, refer to List of Diagnos-
tic Trouble Code (DTC). <Ref. toEN(H4DOTC)(di-
EN-02533
EN(H4DOTC)(diag)-31
General Scan Tool
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)
ertrain system.
NOTE:
$01
Number of emission-related powertrain DTC, and malfunction indicator light status and diag-
nosis support information

$0D Vehicle speed MPH
$0F Intake air temperature C
$10 Air flow rate from mass air flow sensor gm/s
$12 Secondary air control status
$15 Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor V and %
$21 Running distance after MIL turns on miles
$24 A/F value and A/F sensor output voltage and V
$2F Fuel level %
$32 Fuel tank pressure mmHg
$33 Atmospheric pressure mmHg
$34 A/F sensor value, current , A
$3C Catalyzer temperature C
$43 Absolute load %
$4D Engine operation time during MIL on min
$51 Fuel used
EN(H4DOTC)(diag)-32
General Scan Tool
NOTE:
ertrain DTC. <Ref. to EN(H4DOTC)(diag)-83, List of Diagnostic Trouble Code (DTC).>
information).
NOTE:
mation (MODE $04).
$02 DTC that caused the freeze frame data storage required by CARB.
$0D Vehicle speed MPH
$0F Intake air temperature C
$10 Air flow rate from mass air flow sensor gm/s
$12 Secondary air control status
$13 Air fuel ratio sensor
$15 Rear oxygen sensor voltage, compensation value V,
$2F Fuel level %
$43 Absolute load %
EN(H4DOTC)(diag)-33
General Scan Tool
6. MODE $06
$01
$81 $0A
A/F sensor conduction abnormal (B1S1) $82 $8D
$83 $14
$84 $1E
A/F sensor range abnormal (B1S1)
$85 $1E
$86 $20 A/F sensor response abnormal (B1S1)
$02
$87 $0B
Oxygen sensor circuit abnormal (B1S2)
$88 $0B
$07 $0B
Oxygen sensor drop abnormal (B1S2) $08 $0B
$A5 $0B
$05 $10
Oxygen sensor response abnormal (B1S2)
$06 $10
$21 $89 $20 Catalyst degradation diagnosis (B1)
$39 $93 $FE Evaporative emission control system leak detected (Fuel filler cap off)
$3B
$94 $FE
$95 $FE
$3C
$96 $FE
$97 $FE
$41
$99 $24
A/F sensor heater abnormal (B1S1)
$9A $24
$9B $14 A/F sensor heater characteristic abnormal (B1S1)
$42
$9C $24
Oxygen sensor heater abnormal (B1S2)
$9D $24
$71
$9E $17
Secondary air system (whole system) $9F $0B
$A0 $0B
$B0 $17
Secondary air system (relay 2 combination valve 2)
$B1 $0B
$B1 $17
$B2 $0B
$B2 $17
$B3 $0B
$B4 $0B
$B5 $0B
$B6 $31
$B7 $31
$A1
$0B $24
$0C $24
$A2
$0B $24
$0C $24
$A3
$0B $24
$0C $24
$A4
$0B $24
$0C $24
EN(H4DOTC)(diag)-34
General Scan Tool
7. MODE $07
8. MODE $09
Refer to the data of vehicle specification (V.I.N., calibration ID, etc.).
$A5
$0B $24
$0C $24
$E1 $A6 $FE Purge control solenoid valve 2 close seized
EN(H4DOTC)(diag)-35
A: OPERATION
MONITOR
EN(H4DOTC)(diag)-7, PREPARATION TOOL,
General Description.>
Monitor).
NOTE:
drivers side).
CAUTION:
Monitor.
NOTE:
Refer to Read Diagnostic Trouble Code for infor-
mation about how to display a DTC. <Ref. to
EN(H4DOTC)(diag)-44, Read Diagnostic Trouble
Code (DTC).>
mation about how to display a DTC. <Ref. to
EN(H4DOTC)(diag)-44, Read Diagnostic Trouble
Code (DTC).>
EN-05692
EN-02533
EN(H4DOTC)(diag)-36
Contents Display Unit of measure Note (at idling)
Engine Load Engine Load % 21.0%
80 100C
or 176 212F
A/F correction 1 A/F Correction #1 % 10 +10%
A/F learning 1 A/F Learning #1 % 15 +15%
mmHg, kPa,
inHg or psig
220 275 mmHg,
29.5 37 kPa,
8.7 10 inHg
or 4.2 5.3 psig
630 770 rpm
(Agree with the
tachometer indication)
Meter vehicle speed signal Meter Vehicle Speed km/h or MPH
0 km/h or 0 MPH
(at parking)
Intake air temperature signal Intake Air Temp. C or F
20 50C
or 68 122F
2.1 3.1 g/s
or 0.35 0.40 lb/m
Throttle opening angle signal Throttle Opening Angle % 2.0 2.4%
Rear oxygen sensor voltage Rear O2 Sensor V 0 1.0 V
Mass air flow voltage Air Flow Sensor Voltage V 1.0 1.7 V
Injection 1 pulse width Fuel Injection #1 Pulse ms 1.2 2.2 ms
Barometric pressure Atmosphere Pressure
mmHg, kPa,
inHg or psig

mmHg, kPa,
inHg or psig
(Intake manifold absolute
pressure atmosphere
pressure)
Ignition learning value Learned Ignition Timing deg 0 deg
Acceleration opening angle signal Accel. Opening Angle % 0.0%
Fuel temperature signal Fuel Temp. C or F +28C or 82F
Primary supercharged pressure control signal Primary Control % 0.0%
Purge control solenoid duty ratio
Purge control solenoid
duty ratio
% 0 25%
Tumble generator valve RH opening signal TGV Position Sensor R V 0.81 V
Tumble generator valve LH opening signal TGV Position Sensor L V 0.81 V
Fuel pump duty ratio Fuel Pump Duty % 30 40%
AVCS advance angle amount RH
AVCS advance angle
amount RH
deg 5 deg
AVCS advance angle amount LH
AVCS advance angle
amount LH
deg 5 deg
Oil flow control solenoid valve duty RH (AVCS) OCV Duty R % 0 20%
Oil flow control solenoid valve duty LH (AVCS) OCV Duty L % 0 20%
Oil flow control solenoid valve current RH OCV Current R mA 40 100 mA
EN(H4DOTC)(diag)-37
Oil flow control solenoid valve current LH OCV Current L mA 40 100 mA
A/F sensor current value 1 A/F Sensor #1 Current mA 20 20 mA
A/F sensor resistance value 1
A/F Sensor #1
Resistance
27 35 mA
A/F sensor output lambda 1 A/F Sensor #1 1.0
A/F learning 3 A/F learning 3 % 0.00%
Throttle motor duty Throttle Motor Duty % 5%
Throttle power supply voltage Throttle Motor Voltage V 12 15 V
Sub throttle sensor voltage Sub-throttle Sensor V 1.5 V
Main throttle sensor voltage Main-throttle Sensor V 0.6 V
Sub accelerator sensor voltage Sub-accelerator Sensor V 1.1 V
Main accelerator sensor voltage Main-accelerator Sensor V 1.0 V
Secondary air supply piping pressure signal
Secondary air supply
piping pressure
mmHg, kPa,
inHg or psig
765 mmHg, 102 kPa,
30.1 inHg or 14.8 psig
Secondary airflow signal
Secondary airflow
amount
g/s or lb/m 0.00 g/s or 0.00 lb/m
Memorized Cruise
Speed
km/h or MPH
Fuel level sensor resistance Fuel level resistance 4 96
Odd Meter
Estimated Cumulative
Driving Distance
km
Knock sensor compensation Knock Correction deg 0.0 deg
mmHg, kPa,
inHg or psig
+8.8 mmHg, +1.2 kPa,
+0.4 inHg or +0.2 psig
AT/MT identification terminal AT Vehicle ID Signal AT/MT
D check request flag D-check Flag OFF
Delivery (test) mode terminal
Delivery Mode
Connector
OFF
Neutral position switch signal Neutral Position Switch Neutral
Soft idle switch signal Soft Idle Switch Signal At idle
Ignition switch signal Ignition Switch ON input
Power steering switch signal P/S Switch OFF input (At OFF)
Air conditioning switch signal A/C Switch OFF input (At OFF)
Rear oxygen monitor Rear O2 Rich Signal Rich/Lean
Knocking signal Knock Signal None
Crankshaft position sensor signal Crankshaft Position Sig. Provided
Camshaft position sensor signal Camshaft Position Sig. Provided
Rear defogger switch signal Rear Defogger SW OFF input (At OFF)
Blower fan switch signal Blower Fan SW OFF input (At OFF)
Light switch signal Light Switch OFF input (At OFF)
A/C middle pressure switch signal A/C Mid Pressure Switch OFF input (At OFF)
Air conditioner compressor relay output signal A/C Compressor Signal OFF output (At OFF)
Radiator fan relay 1 signal Radiator Fan Relay #1 OFF output (At OFF)
Radiator fan relay 2 signal Radiator Fan Relay #2 OFF output (At OFF)
EN(H4DOTC)(diag)-38
NOTE:
PCV hose assembly diagnosis signal Blow-by Leak Connector Connected
Pressure control solenoid valve signal PCV Solenoid OFF output (At OFF)
Tumble generator valve output signal TGV Output None
Tumble generator valve drive signal TGV Drive Opening direction
Drain valve signal Vent Control Solenoid OFF output (At OFF)
Purge control solenoid valve 2 signal CPC Solenoid 2 OFF (At OFF)
AT coordinate retard angle demand signal Retard Signal from AT None
AT coordinate fuel cut demand signal Fuel Cut Signal from AT None
Vehicle dynamics control (VDC) torque down prohibition
output
Ban of Torque Down Permission
Vehicle dynamics control (VDC) torque down demand Request Torque Down None
AT coordinate permission signal
AT coordinate permis-
sion signal
ON/OFF
ETC motor relay signal ETC Motor Relay ON
Clutch switch signal Clutch Switch OFF (At OFF)
Stop light switch signal Stop Light Switch OFF (At OFF)
SET/COAST switch signal SET/COAST Switch OFF (At OFF)
RES/ACC switch signal RESUME/ACCEL Switch OFF (At OFF)
Brake switch signal Brake Switch OFF (At OFF)
Main switch signal Main Switch OFF (At OFF)
Body int. unit data reception Body Int. Unit Data Provided
Integrated unit data update Body Int. Unit Count Provided
Secondary air combination valve relay 2 signal Sec. Air Combi V Relay 2 OFF (At OFF)
Secondary air pump relay signal Sec. Air Pump Relay OFF (At OFF)
Secondary air combination valve relay 2 signal Sec. Air Combi V Relay 1 OFF (At OFF)
Cruise control cancel switch signal CC Cancel SW OFF (At OFF)
Malfunction indicator light signal MIL Lit Off (when unlit)
SI drive mode SI Drive mode I, S or S#
EN(H4DOTC)(diag)-39
Contents Display
Referential value
(at idling)
Unit of measure
Number of diagnosis code Number of Diag. Code: 0
Monitoring test of misfire Misfire Monitoring (Supp) YES
Monitoring test of misfire Misfire Monitoring (Rdy) YES
(Supp)
YES
(Rdy)
YES
(Supp)
YES
(Rdy)
YES
Test of catalyst Catalyst Diagnosis (Supp) YES
Evaporative purge
system (Supp)
YES
Evaporative purge
system (Rdy)
NO
(Supp)
YES
(Rdy)
NO
(Supp)
NO
(Rdy)
N/A
Test of oxygen sensor
O2 Heater Diagnosis
(Supp)
YES
Test of oxygen sensor
O2 Heater Diagnosis
(Rdy)
NO
O2 Heater Diagnosis
(Supp)
YES
O2 Heater Diagnosis
(Rdy)
YES
Test of EGR system EGR system (Supp) NO
Test of EGR system EGR system (Rdy) N/A
Air fuel ratio control system for bank 1 Fuel System for Bank 1 Normal CLOSE
Engine load data Calculated load value 19.2 %
Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Short term fuel trim B1 17.2 %
Long term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim B1 5.5 %
EN(H4DOTC)(diag)-40
#1 Cylinder ignition timing Ignition timing adv. #1 13.5
Secondary air control status Secondary air system Stop
Oxygen sensor (Bank 1 Sensor 2) Oxygen Sensor #12 0.1 0.7 V
A/F correction (Bank 1 Sensor 2) A/F Correction #12 0.0 %
On-board diagnostic system OBD System OBD/OBD2
Front oxygen (A/F) sensor (Bank 1 Sensor 1) Oxygen Sensor #11 Support
Oxygen sensor (Bank 1 Sensor 2) Oxygen Sensor #12 Support
Time elapsed after engine start
Elapsed Time After
Starting Engine
sec
Driving distance after the malfunction indicator light
illuminates
Time while MIL lighted km
A/F sensor output signal (Bank 1 Sensor 1) A/F sensor #11 2.468 V
Evaporative purge Evaporative purge 0 %
Fuel level signal Fuel level %
Number of warm ups after DTC clear
Number Of Warm Ups
After DTC Clear

Driving distance after DTC clear Time since DTC cleared km
Barometric pressure signal Atmospheric Pressure Barometric pressure mmHg
A/F sensor output signal (Bank 1 Sensor 1) A/F sensor #11 0.18 mA
Misfire Monitoring
(Enable)
YES
Monitoring test of misfire Misfire Monitoring (Comp) YES
(Enable)
YES
(Comp)
NO
(Enable)
NO
(Comp)
NO
Test of catalyst
Catalyst Diagnosis
(Enable)
YES
Test of catalyst
Catalyst Diagnosis
(Comp)
NO
Evaporative purge system
(Enable)
YES
Evaporative purge system
(Comp)
NO
Contents Display
Referential value
(at idling)
Unit of measure
EN(H4DOTC)(diag)-41
NOTE:
(Enable)
YES
(Comp)
NO
(Enable)
N/A
(Comp)
N/A
Test of oxygen sensor Oxygen sensor (Enable) YES
Test of oxygen sensor Oxygen sensor (Comp) NO
O2 Heater Diagnosis
(Enable)
YES
O2 Heater Diagnosis
(Comp)
YES
Test of EGR system EGR system (Enable) N/A
Test of EGR system EGR system (Comp) N/A
ECM power voltage ECM power voltage 13.848 V
Absolute load Absolute load 21 %
A/F ratio target lambda A/F target lambda 0.993
Relative throttle opening angle Relative throttle position 2 %
Ambient temperature Ambient temperature Ambient temperature C
Absolute throttle opening angle 2
Absolute throttle opening
angle 2
31 %
Absolute accelerator opening angle 1
Absolute accelerator
opening angle 1
13 %
Absolute accelerator opening angle 2
Absolute accelerator
opening angle 2
13 %
Target throttle opening angle
Target throttle opening
angle
0 %
Engine operating time while malfunction indicator lit
Engine operating time dur-
ing MIL illuminates
min
Time elapsed after DTC clear
Elapsed time after DTC
clear
min
Fuel used Fuel used GAS
Relative accelerator opening angle
Relative accelerator open-
ing angle
0 %
Contents Display
Referential value
(at idling)
Unit of measure
EN(H4DOTC)(diag)-42
NOTE:
DTC of freeze frame data Freeze frame data Diagnostic code
Engine load data Calculated load value %
Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Short term fuel trim B1 %
Long term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim B1 %
Intake manifold absolute pressure signal Mani.Absolute Pressure mmHg, kPa, inHg or psi
Ignition timing #1 Ignition timing adv. #1
Intake air temperature Intake Air Temp. C
Amount of intake air Mass Air Flow g/s
Throttle opening angle Throttle Opening Angle %
Secondary air control status Secondary air system
Oxygen sensor #12 Oxygen sensor #12 V
A/F correction #12 A/F correction #12 %
OBD system OBD System
Oxygen sensor #11 Oxygen sensor #11 Support
Elapsed time after starting the engine Elapsed Time After Starting Engine sec
Evaporative purge Evaporative purge %
Fuel level Fuel level %
Fuel tank pressure Tank pressure mmHg, kPa, inHg or psig
Atmospheric pressure Atmospheric Pressure mmHg, kPa, inHg or psig
ECM power voltage ECM power voltage V
Absolute load Absolute load %
A/F target lambda A/F target lambda
Relative throttle opening angle Relative throttle position %
Ambient temperature Ambient temperature C or F
Absolute throttle opening angle 2 Absolute throttle opening angle 2 %
Absolute accelerator opening angle 1 Absolute accelerator opening angle 1 %
Absolute accelerator opening angle 2 Absolute accelerator opening angle 2 %
Target throttle opening angle Target throttle opening angle %
EN(H4DOTC)(diag)-43
7. V.I.N. REGISTRATION
NOTE:
EN(H4DOTC)(diag)-44
Code (DTC)
A: OPERATION
MODE)
2) On the System Selection Menu display screen,
select the {Engine Control System}.
5) On the Diagnostic Code(s) Display screen, se-
lect the {Temporary Diagnostic Code(s)} or {Memo-
rized Diagnostic Code(s)}.
NOTE:
For details concerning DTC, refer to List of Diagnostic
Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag)-83,
List of Diagnostic Trouble Code (DTC).>
MODE)
NOTE:
Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag)-83,
Refer to data denoting emission-related powertrain
DTC.
Trouble Code (DTC). <Ref. toEN(H4DOTC)(diag)-83,
NOTE:
Refer to general scan tool manufacturers instruc-
tion manual to access powertrain DTC (MODE
$03).
EN(H4DOTC)(diag)-45
Inspection Mode
11.Inspection Mode
A: PROCEDURE
When performing the diagnosis not listed in List of Diagnostic Trouble Code (DTC), refer to the item on the
drive cycle. <Ref. to EN(H4DOTC)(diag)-50, Drive Cycle.>
DTC Item Condition
P0011 Intake Camshaft Position - Timing Over-Advanced Or System Performance
(Bank 1)

P0016 Crankshaft Position - Camshaft Position Correlation (Bank 1)
(Bank 2)

P0230 Fuel Pump Primary Circuit
P0245 Turbo/Super Charger Wastegate Solenoid A Low
P0413 Secondary Air Injection System Switching Valve A Circuit Open
P0416 Secondary Air Injection System Switching Valve B Circuit Open
P0418 Secondary Air Injection System Control A Circuit
EN(H4DOTC)(diag)-46
Inspection Mode
P1410 Secondary Air Injection System Switching Valve Stuck Open
P1491 Positive Crankcase Ventilation (Blow-by) Function Problem
P1570 Antenna
P1578 Meter Failure
P2006 Intake Manifold Runner Control Stuck Closed (Bank 1)
P2007 Intake Manifold Runner Control Stuck Closed (Bank 2)
P2008 Intake Manifold Runner Control Circuit / Open (Bank 1)
P2009 Intake Manifold Runner Control Circuit Low (Bank 1)
P2011 Intake Manifold Runner Control Circuit / Open (Bank 2)
P2012 Intake Manifold Runner Control Circuit Low (Bank 2)
P2016 Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 1)
P2017 Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 1)
P2021 Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 2)
P2022 Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 2)
P2088 Intake Camshaft Position Actuator Control Circuit Low (Bank 1)
P2089 Intake Camshaft Position Actuator Control Circuit High (Bank 1)
DTC Item Condition
EN(H4DOTC)(diag)-47
Inspection Mode
MODE
10.6 US gal, 4.4 8.8 Imp gal)].
ers.
WARNING:
brakes are applied.
id rack.
wheels.
and vehicle.
P2419 Evaporative Emission System Switching Valve Control Circuit Low
P2420 Evaporative Emission System Switching Valve Control Circuit High
P2431 Secondary Air Injection System Air Flow /Pressure Sensor Circuit Range/Per-
formance

P2432 Secondary Air Injection System Air Flow /Pressure Sensor Circuit Low
P2433 Secondary Air Injection System Air Flow /Pressure Sensor Circuit High
P2444 Secondary Air Injection System Pump Stuck ON
DTC Item Condition
(A) Rigid racks
(B) Free rollers
EN-00041
(A)
(B)
EN(H4DOTC)(diag)-48
Inspection Mode
1) After clearing the memory, check for any remaining
unresolved trouble data. <Ref. to EN(H4DOTC)(diag)-
Monitor).
NOTE:
drivers side).
CAUTION:
Monitor.
lect the {D Check}.
ton.
NOTE:
For details concerning DTC, refer to List of Di-
agnostic Trouble Code (DTC).
<Ref. to EN(H4DOTC)(diag)-83, List of Diagnos-
this does not indicate a malfunction. When en-
gine control diagnosis is finished, perform the
ABS memory clearance procedure of the self-di-
agnosis system. <Ref. to ABS(diag)-24, Clear
Memory Mode.>
EN-05692
PI-00201
(A)
EN-02533
EN(H4DOTC)(diag)-49
Inspection Mode
1) After clearing the memory, check for any remaining
unresolved trouble data. <Ref. to EN(H4DOTC)(diag)-
CAUTION:
NOTE:
Make sure the select lever is placed in the P po-
sition before starting. (AT model)
Depress the clutch pedal when starting engine.
(MT model)
6) Using the select lever or shift lever, turn the P
position switch and N position switch on.
ON. (AT model)
9) Place the select lever or shift lever in D position
(AT model) or 1st gear (MT model) and drive the
vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
clearance procedure of self-diagnosis system.
10) Using the general scan tool, check DTC and
NOTE:
<Ref. to EN(H4DOTC)(diag)-83, List of Diagnostic
PI-00201
(A)
EN-02533
EN(H4DOTC)(diag)-50
Drive Cycle
12.Drive Cycle
A: PROCEDURE
For the troubleshooting, there are driving patterns
described below. Driving in the specified pattern al-
lows 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.
10.6 US gal, 4.4 8.8 Imp gal)].
ble data. <Ref. to EN(H4DOTC)(diag)-56, Clear
Memory Mode.>
NOTE:
Perform the diagnosis after warming up the en-
gine except when the engine coolant temperature
at starting is specified.
Perform the diagnosis twice if the DTC marked
with *. After completing the first diagnosis, stop the
engine and perform second diagnosis in same con-
dition.
EN(H4DOTC)(diag)-51
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
start is less than 20C (68F).
*P0128
Coolant Thermostat (Engine Coolant Temperature Below Thermostat
or C as well.
or C as well.
or C as well.
or C as well.
or C as well.
or C as well.
*P0441 Evaporative Emission System Incorrect Purge Flow
*P0457
Evaporative Emission Control System Leak Detected (Fuel Cap Loose/
Off)
P0459 Evaporative Emission System Purge Control Valve Circuit High
or C as well.
or C as well.
or C as well.
EN(H4DOTC)(diag)-52
Drive Cycle
NOTE:
Drive the vehicle at 10 km/h (6 MPH) or faster before diagnosis.
DTC Item Condition
more.
(D) Decelerate with fully closed throt-
tle to 64 km/h (40 MPH).
(G) Stop the vehicle with throttle fully
closed.
(B) Accelerate to 97 km/h (60 MPH)
within 20 seconds.
(E) Drive the vehicle at 64 km/h
(40 MPH) for 20 seconds.
(I) Sec.
(C) Drive the vehicle at 97 km/h (60
(F) Accelerate to 97 km/h (60 MPH)
within 10 seconds.
EN-00842
(C)
(H)
(I)
(60) 97
64 (40)
(B)
(A)
(F) (D)
(E)
150 100 50
0
(G)
EN(H4DOTC)(diag)-53
Drive Cycle
5. DRIVE CYCLE D
DRIFT DIAGNOSIS
more.
STUCK DIAGNOSIS
2) Perform the Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-56, 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:
tery terminals.)
DTC Item Condition
P0068 MAP/MAF - Throttle Position Correlation
*P0244 Turbo/Super Charger Wastegate Solenoid A Range/Performance
P0246 Turbo/Super Charger Wastegate Solenoid A High
P2004 Intake Manifold Runner Control Stuck Open (Bank 1)
P2005 Intake Manifold Runner Control Stuck Open (Bank 2)
DTC Item Condition
EN(H4DOTC)(diag)-54
Drive Cycle
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:
tery terminals.)
7. DRIVE CYCLE F
2) Start the engine, and warm it up until engine coolant temperature increases over 95C (203F).
NOTE:
terminals.)
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).
3) Start the engine and warm-up engine until coolant temperature is 40C (104F) or less.
NOTE:
Do not let engine coolant temperature drop below 5C (41F).
4) Start the engine and warm-up engine until coolant temperature is 80C (176F).
5) Start the engine and warm-up engine until coolant temperature is 40C (104F) or less.
NOTE:
Do not let engine coolant temperature drop below 5C (41F).
DTC Item Condition
DTC Item Condition
DTC Item Condition
*
P0410 Secondary Air Injection System
*
P0411 Secondary Air Injection System Incorrect Flow Detected
P0414 Secondary Air Injection System Switching Valve A Circuit Shorted
P0417 Secondary Air Injection System Switching Valve B Circuit Shorted
P1418 Secondary Air Injection System Control A Circuit
*
P2440 Secondary Air Injection System Switching Valve Stuck Open (Bank 1)
*
P2441 Secondary Air Injection System Switching Valve Stuck Closed (Bank 1)
*
P2442 Secondary Air Injection System Switching Valve Stuck Open (Bank 2)
*
P2443 Secondary Air Injection System Switching Valve Stuck Closed (Bank 2)
EN(H4DOTC)(diag)-55
Drive Cycle
9. DRIVE CYCLE H
ature. <Ref. to EN(H4DOTC)(diag)-36, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPER-
ATION, Subaru Select Monitor.>
Condition:
NOTE:
DTC Item Condition
*
EN(H4DOTC)(diag)-56
Clear Memory Mode
A: OPERATION
MODE)
6) When Done and Turn ignition switch to OFF
is shown on the display screen, turn the ignition
switch to OFF.
NOTE:
performed after memory clearance. For this rea-
son, start the engine after 10 seconds or more have
MODE)
6) When the Clear Diagnostic Code? is shown on
the screen, click the [Yes] button.
switch to OFF.
NOTE:
For procedures clearing memory using the general
scan tool, refer to the general scan tool operation
manual.
NOTE:
EN(H4DOTC)(diag)-57
Check Mode
A: OPERATION
EN(H4DOTC)(diag)-7, PREPARATION TOOL, Gen-
eral Description.>
Monitor).
NOTE:
drivers side).
CAUTION:
Monitor.
13) On the System Operation Check Mode dis-
play screen, select the {Actuator ON/OFF Opera-
tion}.
14) Select the desired compulsory actuator on the
Actuator ON/OFF Operation display screen and
click the [Next] button.
EN-05692
PI-00201
(A)
EN-02533
EN(H4DOTC)(diag)-58
play will then return to the Actuator ON/OFF Op-
eration screen.
table.
NOTE:
functional.
Description Display
Compulsory fuel pump relay operation
check
Fuel Pump
Compulsory purge control solenoid
valve operation check
CPC Solenoid
Compulsory purge control solenoid
valve 2 operation check
CPC Solenoid 2
Compulsory radiator fan relay operation
check
Radiator Fan
Relay
operation check
A/C Compressor
Relay
Compulsory wastegate control
Wastegate con-
trol Solenoid
Compulsory pressure control solenoid
valve operation check
PCV solenoid
Compulsory drain valve operation
check
Vent Control
Solenoid
Compulsory secondary air combination
Secondary Air
Combination
Valve 1
Compulsory secondary air combination
Secondary Air
Combination
Valve 2
Compulsory secondary air pump relay
operation check
Secondary air
pump relay
Display
EGR Solenoid
ASV Solenoid
FICD Solenoid
Pressure Switching Sol.1
AAI Solenoid
EXH. Bypass Control Permit Flag
EN(H4DOTC)(diag)-59
Mode
A: OPERATION
Monitor).
NOTE:
drivers side).
CAUTION:
Monitor.
EN-05692
Display
Security System
Fuel Pump Control
Idle Speed Control
Injector Control
EN-02533
EN(H4DOTC)(diag)-60
1. FUEL PUMP CONTROL (OFF DRIVE)
CAUTION:
After executing the operation check mode, exe-
cute the Clear Memory Mode <Ref. to
EN(H4DOTC)(diag)-56, OPERATION, Clear
Memory Mode.>.
play, select the {Fuel Pump Control}.
screen.
NOTE:
2. FUEL PUMP CONTROL (ON/OFF DRIVE)
CAUTION:
Memory Mode.>.
play, select the {Fuel Pump Control}.
Control screen.
NOTE:
CAUTION:
Memory Mode.>.
play screen, select the {Fixed Idle Ignition Timing }.
NOTE:
CAUTION:
Memory Mode.>.
play screen, select the {Idle Speed Control}.
2,000 rpm, in increments of 50 rpm. However, the
vary depending on the vehicle.
NOTE:
STOP MODE)
CAUTION:
Memory Mode.>.
play, select the {Injector Control}.
trol screen.
NOTE:
EN(H4DOTC)(diag)-61
QUANTITY CONTROL)
CAUTION:
Memory Mode.>.
play, select the {Injector Control}.
increments of 1%.
NOTE:
EN(H4DOTC)(diag)-62
A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4DOTC)(diag)-63, ACTIVATION OF MALFUNCTION INDICATOR LIGHT,
2. Malfunction indicator light does not come on. <Ref. to EN(H4DOTC)(diag)-64, MALFUNCTION INDICATOR LIGHT DOES NOT
3. Malfunction indicator light does not go off. <Ref. to EN(H4DOTC)(diag)-66, MALFUNCTION INDICATOR LIGHT DOES NOT
GO OFF, Malfunction Indicator Light.>
4. Malfunction indicator light does not blink. <Ref. to EN(H4DOTC)(diag)-67, MALFUNCTION INDICATOR LIGHT DOES NOT
5. Malfunction indicator light keep blinking. <Ref. to EN(H4DOTC)(diag)-69, MALFUNCTION INDICATOR LIGHT REMAINS
EN(H4DOTC)(diag)-63
INDICATOR LIGHT
NOTE:
If the malfunction indicator light does not illuminate,
perform diagnostics of the CHECK ENGINE light
circuit or the combination meter circuit. <Ref. to
EN(H4DOTC)(diag)-64, MALFUNCTION INDICA-
TOR LIGHT DOES NOT COME ON, Malfunction
Indicator Light.>
luminates.
sis)
(1) No DTC
(2) Trouble occurs
(3) ON
(4) OFF
(6) Engine start
EN-05079
(A)
EN-01679
(1)
(2)
(5)
(6)
(3)
(4)
(3)
(4)
(1) ON
(2) OFF
(4) 1 second
EN-01681
(2)
(1)
(4)
(3)
EN(H4DOTC)(diag)-64
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
EN-05122
SBF-6 MAIN SBF No.5
B72
B38
B136
ECM
i3
E
3
1
1
i10
3
16
8
B72 i10
B38
COMBINATION
METER
IGNITION SWITCH
BATTERY
B136
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
1 3
4 5 6
2 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
EN(H4DOTC)(diag)-65
Step Check Yes No
chassis ground.
light illuminate?
Repair poor con-
tact of the ECM
connector.
Go to step 3.
connected?
Replace the ECM.
<Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
Repair the connec-
tion of ECM con-
nector.
and combination meter.
ECM and combination meter connector.
(B136) No. 11 (i10) No. 16:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and combi-
nation meter con-
nector
Poor contact of
coupling connector
nector.
Repair the poor
contact of combi-
nation meter con-
nector.
Go to step 6.
NECTOR.
bination meter cir-
IDI-19, Combina-
tion Meter.>
Check the follow-
ing item and repair
if necessary.
NOTE:
Blown out of fuse
(No. 5)
Open or short
circuit in harness
between fuse (No.
5) and battery ter-
minal
Poor contact of
nector
EN(H4DOTC)(diag)-66
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
Step Check Yes No
TION METER AND ECM.
light illuminate?
Repair the short
circuit of harness
between combina-
tion meter and
ECM connector.
Replace the ECM.
<Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
EN-05122
SBF-6 MAIN SBF No.5
B72
B38
B136
ECM
i3
E
3
1
1
i10
3
16
8
B72 i10
B38
COMBINATION
METER
IGNITION SWITCH
BATTERY
B136
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
1 3
4 5 6
2 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
EN(H4DOTC)(diag)-67
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
EN-05664
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
SBF-6 MAIN SBF No.5
B72
B38
B135 B136 ECM
i3
E
1 1
C
1
1
B
2
7
i10
B: C:
B72 B75
i10
B136
1
2
1
2
1
2
1
2
C: B135
B38
B:
3
16
8
*
*
C
6
B122
1 3
4 5 6
2
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5 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
B122
B76 B75
B76
*
3 1
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
COMBINATION
METER
IGNITION
SWITCH
BATTERY
ARRANGEMENT
DELIVERY (TEST) MODE CONNECTOR
EN(H4DOTC)(diag)-68
Step Check Yes No
CATOR LIGHT.
tor.
light illuminate?
Go to step 2. Repair the mal-
function indicator
light circuit. <Ref.
to
EN(H4DOTC)(diag
)-64, MALFUNC-
TION INDICATOR
LIGHT DOES NOT
COME ON, Mal-
function Indicator
Light.>
COMBINATION METER CONNECTOR.
light illuminate?
Repair the ground
ness between
ECM and combi-
nation meter con-
nector.
Go to step 3.
ECM and delivery (test) mode connector.
(B76) No. 1 (B136) No. 6:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and delivery
(test) mode con-
nector
Poor contact of
joint connector
connector?
Repair poor con-
tact of the ECM
connector.
Go to step 5.
ECM terminals.
(B135) No. 27 (B136) No. 6:
circuit of harness
between ECM and
delivery (test)
mode connector.
connector?
Repair poor con-
tact of the ECM
connector.
Replace the ECM.
<Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
EN(H4DOTC)(diag)-69
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
EN-05664
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
SBF-6 MAIN SBF No.5
B72
B38
B135 B136 ECM
i3
E
1 1
C
1
1
B
2
7
i10
B: C:
B72 B75
i10
B136
1
2
1
2
1
2
1
2
C: B135
B38
B:
3
16
8
*
*
C
6
B122
1 3
4 5 6
2
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5 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
B122
B76 B75
B76
*
3 1
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
COMBINATION
METER
IGNITION
SWITCH
BATTERY
ARRANGEMENT
EN(H4DOTC)(diag)-70
Step Check Yes No
TOR.
tor.
light blink?
NOTE:
Malfunction indica-
tor light blinks
when delivery
(test) mode con-
nector is connect-
ed.
CHASSIS GROUND TERMINAL.
circuit of harness
between ECM and
delivery (test)
mode connector.
Replace the ECM.
<Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
EN(H4DOTC)(diag)-71
A: PROCEDURE
1. Check for fuel amount.
2. Inspection of starter motor circuit. <Ref. to EN(H4DOTC)(diag)-72, STARTER MOTOR CIRCUIT, Diagnostics for Engine Start-
ing Failure.>
3. Inspection of ECM power supply and ground line. <Ref. to EN(H4DOTC)(diag)-76, 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)-78, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
5. Inspection of fuel pump circuit. <Ref. to EN(H4DOTC)(diag)-80, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Fail-
ure.>
6. Inspection of fuel injector circuit. <Ref. to EN(H4DOTC)(diag)-81, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
EN(H4DOTC)(diag)-72
CAUTION:
EN(H4DOTC)(diag)-56, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to
EN(H4DOTC)(diag)-45, PROCEDURE, Inspection Mode.>.
WIRING DIAGRAM:
Step Check Yes No
1 CHECK BATTERY.
the battery.
2 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper-
ate?
3
1
3
2
2
0
N
o
.
2
1
B225
MAIN SBF SBF-6
E
1
5
1
3
1
6
1
4
B136
B72
B14
M
2
3
B72
1 3
4 5 6
2
A
T
A
T
2
1
B106
B106
1
2
B226
9
7
1
0
1
1
B136
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
MT
MT
EN-05665
1
1
B55
B225
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
B226
2
3
1 7 8 9
4
6
5 11
10
B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
IGNITION
SWITCH
BATTERY
STARTER MOTOR
STARTER
RELAY
CLUTCH
SWITCH
INHIBITOR
RELAY
TCM
ECM
EN(H4DOTC)(diag)-73
EN(H4DOTC)(diag)-44,
OPERATION, Read Diagnostic
Check the appro-
priate DTC using
tic Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
The circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
TOR.
motor.
3) On AT models, set the select lever to the P
or N range, and on MT models, depress the
clutch pedal.
5) Measure the voltage between the starter
motor connector and the engine ground.
motor. <Ref. to
SC(H4SO)-6,
Starter.>
Go to step 5.
TOR.
1) On AT models, set the select lever to the P
or N range, and on MT models, depress the
clutch pedal.
3) Measure the voltage between starter relay
Is the voltage 10 V or more? Repair the open
circuit of the har-
ness between
starter relay con-
nector and starter
motor.
Go to step 6.
switch.
3) Measure the voltage between ignition
switch connector and chassis ground.
Is the voltage 10 V or more? Go to step 7. Check the follow-
ing item and repair
if necessary.
Blown out of fuse
Open or ground
ness between igni-
tion switch
connector and bat-
tery
Measure the resistance between ignition switch
terminals after turning the ignition switch to
START position.
Terminals
No. 2 No. 3:
tion switch. <Ref.
to SL-48,
REPLACEMENT,
Ignition Key Lock.>
Step Check Yes No
EN(H4DOTC)(diag)-74
LAY.
1) Remove the starter relay.
Is the voltage 10 V or more? Go to step 9. Repair open circuit
of harness
between starter
relay connector
and ignition switch
connector.
relay terminals.
Terminals
No. 13 No. 14:
relay.
STARTER RELAY CONNECTOR.
ECM and starter relay connector.
(B136) No. 20 (B225) No. 16:
circuit of harness
between ECM and
starter relay con-
nector.
11 CHECK TRANSMISSION TYPE. Is the transmission type AT? Go to step 16. Go to step 12.
LAY.
1) Depress the clutch pedal.
CLUTCH SWITCH CONNECTOR.
2) Disconnect the clutch switch connector.
ECM and clutch switch connector.
(B136) No. 32 (B106) No. 2:
Is the resistance less than 1 ? Check the ECM
power supply and
ground line. <Ref.
to
EN(H4DOTC)(diag
)-76, CHECK
POWER SUPPLY
AND GROUND
LINE OF ENGINE
CONTROL MOD-
ULE (ECM), Diag-
nostics for Engine
Starting Failure.>
Repair the open
circuit of harness
between ECM and
clutch switch con-
nector.
14 CHECK INPUT VOLTAGE OF CLUTCH
SWITCH.
2) Disconnect the clutch switch connector.
4) Measure the voltage between the clutch
ing item and repair
if necessary.
Blown out of fuse
Open or ground
ness between igni-
tion switch
connector and
clutch switch con-
nector
Step Check Yes No
EN(H4DOTC)(diag)-75
15 CHECK CLUTCH SWITCH.
Measure the resistance between clutch switch
terminals while depressing the clutch pedal.
Terminals
No. 1 No. 2:
Is the resistance less than 1 ? Repair the open
circuit of harness
between clutch
switch connector
and starter relay
connector.
Replace the clutch
switch. <Ref. to
CL-35, Clutch
Switch.>
LAY.
1) Place the select lever in the P or N range.
HIBITOR RELAY CONNECTOR.
2) Disconnect the inhibitor relay connector.
ECM and inhibitor relay connector.
(B136) No. 31 (B226) No. 7:
(B136) No. 32 (B226) No. 10:
power supply and
ground line. <Ref.
to
EN(H4DOTC)(diag
)-76, CHECK
POWER SUPPLY
AND GROUND
LINE OF ENGINE
CONTROL MOD-
ULE (ECM), Diag-
nostics for Engine
Starting Failure.>
Repair the open
circuit of harness
between ECM and
inhibitor relay con-
nector.
18 CHECK INPUT VOLTAGE OF INHIBITOR RE-
LAY.
4) Measure the voltage between inhibitor relay
ing item and repair
if necessary.
Blown out of fuse
Open or ground
ness between igni-
tion switch
connector and
nector
19 CHECK INHIBITOR RELAY.
1) Connect the battery to inhibitor relay termi-
relay terminals.
Terminals
No. 10 No. 11:
Is the resistance less than 1 ? Go to step 20. Replace the inhibi-
tor relay.
RELAY CONNECTOR AND STARTER RE-
LAY CONNECTOR.
inhibitor relay connector and starter relay con-
nector.
(B226) No. 10 (B225) No. 15:
circuit of harness
between TCM and
nector.
Repair the open
circuit of harness
between inhibitor
relay connector
and starter relay
connector.
Step Check Yes No
EN(H4DOTC)(diag)-76
MODULE (ECM)
CAUTION:
WIRING DIAGRAM:
EN-05666
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
SBF-6 MAIN SBF
SBF-7
B72
A
7
B
2
C
2
3
D
2
A
5
D
3
B
5
B
1
9
No.12 B47
E2
B21
1
2
4
6
5
3
E
E
B134
B135
A:
C: B136
D: B137
B:
3
5
3
4
4
0
3 4
1 2
5 6
B47
No.13
D
7
3
6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B72
1 3
4 5 6
2
A: B:
D:
SBF-5
D
1
3
7
3 1
MAIN RELAY
TO OXYGEN SENSOR
IGNITION
SWITCH BATTERY
ECM
EN(H4DOTC)(diag)-77
Step Check Yes No
1 CHECK MAIN RELAY.
No. 1 and No. 2.
terminals.
Terminals
No. 3 No. 5:
No. 4 No. 6:
?
relay. <Ref. to
EN(H4DOTC)(diag
)-8, Electrical
Component Loca-
tion.>
circuit of harness
between the ECM
and engine ground
terminal.
ground.
of power supply
circuit.
chassis ground.
of power supply
circuit.
of harness of
power supply cir-
cuit.
1) Connect the main relay connector.
chassis ground.
trol system. <Ref.
to
EN(H4DOTC)(diag
)-78, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Starting
Failure.>
Repair the open or
of harness
between ECM and
main relay connec-
tor.
EN(H4DOTC)(diag)-78
CAUTION:
WIRING DIAGRAM:
Step Check Yes No
1 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.>
Is the spark plug condition nor-
mal?
Go to step 2. Replace the spark
plug. <Ref. to
IG(H4DOTC)-4,
Spark Plug.>
EN-05667
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
SBF-6 MAIN SBF
B72
B137
1
8
1
9
2
0
2
1
No.12
E
6 3
2
6
E2
B21
E31
E31
E32
E33
E34
E32 E33 E34
6
1
2
3
B21
312 312
9
4
9
2
0
3
1
1
0
4
1
312312
B137 B72
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 3
4 5 6
2
No.1 No.3 No.4 No.2
IGNITION
SWITCH
ECM
IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL
EN(H4DOTC)(diag)-79
1) Connect the spark plug to ignition coil.
FU(H4DOTC)-50, RELEASING OF FUEL
engine.
4) While opening the throttle valve fully, crank
the engine to check that spark occurs at each
cylinder.
der?
Check fuel pump
system. <Ref. to
EN(H4DOTC)(diag
)-80, FUEL PUMP
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
Go to step 3.
NITION COIL.
ignition coil connector and engine ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ignition coil and ig-
nition switch con-
nector
Poor contact of
coupling connector
4 CHECK HARNESS OF IGNITION COIL
GROUND CIRCUIT.
ignition coil connector.
(E31) No. 2 (B137) No. 6:
(E32) No. 2 (B137) No. 6:
(E33) No. 2 (B137) No. 6:
(E34) No. 2 (B137) No. 6:
(E31) No. 2 (B137) No. 26:
(E32) No. 2 (B137) No. 26:
(E33) No. 2 (B137) No. 26:
(E34) No. 2 (B137) No. 26:
and connector.
NOTE:
the following item:
Open circuit of har-
ness between the
ECM and ignition
coil connector
NITION COIL CONNECTOR.
ignition coil.
the ECM and ignition coil connector.
(B137) No. 18 (E31) No. 1:
(B137) No. 19 (E32) No. 1:
(B137) No. 20 (E33) No. 1:
(B137) No. 21 (E34) No. 1:
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and igni-
tion coil connector
Poor contact of
coupling connector
NITION COIL CONNECTOR.
ECM and engine ground.
more?
ness between the
ECM and ignition
coil connector.
connector?
Repair poor con-
tact of the ECM
connector.
Replace the igni-
tion coil.
Step Check Yes No
EN(H4DOTC)(diag)-80
CAUTION:
WIRING DIAGRAM:
Step Check Yes No
PUMP.
NOTE:
ating sound?
Check the fuel
injector circuit.
<Ref. to
EN(H4DOTC)(diag
)-81, FUEL INJEC-
TOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
Display the DTC.
<Ref. to
EN(H4DOTC)(diag
)-44, OPERA-
TION, Read Diag-
nostic Trouble
Code (DTC).>
EN-05083
E
E
M
1
0
76
56
35
No.11
B362
R122
B135 B:
B136 C:
R58
B97
7
B
3
3
C
1
2
1 2
985
1
9
8
R1
2
0
R1
B97
R46
R67
FUEL PUMP
CONTROL UNIT
FUEL
PUMP
ECM
BATTERY
FUEL PUMP
RELAY
B135 B136 B362 R58
2
5
4
6
1
3
B: C:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
R122
3 4 1 2
5 8 9 10 6 7
5
6
7 8
3
4
1 2
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B97 R67
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
EN(H4DOTC)(diag)-81
CAUTION:
WIRING DIAGRAM:
EN-05668
E
#4
1 2
SBF-7
#3
1 2
#2
1 2
B21
#1
1 2
4
8
5
4
5
3
5
2
5
1
89
1
0
1
1
1 2
5
3
6
4
2
1
B21 B137
E5
E5
E2
E6
E6
E16
E16
E17
B47
E17
B47
3 4
1 2
5 6
B137
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
MAIN RELAY
ECM
BATTERY
FUEL INJECTOR
EN(H4DOTC)(diag)-82
Step Check Yes No
TOR.
this check.
Does the fuel injector emit
operating sound?
Check the fuel
pressure. <Ref. to
ME(H4DOTC)-24,
INSPECTION,
Fuel Pressure.>
Go to step 2.
JECTOR.
and connector.
NOTE:
the following item:
Open circuit of
harness between
main relay and fuel
injector connector
Poor contact of
main relay connec-
tor
Poor contact of
coupling connector
Poor contact of
fuel injector con-
nector
(B137) No. 8 (E5) No. 1:
(B137) No. 9 (E16) No. 1:
(B137) No. 10 (E6) No. 1:
(B137) No. 11 (E17) No. 1:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel in-
jector connector
Poor contact of
coupling connector
more?
ness between
ECM and fuel
injector connector.
injector terminals.
Terminals
No. 1 No. 2:
20 ?
fuel injector.
connector?
Repair poor con-
tact of the ECM
connector.
Inspection using
General Diagnos-
tic Table <Ref. to
EN(H4DOTC)(diag
)-372, INSPEC-
TION, General
Diagnostic Table.>
EN(H4DOTC)(diag)-83
A: LIST
DTC Item Reference
P0011 Intake Camshaft Position - Timing
Over-Advanced Or System Perfor-
mance (Bank 1)
<Ref. to EN(H4DOTC)(diag)-91, DTC P0011 INTAKE CAMSHAFT POSI-
TION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE
(BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0016 Crankshaft Position - Camshaft Posi-
tion Correlation (Bank 1)
<Ref. to EN(H4DOTC)(diag)-92, DTC P0016 CRANKSHAFT POSITION -
CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Procedure
tion Correlation (Bank 2)
<Ref. to EN(H4DOTC)(diag)-93, DTC P0018 CRANKSHAFT POSITION -
CAMSHAFT POSITION CORRELATION (BANK2), Diagnostic Procedure
Over-Advanced or System Perfor-
mance (Bank 2)
TION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE
P0030 HO2S Heater Control Circuit (Bank 1
Sensor 1)
<Ref. to EN(H4DOTC)(diag)-95, DTC P0030 HO2S HEATER CONTROL
CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
(Bank 1 Sensor 1)
CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnos-
(Bank 1 Sensor 1)
CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diag-
(Bank 1 Sensor 2)
CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnos-
(Bank 1 Sensor 2)
CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Procedure with Diag-
P0068 MAP/MAF - Throttle Position Corre-
lation
<Ref. to EN(H4DOTC)(diag)-105, DTC P0068 MAP/MAF - THROTTLE
POSITION CORRELATION, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Range/Performance
<Ref. to EN(H4DOTC)(diag)-107, DTC P0101 MASS OR VOLUME AIR
FLOW CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with
Input
FLOW CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
Input
FLOW CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0107 Manifold Absolute Pressure/Baro-
metric Pressure Circuit Low Input
<Ref. to EN(H4DOTC)(diag)-113, DTC P0107 MANIFOLD ABSOLUTE
PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnos-
metric Pressure Circuit High Input
<Ref. to EN(H4DOTC)(diag)-115, DTC P0108 MANIFOLD ABSOLUTE
PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diag-
<Ref. to EN(H4DOTC)(diag)-117, DTC P0111 INTAKE AIR TEMPERA-
TURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Proce-
cuit Low
TURE SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with Diagnostic
EN(H4DOTC)(diag)-84
cuit High
TURE SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic
Low
<Ref. to EN(H4DOTC)(diag)-123, DTC P0117 ENGINE COOLANT TEM-
PERATURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
High
<Ref. to EN(H4DOTC)(diag)-125, DTC P0118 ENGINE COOLANT TEM-
PERATURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-127, DTC P0122 THROTTLE/PEDAL POSI-
TION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Procedure with
TION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-131, DTC P0125 INSUFFICIENT COOLANT
TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-132, DTC P0126 INSUFFICIENT ENGINE
COOLANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Pro-
<Ref. to EN(H4DOTC)(diag)-133, DTC P0128 COOLANT THERMOSTAT
(ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGU-
LATING TEMPERATURE), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
(Bank 1 Sensor 1)
<Ref. to EN(H4DOTC)(diag)-134, DTC P0131 O2 SENSOR CIRCUIT
LOW VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diag-
(Bank 1 Sensor 1)
HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diag-
(Bank 1 Sensor 1)
SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-140, DTC P0134 O2 SENSOR CIRCUIT NO
ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Procedure with
(Bank 1 Sensor 2)
LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diag-
(Bank 1 Sensor 2)
HIGH VOLTAGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diag-
(Bank 1 Sensor 2)
SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-148, DTC P0140 O2 SENSOR CIRCUIT NO
P0171 System Too Lean (Bank 1) <Ref. to EN(H4DOTC)(diag)-150, DTC P0171 SYSTEM TOO LEAN
P0172 System Too Rich (Bank 1) <Ref. to EN(H4DOTC)(diag)-151, DTC P0172 SYSTEM TOO RICH
Range/Performance
<Ref. to EN(H4DOTC)(diag)-154, DTC P0181 FUEL TEMPERATURE
SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure
DTC Item Reference
EN(H4DOTC)(diag)-85
Low Input
SENSOR A CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic
High Input
SENSOR A CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnos-
TION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Procedure with
TION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Procedure with
P0230 Fuel Pump Primary Circuit <Ref. to EN(H4DOTC)(diag)-164, DTC P0230 FUEL PUMP PRIMARY
CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0244 Turbo/Super Charger Wastegate
Solenoid A Range/Performance
<Ref. to EN(H4DOTC)(diag)-167, DTC P0244 TURBO/SUPER
CHARGER WASTEGATE SOLENOID A RANGE/PERFORMANCE,
Solenoid A Low
CHARGER WASTEGATE SOLENOID A LOW, Diagnostic Procedure
Solenoid A High
CHARGER WASTEGATE SOLENOID A HIGH, Diagnostic Procedure
P0301 Cylinder 1 Misfire Detected <Ref. to EN(H4DOTC)(diag)-172, DTC P0301 CYLINDER 1 MISFIRE
P0327 Knock Sensor 1 Circuit Low (Bank 1
or Single Sensor)
<Ref. to EN(H4DOTC)(diag)-179, DTC P0327 KNOCK SENSOR 1 CIR-
CUIT LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with
P0328 Knock Sensor 1 Circuit High (Bank 1
or Single Sensor)
<Ref. to EN(H4DOTC)(diag)-181, DTC P0328 KNOCK SENSOR 1 CIR-
CUIT HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with
P0335 Crankshaft Position Sensor A Cir-
cuit
<Ref. to EN(H4DOTC)(diag)-183, DTC P0335 CRANKSHAFT POSITION
SENSOR A CIRCUIT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-185, DTC P0336 CRANKSHAFT POSITION
SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-187, DTC P0340 CAMSHAFT POSITION
SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Pro-
(Bank 2)
<Ref. to EN(H4DOTC)(diag)-189, DTC P0345 CAMSHAFT POSITION
SENSOR A CIRCUIT (BANK 2), Diagnostic Procedure with Diagnostic
P0410 Secondary Air Injection System <Ref. to EN(H4DOTC)(diag)-191, DTC P0410 SECONDARY AIR INJEC-
TION SYSTEM, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Incorrect Flow Detected
<Ref. to EN(H4DOTC)(diag)-195, DTC P0411 SECONDARY AIR INJEC-
TION SYSTEM INCORRECT FLOW DETECTED, Diagnostic Procedure
DTC Item Reference
EN(H4DOTC)(diag)-86
Switching Valve A Circuit Open
TION SYSTEM SWITCHING VALVE A CIRCUIT OPEN, Diagnostic Pro-
Switching Valve A Circuit Shorted
TION SYSTEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic
Switching Valve B Circuit Open
TION SYSTEM SWITCHING VALVE "B" CIRCUIT OPEN, Diagnostic Pro-
Switching Valve B Circuit Shorted
TION SYSTEM SWITCHING VALVE "B" CIRCUIT SHORTED, Diagnostic
P0418 Secondary Air Injection System Con-
trol A Circuit
TION SYSTEM CONTROL A CIRCUIT, Diagnostic Procedure with Diag-
Threshold (Bank 1)
<Ref. to EN(H4DOTC)(diag)-213, DTC P0420 CATALYST SYSTEM EFFI-
CIENCY BELOW THRESHOLD (BANK 1), Diagnostic Procedure with
P0441 Evaporative Emission System Incor-
rect Purge Flow
<Ref. to EN(H4DOTC)(diag)-217, DTC P0441 EVAPORATIVE EMISSION
SYSTEM INCORRECT PURGE FLOW, Diagnostic Procedure with Diag-
CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Pro-
CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Pro-
CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic
tem Pressure Sensor
CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Procedure with
CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Pro-
CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Pro-
tem Leak Detected (Very Small
Leak)
CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic
Off)
CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diag-
SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Proce-
SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Proce-
Performance
<Ref. to EN(H4DOTC)(diag)-240, DTC P0461 FUEL LEVEL SENSOR A
CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnos-
P0462 Fuel Level Sensor A Circuit Low <Ref. to EN(H4DOTC)(diag)-240, DTC P0462 FUEL LEVEL SENSOR A
CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
DTC Item Reference
EN(H4DOTC)(diag)-87
P0463 Fuel Level Sensor A Circuit High <Ref. to EN(H4DOTC)(diag)-241, DTC P0463 FUEL LEVEL SENSOR A
CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0464 Fuel Level Sensor Circuit Intermit-
tent
<Ref. to EN(H4DOTC)(diag)-241, DTC P0464 FUEL LEVEL SENSOR
CIRCUIT INTERMITTENT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0500 Vehicle Speed Sensor A <Ref. to EN(H4DOTC)(diag)-242, DTC P0500 VEHICLE SPEED SENSOR
A, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Than Expected
<Ref. to EN(H4DOTC)(diag)-243, DTC P0506 IDLE AIR CONTROL SYS-
TEM RPM LOWER THAN EXPECTED, Diagnostic Procedure with Diag-
Than Expected
<Ref. to EN(H4DOTC)(diag)-245, DTC P0507 IDLE AIR CONTROL SYS-
TEM RPM HIGHER THAN EXPECTED, Diagnostic Procedure with Diag-
P0512 Starter Request Circuit <Ref. to EN(H4DOTC)(diag)-247, DTC P0512 STARTER REQUEST CIR-
CUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0513 Incorrect Immobilizer Key <Ref. to IM(diag)-16, DTC P0513 INCORRECT IMMOBILIZER KEY, Diag-
P0600 Serial Communication Link <Ref. to EN(H4DOTC)(diag)-248, DTC P0600 SERIAL COMMUNICATION
LINK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-249, DTC P0604 INTERNAL CONTROL
MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Pro-
Memory (ROM) Error
<Ref. to EN(H4DOTC)(diag)-250, DTC P0605 INTERNAL CONTROL
MODULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure
P0607 Control Module Performance <Ref. to EN(H4DOTC)(diag)-251, DTC P0607 CONTROL MODULE PER-
FORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0638 Throttle Actuator Control Range/Per-
formance (Bank 1)
<Ref. to EN(H4DOTC)(diag)-252, DTC P0638 THROTTLE ACTUATOR
CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure
Request)
<Ref. to EN(H4DOTC)(diag)-252, DTC P0700 TRANSMISSION CON-
TROL SYSTEM (MIL REQUEST), Diagnostic Procedure with Diagnostic
P0851 Park/Neutral Switch Input Circuit
Low (AT Model)
<Ref. to 5AT(diag)-2, Basic Diagnostic Procedure.>
P0851 Neutral Switch Input Circuit Low (MT
Model)
<Ref. to EN(H4DOTC)(diag)-253, DTC P0851 NEUTRAL SWITCH INPUT
CIRCUIT LOW (MT MODEL), Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
High (AT Model)
<Ref. to 5AT(diag)-2, Basic Diagnostic Procedure.>
P0852 Neutral Switch Input Circuit High (MT
Model)
<Ref. to EN(H4DOTC)(diag)-255, DTC P0852 NEUTRAL SWITCH INPUT
CIRCUIT HIGH (MT MODEL), Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
mance (Low) (Bank1 Sensor1)
RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Proce-
mance (High) (Bank1 Sensor1)
RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Proce-
P1160 Return Spring Failure <Ref. to EN(H4DOTC)(diag)-260, DTC P1160 RETURN SPRING FAIL-
URE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Valve Circuit Low
<Ref. to EN(H4DOTC)(diag)-261, DTC P1400 FUEL TANK PRESSURE
CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Procedure with
DTC Item Reference
EN(H4DOTC)(diag)-88
Switching Valve Stuck Open
TION SYSTEM SWITCHING VALVE STUCK OPEN, Diagnostic Procedure
P1418 Secondary Air Injection System Con-
trol A Circuit Shorted
TION SYSTEM CONTROL A CIRCUIT SHORTED, Diagnostic Proce-
P1420 Fuel Tank Pressure Control Sol.
Valve Circuit High
<Ref. to EN(H4DOTC)(diag)-269, DTC P1420 FUEL TANK PRESSURE
CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Procedure with Diag-
P1443 Vent Control Solenoid Valve Func-
tion Problem
<Ref. to EN(H4DOTC)(diag)-271, DTC P1443 VENT CONTROL SOLE-
NOID VALVE FUNCTION PROBLEM, Diagnostic Procedure with Diagnos-
<Ref. to EN(H4DOTC)(diag)-273, DTC P1491 POSITIVE CRANKCASE
VENTILATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Procedure
P1560 Back-up Voltage Circuit Malfunction <Ref. to EN(H4DOTC)(diag)-275, DTC P1560 BACK-UP VOLTAGE CIR-
CUIT MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1570 Antenna <Ref. to IM(diag)-17, DTC P1570 ANTENNA, Diagnostic Procedure with
P1571 Reference Code Incompatibility <Ref. to IM(diag)-19, DTC P1571 REFERENCE CODE INCOMPATIBIL-
ITY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Circuit)
(DTC).>
P1574 Key Communication Failure <Ref. to IM(diag)-22, DTC P1574 KEY COMMUNICATION FAILURE,
P1576 EGI Control Module EEPROM <Ref. to IM(diag)-23, DTC P1576 EGI CONTROL MODULE EEPROM,
P1577 IMM Control Module EEPROM <Ref. to IM(diag)-23, DTC P1577 IMM CONTROL MODULE EEPROM,
P1602 Control Module Programming Error <Ref. to EN(H4DOTC)(diag)-277, DTC P1602 CONTROL MODULE PRO-
GRAMMING ERROR, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P2004 Intake Manifold Runner Control
Stuck Open (Bank 1)
<Ref. to EN(H4DOTC)(diag)-287, DTC P2004 INTAKE MANIFOLD RUN-
NER CONTROL STUCK OPEN (BANK 1), Diagnostic Procedure with
Stuck Open (Bank 2)
NER CONTROL STUCK OPEN (BANK 2), Diagnostic Procedure with
Stuck Closed (Bank 1)
NER CONTROL STUCK CLOSED (BANK 1), Diagnostic Procedure with
NER CONTROL STUCK CLOSED (BANK 2), Diagnostic Procedure with
P2008 Intake Manifold Runner Control Cir-
cuit / Open (Bank 1)
NER CONTROL CIRCUIT / OPEN (BANK 1), Diagnostic Procedure with
cuit Low (Bank 1)
NER CONTROL CIRCUIT LOW (BANK 1), Diagnostic Procedure with
DTC Item Reference
EN(H4DOTC)(diag)-89
cuit / Open (Bank 2)
NER CONTROL CIRCUIT / OPEN (BANK 2), Diagnostic Procedure with
cuit Low (Bank 2)
NER CONTROL CIRCUIT LOW (BANK 2), Diagnostic Procedure with
P2016 Intake Manifold Runner Position
Sensor / Switch Circuit Low (Bank 1)
NER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1), Diagnostic
Sensor / Switch Circuit High (Bank 1)
NER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1), Diagnos-
Sensor / Switch Circuit Low (Bank 2)
NER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2), Diagnostic
Sensor / Switch Circuit High (Bank 2)
NER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2), Diagnos-
P2088 Intake Camshaft Position Actuator
Control Circuit Low (Bank 1)
TION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Proce-
Control Circuit High (Bank 1)
TION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Pro-
TION ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Proce-
TION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Pro-
Lean Bank 1
<Ref. to EN(H4DOTC)(diag)-312, DTC P2096 POST CATALYST FUEL
TRIM SYSTEM TOO LEAN BANK 1, Diagnostic Procedure with Diagnos-
Rich Bank 1
<Ref. to EN(H4DOTC)(diag)-313, DTC P2097 POST CATALYST FUEL
TRIM SYSTEM TOO RICH BANK 1, Diagnostic Procedure with Diagnostic
P2101 Throttle Actuator Control Motor Cir-
CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Pro-
cuit Low
CONTROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic
cuit High
CONTROL MOTOR CIRCUIT HIGH, Diagnostic Procedure with Diagnos-
TION SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Proce-
TION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Procedure
TION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Proce-
TION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Procedure
DTC Item Reference
EN(H4DOTC)(diag)-90
TION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Proce-
TION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic
TION SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic
P2419 Evaporative Emission System
Switching Valve Control Circuit Low
SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW, Diagnostic Pro-
Switching Valve Control Circuit High
SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH, Diagnostic
P2431 Secondary Air Injection System Air
Flow /Pressure Sensor Circuit
Range/Performance
TION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/
PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Flow /Pressure Sensor Circuit Low
TION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT LOW, Diag-
Flow /Pressure Sensor Circuit High
TION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT HIGH, Diag-
Switching Valve Stuck Open (Bank1)
TION SYSTEM SWITCHING VALVE STUCK OPEN (BANK 1), Diagnostic
Switching Valve Stuck Closed
(Bank1)
TION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK 1), Diag-
Switching Valve Stuck Open (Bank2)
TION SYSTEM SWITCHING VALVE STUCK OPEN (BANK2), Diagnostic
(Bank2)
TION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK2), Diagnos-
Pump Stuck On
TION SYSTEM PUMP STUCK ON, Diagnostic Procedure with Diagnostic
DTC Item Reference
EN(H4DOTC)(diag)-91
A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR
SYSTEM PERFORMANCE (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-10, DTC P0011 INTAKE CAMSHAFT POSITION -
TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) De-
tecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
CAUTION:
Step Check Yes No
1) Start the engine and let it idle.
2) Measure the AVCS system operating angle
scan tool.
NOTE:
to EN(H4DOTC)(diag)-35, Subaru Select Moni-
tor.>
General scan tool
Is the AVCS system operating
angle approx. 0?
Go to step 2. Check the follow-
ing item and repair
or replace if neces-
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
(clog or dirt of oil
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
1) Drive (accelerate or decelerate) the vehicle
at 80 km/h (50 MPH) or less.
NOTE:
Drive the vehicle so that duty output of the oil
flow control solenoid valve increases.
and oil flow control solenoid valve duty output
tool.
NOTE:
tor.>
General scan tool
When the oil flow control sole-
noid valve duty output exceeds
10%, is the AVCS system oper-
ating angle approx. 0?
Check the follow-
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
Perform the follow-
ing procedures,
and clean the oil
routing.
Replace the
engine oil and idle
the engine for 5
minutes, then
replace the oil filter
and engine oil.
<Ref. to
LU(H4DOTC)-9,
REPLACEMENT,
Engine Oil.> <Ref.
to LU(H4DOTC)-
23, Engine Oil Fil-
ter.>
EN(H4DOTC)(diag)-92
B: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION
CORRELATION (BANK1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-13, DTC P0016 CRANKSHAFT POSITION - CAM-
SHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
CAUTION:
Step Check Yes No
tool.
NOTE:
tor.>
General scan tool
angle approx. 0, and oil flow
control solenoid valve duty out-
put approx. 10%?
Perform the follow-
ing procedures,
and clean the oil
routing.
Replace the
engine oil and idle
the engine for 5
minutes, then
and engine oil.
<Ref. to
LU(H4DOTC)-9,
REPLACEMENT,
Engine Oil.> <Ref.
to LU(H4DOTC)-
23, Engine Oil Fil-
ter.>
Check the follow-
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
Timing belt
(matching of timing
mark)
EN(H4DOTC)(diag)-93
C: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION
CORRELATION (BANK2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-15, DTC P0018 CRANKSHAFT POSITION - CAM-
SHAFT POSITION CORRELATION (BANK2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
CAUTION:
Step Check Yes No
tool.
NOTE:
tor.>
General scan tool
put approx. 10%?
Perform the follow-
ing procedures,
and clean the oil
routing.
Replace the
engine oil and idle
the engine for 5
minutes, then
and engine oil.
<Ref. to
LU(H4DOTC)-9,
REPLACEMENT,
Engine Oil.> <Ref.
to LU(H4DOTC)-
23, Engine Oil Fil-
ter.>
Check the follow-
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
Timing belt
(matching of timing
mark)
EN(H4DOTC)(diag)-94
D: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-15, DTC P0021 INTAKE CAMSHAFT POSITION -
TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) De-
tecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
CAUTION:
Step Check Yes No
scan tool.
NOTE:
tor.>
General scan tool
angle approx. 0?
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
NOTE:
tool.
NOTE:
tor.>
General scan tool
Check the follow-
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
Perform the follow-
ing procedures,
and clean the oil
routing.
Replace the
engine oil and idle
the engine for 5
minutes, then
and engine oil.
<Ref. to
LU(H4DOTC)-9,
REPLACEMENT,
Engine Oil.> <Ref.
to LU(H4DOTC)-
23, Engine Oil Fil-
ter.>
EN(H4DOTC)(diag)-95
E: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-16, DTC P0030 HO2S HEATER CONTROL CIRCUIT
CAUTION:
WIRING DIAGRAM:
EN-05669
SBF-5
B47
B21
E2
B21
E2
1
2
4
6
3
5
E
E
C
2
C
3
B
8
B
9
B
1
B134
4
3 21
E79
3 4
1 2
3 4
1 2
5 6
B21
B47
E79
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
B138
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B:
D:
1 2 3 4
5 6 7 8
B138
4
2
2
6
4
3
1
5
MAIN RELAY
BATTERY
FRONT
OXYGEN (A/F)
SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
EN(H4DOTC)(diag)-96
Step Check Yes No
TOR.
(B136) No. 3 (E79) No. 2:
(B136) No. 2 (E79) No. 2:
circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
TOR.
(B135) No. 9 (E79) No. 1:
(B135) No. 8 (E79) No. 3:
circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
Terminals
No. 4 No. 2:
3 ?
Go to step 4. Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>
nector?
Repair the poor
contact of ECM or
front oxygen (A/F)
sensor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>
EN(H4DOTC)(diag)-97
CAUTION:
WIRING DIAGRAM:
EN-05669
SBF-5
B47
B21
E2
B21
E2
1
2
4
6
3
5
E
E
C
2
C
3
B
8
B
9
B
1
B134
4
3 21
E79
3 4
1 2
3 4
1 2
5 6
B21
B47
E79
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
B138
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B:
D:
1 2 3 4
5 6 7 8
B138
4
2
2
6
4
3
1
5
MAIN RELAY
BATTERY
FRONT
OXYGEN (A/F)
SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
EN(H4DOTC)(diag)-98
Step Check Yes No
GEN (A/F) SENSOR.
(A/F) sensor.
supply line.
NOTE:
the following item:
Open circuit of
harness between
main relay and
front oxygen (A/F)
sensor connector
Poor contact of
main relay connec-
tor
Poor contact in
coupling connector
Malfunction in
main relay
(B136) No. 3 (E79) No. 2:
(B136) No. 2 (E79) No. 2:
circuit of harness
between ECM and
front oxygen (A/F)
sensor.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
Terminals
No. 2 No. 1:
3 ?
Repair poor con-
tact of the ECM
connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>
EN(H4DOTC)(diag)-99
CAUTION:
WIRING DIAGRAM:
EN-05669
SBF-5
B47
B21
E2
B21
E2
1
2
4
6
3
5
E
E
C
2
C
3
B
8
B
9
B
1
B134
4
3 21
E79
3 4
1 2
3 4
1 2
5 6
B21
B47
E79
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
B138
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B:
D:
1 2 3 4
5 6 7 8
B138
4
2
2
6
4
3
1
5
MAIN RELAY
BATTERY
FRONT
OXYGEN (A/F)
SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
EN(H4DOTC)(diag)-100
Step Check Yes No
chassis ground.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
nector.
Go to step 2.
chassis ground.
contact of the ECM
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact of
coupling connector
H: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)
CAUTION:
WIRING DIAGRAM:
EN-05670
B83
1 2 3 4
5 6 7 8
B138
B47
1
2
4
6
3
5
E
*
* B138
B83
3 4
1 2
5 6
B135
B47
B19
B136
B:
C:
B137 D:
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B19
T5
2
2
T5
B19
3 14
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
T6
SBF-5
*
1
*
2
1
1
*
*
2
2
C
4
B
4
B
3
0
B
1
B134
T6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
1 2
3 4
3 14
MAIN RELAY
REAR
OXYGEN SENSOR
BATTERY
ECM
ARRANGEMENT
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
GEN SENSOR.
gen sensor.
(T6) No. 2 (+) Engine ground ():
supply line.
NOTE:
the following item:
Open circuit of
harness between
main relay and rear
oxygen sensor
Poor contact of
main relay connec-
tor
Poor contact in
coupling connector
Malfunction in
main relay
REAR OXYGEN SENSOR.
(B136) No. 4 (T6) No. 1:
circuit of the har-
ness between
ECM and rear oxy-
gen sensor.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
Terminals
No. 1 No. 2:
7 ?
Repair poor con-
tact of the ECM
connector.
Replace the rear
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Rear Oxygen Sen-
sor.>
I: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
CAUTION:
WIRING DIAGRAM:
EN-05670
B83
1 2 3 4
5 6 7 8
B138
B47
1
2
4
6
3
5
E
*
* B138
B83
3 4
1 2
5 6
B135
B47
B19
B136
B:
C:
B137 D:
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B19
T5
2
2
T5
B19
3 14
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
T6
SBF-5
*
1
*
2
1
1
*
*
2
2
C
4
B
4
B
3
0
B
1
B134
T6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
1 2
3 4
3 14
MAIN RELAY
REAR
OXYGEN SENSOR
BATTERY
ECM
ARRANGEMENT
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
REAR OXYGEN SENSOR.
chassis ground.
circuit to power in
the harness
between ECM and
rear oxygen sensor
connector.
Go to step 2.
chassis ground.
contact of the ECM
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact of
coupling connector
J: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-26, DTC P0068 MAP/MAF - THROTTLE POSITION
CAUTION:
WIRING DIAGRAM:
EN-05671
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
2
3
2
8
6
B21
E2
23 1
E21
E21
B21
B134
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
1 2 3
6
2
9
1
9
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
ECM
Step Check Yes No
intake system?
Repair the air
intake system.
Go to step 2.
SENSOR.
(167F).
general scan tool.
NOTE:
tor.>
General scan tool
106.6 kPa (550 800 mmHg,
46.7 kPa (150 350 mmHg,
idling?
fold absolute pres-
sure sensor. <Ref.
to FU(H4DOTC)-
31, Manifold Abso-
lute Pressure Sen-
sor.>
NOTE:
tor.>
General scan tool
closed?
trol. <Ref. to
FU(H4DOTC)-11,
Throttle Body.>
open?
Replace the mani-
fold absolute pres-
sure sensor. <Ref.
to FU(H4DOTC)-
31, Manifold Abso-
lute Pressure Sen-
sor.>
Replace the elec-
trol. <Ref. to
FU(H4DOTC)-11,
Throttle Body.>
K: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE
/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-29, DTC P0101 MASS OR VOLUME AIR FLOW CIR-
CUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05087
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B3
E
B83
1
B3
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
B83
BATTERY
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE
SENSOR
MAIN RELAY
ARRANGEMENT
*
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
L: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT
CUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05087
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B3
E
B83
1
B3
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
B83
BATTERY
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE
SENSOR
MAIN RELAY
ARRANGEMENT
*
Step Check Yes No
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
SENSOR.
and engine ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
the main relay and
the mass air flow
and intake air tem-
perature sensor
connector.
Poor contact of
main relay connec-
tor
(B135) No. 26 (B3) No. 3:
circuit of harness
between the ECM
and the mass air
flow and intake air
temperature sen-
sor connector.
chassis ground.
more?
ness between the
ECM and the mass
air flow and intake
air temperature
sensor connector.
mass air flow & intake air temperature sensor
connectors.
connectors?
Repair any poor
contact in the ECM
& intake air tem-
perature sensor
connectors.
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
M: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT
CUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05087
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B3
E
B83
1
B3
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
B83
BATTERY
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE
SENSOR
MAIN RELAY
ARRANGEMENT
*
Step Check Yes No
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
NOTE:
tor.>
General scan tool
circuit to power in
the harness
between the ECM
and the mass air
flow & intake air
temperature sen-
sor connectors.
Go to step 3.
the mass air flow and intake air temperature
and connector.
NOTE:
the following item:
OPEN CIRCUIT
OF HARNESS BE-
TWEEN ECM,
MASS AIR FLOW
AND INTAKE AIR
TEMPERATURE
SENSOR CON-
NECTORS.
Poor contact in
ECM connector
Check for any poor contact between the mass
nectors.
temperature sensor connec-
tors?
Repair any poor
contact of the
mass air flow and
intake air tempera-
ture sensor con-
nectors.
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
N: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT LOW INPUT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-36, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/
CAUTION:
WIRING DIAGRAM:
EN-05671
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
2
3
2
8
6
B21
E2
23 1
E21
E21
B21
B134
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
1 2 3
6
2
9
1
9
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
ECM
Step Check Yes No
general scan tool.
NOTE:
tor.>
General scan tool
13.3 kPa (100 mmHg, 3.94
inHg) ?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
engine ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and manifold
absolute pressure
sensor connector.
Poor contact in
ECM connector
Poor contact of
coupling connector
SOR CONNECTOR.
connector.
(B134) No. 6 (E21) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and manifold
absolute pressure
sensor connector.
Poor contact of
coupling connector
SOR CONNECTOR.
chassis ground.
more?
ness between
ECM and manifold
absolute pressure
sensor connector.
Repair the poor
contact in the ECM
or manifold abso-
lute pressure sen-
sor connector.
Replace the mani-
fold absolute pres-
sure sensor. <Ref.
to FU(H4DOTC)-
31, Manifold Abso-
lute Pressure Sen-
sor.>
O: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT HIGH INPUT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-38, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/
CAUTION:
WIRING DIAGRAM:
EN-05671
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
2
3
2
8
6
B21
E2
23 1
E21
E21
B21
B134
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
1 2 3
6
2
9
1
9
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
ECM
Step Check Yes No
general scan tool.
NOTE:
tor.>
General scan tool
kPa (896.5 mmHg, 35.29 inHg)
or more?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
SOR CONNECTOR.
general scan tool.
NOTE:
tor.>
General scan tool
kPa (896.5 mmHg, 35.29 inHg)
or more?
Repair the short
circuit to power in
the harness
between ECM and
manifold absolute
pressure sensor
connector.
Go to step 3.
SOR CONNECTOR.
and engine ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and manifold
absolute pressure
sensor connector.
Poor contact in
ECM connector
Poor contact of
coupling connector
connector?
Repair the poor
contact of mani-
fold absolute pres-
sure sensor
connector.
Replace the mani-
fold absolute pres-
sure sensor. <Ref.
to FU(H4DOTC)-
31, Manifold Abso-
lute Pressure Sen-
sor.>
P: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE
/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-40, DTC P0111 INTAKE AIR TEMPERATURE SEN-
SOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05087
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B3
E
B83
1
B3
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
B83
BATTERY
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE
SENSOR
MAIN RELAY
ARRANGEMENT
*
Step Check Yes No
TURE.
scan tool.
NOTE:
tor.>
General scan tool
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Check DTC P0125
using List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Q: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
SOR 1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05087
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B3
E
B83
1
B3
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
B83
BATTERY
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE
SENSOR
MAIN RELAY
ARRANGEMENT
*
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
120C (248F) or more?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
sensor.
chassis ground.
more?
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Repair the ground
ness between the
ECM and the mass
air flow & intake air
temperature sen-
sor connectors.
R: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
SOR 1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05087
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B3
E
B83
1
B3
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
B83
BATTERY
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE
SENSOR
MAIN RELAY
ARRANGEMENT
*
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
the mass air flow & intake air temperature sen-
sor connectors.
connectors?
Repair any poor
contact between
the ECM and the
mass air flow &
intake air tempera-
ture sensor con-
nectors.
Go to step 3.
sensor.
ECM and mass air flow & intake air temperature
sensor connectors.
(B135) No. 18 (B3) No. 4:
(B135) No. 30 (B3) No. 5:
circuit of harness
between the ECM
and mass air flow &
intake air tempera-
ture sensor con-
nectors.
chassis ground.
circuit to power in
the harness
between the ECM
and the mass air
flow & intake air
temperature sen-
sor connectors.
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
S: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-46, DTC P0117 ENGINE COOLANT TEMPERATURE
TROUBLE SYMPTOM:
Hard to start
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05672
B134
3
4
E8
21
1
2
6
E8
B134
B21
E2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 2
2
9
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
ENGINE
COOLANT
TEMPERATURE
SENSOR
ECM
Step Check Yes No
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
CONNECTOR.
chassis ground.
more?
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H4DOTC)-25,
Engine Coolant
Temperature Sen-
sor.>
Repair the ground
harness between
the ECM and
engine coolant
temperature sen-
sor.
T: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-48, DTC P0118 ENGINE COOLANT TEMPERATURE
TROUBLE SYMPTOM:
Hard to start
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05672
B134
3
4
E8
21
1
2
6
E8
B134
B21
E2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 2
2
9
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
ENGINE
COOLANT
TEMPERATURE
SENSOR
ECM
Step Check Yes No
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Repair any poor
contact between
the ECM and
engine coolant
temperature sen-
sor connectors.
Go to step 3.
CONNECTOR.
(B134) No. 34 (E8) No. 2:
(B134) No. 29 (E8) No. 1:
circuit of the har-
ness between the
ECM and engine
coolant tempera-
ture sensor con-
nector.
CONNECTOR.
chassis ground.
circuit to power in
the harness
between the ECM
and engine coolant
temperature sen-
sor connector.
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H4DOTC)-25,
Engine Coolant
Temperature Sen-
sor.>
U: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT
LOW
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-50, DTC P0122 THROTTLE/PEDAL POSITION SEN-
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05673
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4 5 6
E57 B47
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
4
0
3
4
3
5
3
7
E2
B21
C
2
1
C
1
A
2
9
6
A
1
8
C
6
A
2
8
6 4
2
5
*
*
B122
2
4
E
3
8
3
9
2
8
D
5
D
4
A
1
9
A
5
D
7
D
1
D
2
D
3
3
E57
2 1 5
B134
B362
B47
5
7
6
A: B137 B136 D: C:
*
E
SBF-7
8
6 4
E
3 4
1 2
5 6
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
Step Check Yes No
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
1) Connect the ECM.
more?
Replace the elec-
trol. <Ref. to
FU(H4DOTC)-11,
Throttle Body.>
Repair the ground
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
V: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT
HIGH
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05673
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4 5 6
E57 B47
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
4
0
3
4
3
5
3
7
E2
B21
C
2
1
C
1
A
2
9
6
A
1
8
C
6
A
2
8
6 4
2
5
*
*
B122
2
4
E
3
8
3
9
2
8
D
5
D
4
A
1
9
A
5
D
7
D
1
D
2
D
3
3
E57
2 1 5
B134
B362
B47
5
7
6
A: B137 B136 D: C:
*
E
SBF-7
8
6 4
E
3 4
1 2
5 6
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
Step Check Yes No
(B134) No. 18 (E57) No. 6:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
1) Connect the ECM.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 4.
nectors.
(B134) No. 19 (B134) No. 18:
more?
Repair poor con-
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4DOTC)-11,
Throttle Body.>
Repair the short
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
W: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP
FUEL CONTROL
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-54, DTC P0125 INSUFFICIENT COOLANT TEMPER-
ATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
Step Check Yes No
1 CHECK TIRE SIZE. Is the tire size as specified? and
wheels?
engine coolant.
<Ref. to
CO(H4DOTC)-14,
INSPECTION,
Engine Coolant.>
opened?
Replace the ther-
mostat. <Ref. to
CO(H4DOTC)-17,
Thermostat.>
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H4DOTC)-25,
Engine Coolant
Temperature Sen-
sor.>
X: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR
STABLE OPERATION
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-57, DTC P0126 INSUFFICIENT ENGINE COOLANT
TROUBLE SYMPTOM:
Hard to start
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05672
B134
3
4
E8
21
1
2
6
E8
B134
B21
E2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 2
2
9
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
ENGINE
COOLANT
TEMPERATURE
SENSOR
ECM
Y: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-59, DTC P0128 COOLANT THERMOSTAT (ENGINE
TROUBLE SYMPTOM:
CAUTION:
Step Check Yes No
SENSOR.
Terminals
No. 1 No. 2:
warmed-up?
Repair the poor
contact of the ECM
connector.
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H4DOTC)-25,
Engine Coolant
Temperature Sen-
sor.>
Step Check Yes No
engine coolant.
<Ref. to
CO(H4DOTC)-13,
REPLACEMENT,
Engine Coolant.>
more during idling?
Repair radiator fan
circuit. <Ref. to
CO(H4DOTC)-24,
Radiator Main Fan
and Fan
Motor.>and <Ref.
to CO(H4DOTC)-
26, Radiator Sub
Fan and Fan
Motor.>
Replace the ther-
mostat. <Ref. to
CO(H4DOTC)-17,
Thermostat.>
Z: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-61, DTC P0131 O2 SENSOR CIRCUIT LOW VOLT-
AGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05669
SBF-5
B47
B21
E2
B21
E2
1
2
4
6
3
5
E
E
C
2
C
3
B
8
B
9
B
1
B134
4
3 21
E79
3 4
1 2
3 4
1 2
5 6
B21
B47
E79
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
B138
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B:
D:
1 2 3 4
5 6 7 8
B138
4
2
2
6
4
3
1
5
MAIN RELAY
BATTERY
FRONT
OXYGEN (A/F)
SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
Check poor contact of front oxygen (A/F) sensor
connector.
tor?
Repair the poor
oxygen (A/F) sen-
sor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>
AA:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-63, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLT-
CAUTION:
WIRING DIAGRAM:
EN-05669
SBF-5
B47
B21
E2
B21
E2
1
2
4
6
3
5
E
E
C
2
C
3
B
8
B
9
B
1
B134
4
3 21
E79
3 4
1 2
3 4
1 2
5 6
B21
B47
E79
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
B138
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B:
D:
1 2 3 4
5 6 7 8
B138
4
2
2
6
4
3
1
5
MAIN RELAY
BATTERY
FRONT
OXYGEN (A/F)
SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
(A/F) sensor.
chassis ground.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
nector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>
AB:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-65, DTC P0133 O2 SENSOR CIRCUIT SLOW RE-
CAUTION:
WIRING DIAGRAM:
EN-05669
SBF-5
B47
B21
E2
B21
E2
1
2
4
6
3
5
E
E
C
2
C
3
B
8
B
9
B
1
B134
4
3 21
E79
3 4
1 2
3 4
1 2
5 6
B21
B47
E79
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
B138
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B:
D:
1 2 3 4
5 6 7 8
B138
4
2
2
6
4
3
1
5
MAIN RELAY
BATTERY
FRONT
OXYGEN (A/F)
SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
NOTE:
system?
Repair the exhaust
system.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>
AC:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-68, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY
CAUTION:
WIRING DIAGRAM:
EN-05669
SBF-5
B47
B21
E2
B21
E2
1
2
4
6
3
5
E
E
C
2
C
3
B
8
B
9
B
1
B134
4
3 21
E79
3 4
1 2
3 4
1 2
5 6
B21
B47
E79
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
B138
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B:
D:
1 2 3 4
5 6 7 8
B138
4
2
2
6
4
3
1
5
MAIN RELAY
BATTERY
FRONT
OXYGEN (A/F)
SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
TOR.
(B135) No. 9 (E79) No. 1:
(B135) No. 8 (E79) No. 3:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact of
coupling connector
nector?
Repair the poor
contact of ECM or
front oxygen (A/F)
sensor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>
AD:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-70, DTC P0137 O2 SENSOR CIRCUIT LOW VOLT-
CAUTION:
WIRING DIAGRAM:
EN-05670
B83
1 2 3 4
5 6 7 8
B138
B47
1
2
4
6
3
5
E
*
* B138
B83
3 4
1 2
5 6
B135
B47
B19
B136
B:
C:
B137 D:
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B19
T5
2
2
T5
B19
3 14
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
T6
SBF-5
*
1
*
2
1
1
*
*
2
2
C
4
B
4
B
3
0
B
1
B134
T6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
1 2
3 4
3 14
MAIN RELAY
REAR
OXYGEN SENSOR
BATTERY
ECM
ARRANGEMENT
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
maximum)
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 3.
rear oxygen sensor.
(B135) No. 4 (T6) No. 3:
(B135) No. 30 (T6) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
REAR OXYGEN SENSOR.
gen sensor.
(T6) No. 3 (+) Chassis ground ():
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
NOTE:
haust system
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Rear Oxygen Sen-
sor.>
AE:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-73, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLT-
CAUTION:
WIRING DIAGRAM:
EN-05670
B83
1 2 3 4
5 6 7 8
B138
B47
1
2
4
6
3
5
E
*
* B138
B83
3 4
1 2
5 6
B135
B47
B19
B136
B:
C:
B137 D:
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B19
T5
2
2
T5
B19
3 14
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
T6
SBF-5
*
1
*
2
1
1
*
*
2
2
C
4
B
4
B
3
0
B
1
B134
T6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
1 2
3 4
3 14
MAIN RELAY
REAR
OXYGEN SENSOR
BATTERY
ECM
ARRANGEMENT
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
rpm.
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 3.
rear oxygen sensor.
(B135) No. 4 (T6) No. 3:
(B135) No. 30 (T6) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
REAR OXYGEN SENSOR.
gen sensor.
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
NOTE:
haust system
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Rear Oxygen Sen-
sor.>
AF:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-74, DTC P0139 O2 SENSOR CIRCUIT SLOW RE-
CAUTION:
WIRING DIAGRAM:
EN-05670
B83
1 2 3 4
5 6 7 8
B138
B47
1
2
4
6
3
5
E
*
* B138
B83
3 4
1 2
5 6
B135
B47
B19
B136
B:
C:
B137 D:
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B19
T5
2
2
T5
B19
3 14
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
T6
SBF-5
*
1
*
2
1
1
*
*
2
2
C
4
B
4
B
3
0
B
1
B134
T6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
1 2
3 4
3 14
MAIN RELAY
REAR
OXYGEN SENSOR
BATTERY
ECM
ARRANGEMENT
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
rear oxygen sensor.
(B135) No. 4 (T6) No. 3:
circuit of harness
between ECM and
rear oxygen sensor
connector.
(T6) No. 3 Chassis ground:
more?
ness between
ECM and rear oxy-
gen sensor con-
nector.
sensor terminals.
Terminals
No. 3 No. 4
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Rear Oxygen Sen-
sor.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
AG:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-81, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY
CAUTION:
WIRING DIAGRAM:
EN-05670
B83
1 2 3 4
5 6 7 8
B138
B47
1
2
4
6
3
5
E
*
* B138
B83
3 4
1 2
5 6
B135
B47
B19
B136
B:
C:
B137 D:
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B19
T5
2
2
T5
B19
3 14
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
T6
SBF-5
*
1
*
2
1
1
*
*
2
2
C
4
B
4
B
3
0
B
1
B134
T6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
1 2
3 4
3 14
MAIN RELAY
REAR
OXYGEN SENSOR
BATTERY
ECM
ARRANGEMENT
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
maximum)
tool.
NOTE:
tor.>
General scan tool
rpm.
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 4.
rear oxygen sensor.
(B135) No. 4 (T6) No. 3:
(B135) No. 30 (T6) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
AH:DTC P0171 SYSTEM TOO LEAN (BANK 1)
Refer to DTC P0172 for diagnostic procedure. <Ref. to EN(H4DOTC)(diag)-151, DTC P0172 SYSTEM TOO
REAR OXYGEN SENSOR.
gen sensor.
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
NOTE:
haust system
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Rear Oxygen Sen-
sor.>
Step Check Yes No
AI: DTC P0172 SYSTEM TOO RICH (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-84, DTC P0172 SYSTEM TOO RICH (BANK 1), Diag-
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Step Check Yes No
on exhaust system?
Repair the exhaust
system.
Go to step 2.
intake system?
Repair the air
intake system.
Go to step 3.
WARNING:
working area.
CAUTION:
Measure the fuel pressure while disconnecting
pressure regulator vacuum hose from intake
manifold. <Ref. to ME(H4DOTC)-24, INSPEC-
TION, Fuel Pressure.>
CAUTION:
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 284
314 kPa (2.9 3.2 kg/cm
2
, 41
46 psi)?
ing item.
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
After connecting the pressure regulator vacuum
hose, measure fuel pressure. <Ref. to
ME(H4DOTC)-24, INSPECTION, Fuel Pres-
sure.>
CAUTION:
NOTE:
If fuel pressure does not increase, squeeze
pressure again.
If the measured value at this step is out of
specification, check or replace pressure regula-
tor and pressure regulator vacuum hose.
260 kPa (2.35 2.65 kg/cm
2
,
33 38 psi)?
ing item.
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
SENSOR.
NOTE:
tor.>
General scan tool
engine coolant
temperature sen-
sor. <Ref. to
FU(H4DOTC)-25,
Engine Coolant
Temperature Sen-
sor.>
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
5.0 g/s (0.26 0.66 lb/m)?
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Step Check Yes No
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
(18 90F)?
Repair the poor
contact of the ECM
connector.
Check the mass air
flow and intake air
temperature sen-
sor.
<Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Step Check Yes No
AJ:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE
/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-86, DTC P0181 FUEL TEMPERATURE SENSOR A
CAUTION:
WIRING DIAGRAM:
EN-03923
B83
3
0
1
7
ECM B135
R58
R67
R46
R1
B97
B97 R67 R58 B135
23
14
4
1
8
B83
FUEL TEMPERATURE
SENSOR
FUEL TANK
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 19 20
3 4
5 6
1 2
7 8
:TERMINAL No. OPTIONAL
ARRANGEMENT
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Replace the fuel
temperature sen-
sor. <Ref. to
EC(H4DOTC)-12,
Fuel Temperature
Sensor.>
AK:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT
CAUTION:
WIRING DIAGRAM:
EN-03923
B83
3
0
1
7
ECM B135
R58
R67
R46
R1
B97
B97 R67 R58 B135
23
14
4
1
8
B83
FUEL TEMPERATURE
SENSOR
FUEL TANK
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 19 20
3 4
5 6
1 2
7 8
ARRANGEMENT
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
Step Check Yes No
NOTE:
tor.>
(248F) or higher?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
TOR.
chassis ground.
more?
Replace the fuel
temperature sen-
sor. <Ref. to
EC(H4DOTC)-12,
Fuel Temperature
Sensor.>
Repair the ground
ness between
ECM and fuel
pump.
AL:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT
CAUTION:
WIRING DIAGRAM:
EN-03923
B83
3
0
1
7
ECM B135
R58
R67
R46
R1
B97
B97 R67 R58 B135
23
14
4
1
8
B83
FUEL TEMPERATURE
SENSOR
FUEL TANK
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 19 20
3 4
5 6
1 2
7 8
ARRANGEMENT
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
Step Check Yes No
NOTE:
tor.>
40C (40F)?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
sor connectors?
Repair any poor
contact between
the ECM and fuel
temperature sen-
sor connectors.
Go to step 3.
TOR.
connector.
(B135) No. 17 (R58) No. 2:
(B135) No. 30 (R58) No. 3:
circuit of the har-
ness between the
ECM and fuel tem-
perature sensor
connector.
TOR.
chassis ground.
circuit to power in
the harness
between the ECM
and fuel tempera-
ture sensor con-
nector.
Replace the fuel
temperature sen-
sor. <Ref. to
EC(H4DOTC)-12,
Fuel Temperature
Sensor.>
AM:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
LOW
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05673
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4 5 6
E57 B47
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
4
0
3
4
3
5
3
7
E2
B21
C
2
1
C
1
A
2
9
6
A
1
8
C
6
A
2
8
6 4
2
5
*
*
B122
2
4
E
3
8
3
9
2
8
D
5
D
4
A
1
9
A
5
D
7
D
1
D
2
D
3
3
E57
2 1 5
B134
B362
B47
5
7
6
A: B137 B136 D: C:
*
E
SBF-7
8
6 4
E
3 4
1 2
5 6
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
Step Check Yes No
chassis ground.
more?
ness between
ECM and elec-
trol connector.
1) Connect the ECM.
more?
Replace the elec-
trol. <Ref. to
FU(H4DOTC)-11,
Throttle Body.>
Repair the ground
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
AN:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
HIGH
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05673
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4 5 6
E57 B47
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
4
0
3
4
3
5
3
7
E2
B21
C
2
1
C
1
A
2
9
6
A
1
8
C
6
A
2
8
6 4
2
5
*
*
B122
2
4
E
3
8
3
9
2
8
D
5
D
4
A
1
9
A
5
D
7
D
1
D
2
D
3
3
E57
2 1 5
B134
B362
B47
5
7
6
A: B137 B136 D: C:
*
E
SBF-7
8
6 4
E
3 4
1 2
5 6
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
Step Check Yes No
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
1) Connect the ECM.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 4.
nectors.
(B134) No. 19 (B134) No. 28:
more?
Repair poor con-
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4DOTC)-11,
Throttle Body.>
Repair the short
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
AO:DTC P0230 FUEL PUMP PRIMARY CIRCUIT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-97, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Di-
CAUTION:
WIRING DIAGRAM:
EN-05083
E
E
M
1
0
76
56
35
No.11
B362
R122
B135 B:
B136 C:
R58
B97
7
B
3
3
C
1
2
1 2
985
1
9
8
R1
2
0
R1
B97
R46
R67
FUEL PUMP
CONTROL UNIT
FUEL
PUMP
ECM
BATTERY
FUEL PUMP
RELAY
B135 B136 B362 R58
2
5
4
6
1
3
B: C:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
R122
3 4 1 2
5 8 9 10 6 7
5
6
7 8
3
4
1 2
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B97 R67
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
Step Check Yes No
1 CHECK POWER SUPPLY CIRCUIT TO FUEL
PUMP CONTROL UNIT.
2) Disconnect the connector from fuel pump
control unit.
4) Measure the voltage between fuel pump
control unit and chassis ground.
supply circuit.
NOTE:
the following item:
Open or ground
ness between fuel
pump relay and
fuel pump control
unit
Poor contact of
fuel pump control
unit connector
Poor contact of
fuel pump relay
connector
2 CHECK GROUND CIRCUIT OF FUEL PUMP
CONTROL UNIT.
fuel pump control unit and chassis ground.
and connector.
NOTE:
the following item:
Open circuit be-
tween fuel pump
control unit and
chassis ground
Poor contact of
fuel pump control
unit connector
CONTROL UNIT AND FUEL PUMP CONNEC-
TOR.
fuel pump control unit and fuel pump connector.
(R122) No. 7 (R58) No. 5:
(R122) No. 6 (R58) No. 6:
circuit between fuel
pump control unit
and fuel pump.
TOR.
Measure the resistance between fuel pump
more?
ness between fuel
pump control unit
and fuel pump.
FUEL PUMP CONTROL UNIT.
between the ECM and fuel pump control unit.
(B135) No. 33 (R122) No. 9:
(B136) No. 12 (R122) No. 8:
and connector.
NOTE:
the following item:
Open circuit be-
tween the ECM
and fuel pump con-
trol unit
Poor contact be-
tween ECM and
fuel pump control
unit
more?
ness between
ECM and fuel
pump control unit.
Check poor contact of ECM and fuel pump con-
trol unit connector.
Is there poor contact of ECM
and fuel pump control unit con-
nector?
Repair the poor
contact of ECM
and fuel pump con-
Go to step 8.
8 CHECK EXPERIENCE OF RUNNING OUT OF
FUEL.
Has the vehicle experienced
running out of fuel?
Finish the diagno-
sis.
NOTE:
DTC may be re-
corded as a result
of fuel pump idling
while running out
of fuel.
Replace the fuel
pump control unit.
<Ref. to
FU(H4DOTC)-49,
Fuel Pump Control
Unit.>
Step Check Yes No
AP:DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID A
RANGE/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-99, DTC P0244 TURBO/SUPER CHARGER WASTE-
GATE SOLENOID A RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
EN-05674
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
3 4
1 2
5 6
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B47
1
2
4
6
3
5
B137
E
2
7
SBF-7
B47
B137
E64
B21
E64
2 1
B21
E2
5
0
4
8
MAIN RELAY
BATTERY
ECM
WASTEGATE CONTROL
SOLENOID VALVE
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Replace the waste-
gate control sole-
FU(H4DOTC)-39,
Wastegate Control
Solenoid Valve.>
AQ:DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID A LOW
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-101, DTC P0245 TURBO/SUPER CHARGER
WASTEGATE SOLENOID A LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
EN-05674
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
3 4
1 2
5 6
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B47
1
2
4
6
3
5
B137
E
2
7
SBF-7
B47
B137
E64
B21
E64
2 1
B21
E2
5
0
4
8
MAIN RELAY
BATTERY
ECM
WASTEGATE CONTROL
SOLENOID VALVE
Step Check Yes No
chassis ground.
contact of the ECM
connector.
Go to step 2.
WASTEGATE CONTROL SOLENOID
VALVE.
wastegate control solenoid valve.
3) Measure the resistance between wastegate
ground.
more?
ness between
ECM and waste-
gate control sole-
noid valve
connector.
VALVE.
ECM and wastegate control solenoid valve con-
nector.
(B137) No. 27 (E64) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and waste-
gate control sole-
noid valve
connector
Poor contact of
coupling connector
4 CHECK WASTEGATE CONTROL SOLE-
NOID VALVE.
1) Remove the wastegate control solenoid
valve.
Terminals
No. 1 No. 2:
100 ?
Go to step 5. Replace the waste-
gate control sole-
FU(H4DOTC)-39,
Wastegate Control
Solenoid Valve.>
5 CHECK POWER SUPPLY TO WASTEGATE
CONTROL SOLENOID VALVE.
2) Measure the voltage between wastegate
control solenoid valve and engine ground.
tact in wastegate
control solenoid
valve connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
main relay and
wastegate control
solenoid valve
connector
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
AR:DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID A HIGH
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-103, DTC P0246 TURBO/SUPER CHARGER
WASTEGATE SOLENOID A HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
EN-05674
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
3 4
1 2
5 6
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B47
1
2
4
6
3
5
B137
E
2
7
SBF-7
B47
B137
E64
B21
E64
2 1
B21
E2
5
0
4
8
MAIN RELAY
BATTERY
ECM
WASTEGATE CONTROL
SOLENOID VALVE
AS:DTC P0301 CYLINDER 1 MISFIRE DETECTED
NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4DOTC)(diag)-173, DTC P0304 CYLIN-
DER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
NOTE:
NOTE:
Step Check Yes No
VALVE.
wastegate control solenoid valve.
chassis ground.
Is the voltage 10 V or more? Repair short cir-
harness between
ECM and waste-
gate control sole-
noid valve
connector.
Go to step 2.
2 CHECK WASTEGATE CONTROL SOLE-
NOID VALVE.
Terminals
No. 1 No. 2:
Is the resistance less than 1 ? Replace the waste-
gate control sole-
FU(H4DOTC)-39,
Wastegate Control
Solenoid Valve.>
Repair the poor
contact of the ECM
connector.
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-111, DTC P0304 CYLINDER 4 MISFIRE DETECTED,
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
Rough driving
CAUTION:
WIRING DIAGRAM:
EN-05668
E
#4
1 2
SBF-7
#3
1 2
#2
1 2
B21
#1
1 2
4
8
5
4
5
3
5
2
5
1
89
1
0
1
1
1 2
5
3
6
4
2
1
B21 B137
E5
E5
E2
E6
E6
E16
E16
E17
B47
E17
B47
3 4
1 2
5 6
B137
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
MAIN RELAY
ECM
BATTERY
FUEL INJECTOR
Step Check Yes No
FUEL INJECTOR.
cylinders.
more?
ness between
ECM and fuel
injector.
FUEL INJECTOR.
#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:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel in-
jector connector
Poor contact of
coupling connector
Terminals
No. 1 No. 2:
20 ?
to FU(H4DOTC)-
32, Fuel Injector.>
contact of all con-
nectors in fuel
injector circuit.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the main relay and
fuel injector con-
nector on faulty
cylinders
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
Poor contact of
fuel injector con-
nector on faulty
cylinders
FUEL INJECTOR.
circuit to power in
the harness
between the ECM
and fuel injector.
Go to step 7.
Terminals
No. 1 No. 2:
to FU(H4DOTC)-
32, Fuel Injector.>
Go to step 8.
8 CHECK INSTALLATION OF CAMSHAFT PO-
SITION SENSOR/CRANKSHAFT POSITION
SENSOR.
loosely installed?
Tighten the cam-
shaft position sen-
sor or crankshaft
position sensor.
Go to step 9.
Replace the crank
sprocket. <Ref. to
ME(H4DOTC)-52,
Crank Sprocket.>
Go to step 10.
TIMING BELT.
der block.
tion condition of
timing belt. <Ref. to
ME(H4DOTC)-42,
Timing Belt.>
Go to step 11.
higher than the Lower level?
Go to step 12. Replenish fuel so
cation is higher
than the Lower
level. After refuel-
ing, Go to step 12.
CATOR LIGHT.
<Ref. to EN(H4DOTC)(diag)-56, Clear Memory
Mode.>
minutes or more.
Step Check Yes No
13 CHECK CAUSE OF MISFIRE. Was the cause of misfire identi-
fied when the engine is run-
ning?
Finish diagnostics
operation, if the
engine has no
abnormality.
Repair the poor
contact of connec-
tor.
NOTE:
the following item:
Poor contact of
ignition coil con-
nector
Poor contact of
fuel injector con-
nector on faulty
cylinders
Poor contact in
ECM connector
Poor contact of
coupling connector
system?
Repair the air
intake system.
NOTE:
Check the follow-
ing items.
Are there air
caused by loose or
dislocated nuts
and bolts?
Are there cracks
or any disconnec-
tion of hoses?
Go to step 15.
2) Read the DTC.
NOTE:
tor.>
General scan tool
only one DTC?
Step Check Yes No
der?
Repair or replace
faulty parts.
NOTE:
Check the following
items.
Spark plug
Spark plug cord
Fuel injector
Compression ra-
tio
Go to DTC P0171.
<Ref. to
EN(H4DOTC)(diag
)-150, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
#2 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Ignition coil
Compression
ratio
If any fault are
not found, check
the IGNITION
CONTROL SYS-
TEM of #1 and #2
cylinders side.
<Ref. to
EN(H4DOTC)(di-
ag)-78, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Starting
Failure.>
Go to DTC P0171.
<Ref. to
EN(H4DOTC)(diag
)-150, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
#4 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Ignition coil
Compression
ratio
If any fault are
not found, check
the IGNITION
CONTROL SYS-
TEM of #3 and #4
cylinders side.
<Ref. to
EN(H4DOTC)(di-
ag)-78, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Starting
Failure.>
Go to DTC P0171.
<Ref. to
EN(H4DOTC)(diag
)-150, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
Step Check Yes No
#3 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Compression ra-
tio
Skipping timing
belt teeth
Go to DTC P0171.
<Ref. to
EN(H4DOTC)(diag
)-150, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
#4 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Compression ra-
tio
Skipping timing
belt teeth
Go to DTC P0171.
<Ref. to
EN(H4DOTC)(diag
)-150, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
25 CYLINDER AT RANDOM. Is the engine idle rough? Go to DTC P0171.
<Ref. to
EN(H4DOTC)(diag
)-150, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Compression ra-
tio
Step Check Yes No
AW:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-112, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW
TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
EN-05675
1
5
2
5
2
9
1 2
4 6
B134
B21
E2
E14
E
E14
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
B21
1 2
KNOCK SENSOR
ECM
Step Check Yes No
KNOCK SENSOR.
nectors.
(B134) No. 15 (B134) No. 29:
more?
tact of the ECM
connector.
sor.
sensor terminals.
Terminals
No. 1 No. 2:
more?
Replace the knock
sensor. <Ref. to
FU(H4DOTC)-28,
Knock Sensor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and knock
sensor
Poor contact of
knock sensor con-
nector
Poor contact of
coupling connector
AX:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-114, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH
TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
EN-05675
1
5
2
5
2
9
1 2
4 6
B134
B21
E2
E14
E
E14
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
B21
1 2
KNOCK SENSOR
ECM
Step Check Yes No
KNOCK SENSOR.
nectors.
(B134) No. 15 (B134) No. 29:
k?
sor.
sensor connectors.
Terminals
No. 1 No. 2:
k?
Replace the knock
sensor. <Ref. to
FU(H4DOTC)-28,
Knock Sensor.>
Repair the ground
ness between the
ECM and knock
sensor connector.
NOTE:
The harness be-
tween both con-
nectors are
shielded. Remove
the shield and re-
pair the short cir-
cuit of the harness
circuit.
1) Connect the ECM.
chassis ground.
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Repair poor con-
tact of the ECM
connector.
AY:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-116, DTC P0335 CRANKSHAFT POSITION SENSOR
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05676
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
1
4
3
1
4
2
4
B21
E2
E10
E10
1 2
B134
1
3
E
B134
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
B21
CRANKSHAFT
POSITION
SENSOR
ECM
Step Check Yes No
SITION SENSOR.
securely?
shaft position sen-
securely.
Terminals
No. 1 No. 2:
4 k?
shaft position sen-
sor. <Ref. to
FU(H4DOTC)-26,
Crankshaft Posi-
tion Sensor.>
nector.
(B134) No. 13 (E10) No. 1:
(B134) No. 14 (E10) No. 2:
contact of the ECM
and crankshaft
position sensor
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and crank-
shaft position sen-
sor connector
Poor contact of
coupling connector
AZ:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE
/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-118, DTC P0336 CRANKSHAFT POSITION SENSOR
A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05676
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
1
4
3
1
4
2
4
B21
E2
E10
E10
1 2
B134
1
3
E
B134
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
B21
CRANKSHAFT
POSITION
SENSOR
ECM
Step Check Yes No
SITION SENSOR.
securely?
shaft position sen-
securely.
Are crank sprocket teeth
cracked or damaged?
Replace the crank
sprocket. <Ref. to
ME(H4DOTC)-52,
Crank Sprocket.>
Go to step 3.
TIMING BELT.
der block.
tion condition of
ME(H4DOTC)-42,
Timing Belt.>
Replace the crank-
shaft position sen-
sor. <Ref. to
FU(H4DOTC)-26,
Crankshaft Posi-
tion Sensor.>
BA:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT
(BANK 1 OR SINGLE SENSOR)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-120, 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:
EN-05677
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B47
1
2
4
6
3
5
E
3
2
2
SBF-7
E35
E2
B21
2
E36
13
1
1
2 1
B134
3 4
1 2
5 6
E36
B47
1 2 3
B134
E35
2
1
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5
4
8
2
1
3
MAIN RELAY
BATTERY
INTAKE
CAMSHAFT
POSITION
SENSOR LH
INTAKE
CAMSHAFT
POSITION
SENSOR RH
ECM
Step Check Yes No
1 CHECK POWER SUPPLY OF CAMSHAFT
POSITION SENSOR.
2) Disconnect the connector from the cam-
shaft position sensor.
4) Measure the voltage between camshaft
of harness
between main
relay connector
and camshaft posi-
tion sensor con-
nector.
CAMSHAFT POSITION SENSOR CONNEC-
TOR.
3) Measure the resistance between the ECM
and camshaft position sensor connector.
(B134) No. 11 (E36) No. 2:
(B134) No. 22 (E36) No. 3:
circuit of harness
between the ECM
and camshaft posi-
tion sensor.
TOR.
more?
harness between
the ECM and cam-
shaft position sen-
sor.
TOR.
Measure the voltage between camshaft posi-
tion sensor connector and engine ground.
circuit to power in
the harness
between the ECM
and camshaft posi-
tion sensor.
Go to step 5.
5 CHECK CONDITION OF CAMSHAFT POSI-
TION SENSOR.
securely?
shaft position sen-
securely.
Check waveform of camshaft position sensor.
<Ref. to EN(H4DOTC)(diag)-17, Engine Con-
trol Module (ECM) I/O Signal.>
Is there any abnormality in
waveform?
Replace the cam-
shaft position sen-
sor. <Ref. to
FU(H4DOTC)-27,
Camshaft Position
Sensor.>
Repair the follow-
ing item.
Poor contact in
ECM connector
Poor contact of
camshaft position
sensor connector
Poor contact of
coupling connector
BB:DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-122, DTC P0345 CAMSHAFT POSITION SENSOR
A CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05677
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B47
1
2
4
6
3
5
E
3
2
2
SBF-7
E35
E2
B21
2
E36
13
1
1
2 1
B134
3 4
1 2
5 6
E36
B47
1 2 3
B134
E35
2
1
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5
4
8
2
1
3
MAIN RELAY
BATTERY
INTAKE
CAMSHAFT
POSITION
SENSOR LH
INTAKE
CAMSHAFT
POSITION
SENSOR RH
ECM
Step Check Yes No
POSITION SENSOR.
of harness
between main
relay connector
and camshaft posi-
tion sensor con-
nector.
TOR.
(B134) No. 21 (E35) No. 2:
(B134) No. 22 (E35) No. 3:
circuit of harness
between the ECM
and camshaft posi-
tion sensor.
TOR.
more?
harness between
the ECM and cam-
shaft position sen-
sor.
TOR.
circuit to power in
the harness
between the ECM
and camshaft posi-
tion sensor.
Go to step 5.
TION SENSOR.
securely?
shaft position sen-
securely.
Check waveform of camshaft position sensor.
<Ref. to EN(H4DOTC)(diag)-17, Engine Con-
trol Module (ECM) I/O Signal.>
waveform?
Replace the cam-
shaft position sen-
sor. <Ref. to
FU(H4DOTC)-27,
Camshaft Position
Sensor.>
Repair the follow-
ing item.
Poor contact in
ECM connector
Poor contact of
camshaft position
sensor connector
Poor contact of
coupling connector
BC:DTC P0410 SECONDARY AIR INJECTION SYSTEM
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-123, DTC P0410 SECONDARY AIR INJECTION SYS-
TEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
COMBINATION VALVE RH
(WITH BUILT-IN PRESSURE SENSOR)
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
1 CHECK SECONDARY AIR PUMP FUSE.
Check if the secondary air pump fuse (60 A) is
blown out.
Is the fuse blown out? Go to step 2. Go to step 3.
2 CHECK HARNESS BETWEEN FUSE BOX
AND SECONDARY AIR PUMP.
1) Remove the secondary air pump fuse from
the fuse box.
2) Disconnect the secondary air pump con-
nector.
3) Measure the resistance between the sec-
ondary air pump fuse and secondary air pump
connector, and chassis ground.
more?
Replace the fuse
with a new part,
and connect the
secondary air
pump connector.
Go to step 3.
Repair ground
short of the har-
ness between the
fuse box and the
secondary air
pump.
3 CHECK SECONDARY AIR PUMP OPERA-
TION.
4) Perform operation check for the secondary
air pump using the Subaru Select Monitor.
NOTE:
Refer to Clear Memory Mode <Ref. to
EN(H4DOTC)(diag)-56, Clear Memory Mode.>
and Compulsory Valve Operation Check
Mode <Ref. to EN(H4DOTC)(diag)-57, Com-
pulsory Valve Operation Check Mode.> for
more operation procedures.
The compulsory operation using the Subaru
Select Monitor is performed only for 5 seconds
in order to protect the secondary air pump.
When operating again, perform the Clear Mem-
ory Mode.
Does the secondary air pump
operate?
4 CHECK DUCT BETWEEN SECONDARY AIR
PUMP AND COMBINATION VALVE.
Check the duct between the secondary air
pump and combination valve.
Is there damage, clog or dis-
connection of the duct?
Replace, clean or
connect the duct.
Replace the sec-
ondary air combi-
nation valve LH.
<Ref. to
EC(H4DOTC)-21,
Secondary Air
Combination
Valve.>
5 CHECK POWER SUPPLY TO SECONDARY
AIR PUMP.
3) Disconnect the secondary air pump con-
nector.
4) In the condition of step 3, measure the volt-
age between the secondary air pump connector
and the chassis ground.
NOTE:
Mode. <Ref. to EN(H4DOTC)(diag)-56, Clear
Memory Mode.>
Is the voltage 10 V or more? Replace the sec-
ondary air pump.
<Ref. to
EC(H4DOTC)-20,
Secondary Air
Pump.>
Go to step 6.
6 CHECK HARNESS BETWEEN SECONDARY
AIR PUMP RELAY AND SECONDARY AIR
PUMP CONNECTOR.
2) Remove the secondary air pump relay.
secondary air pump relay and secondary air
pump connector.
(F9) No. 11 (F11) No. 2:
circuit of harness
between second-
ary air pump relay
and secondary air
pump connector.
AIR PUMP CONNECTOR AND CHASSIS
GROUND.
Measure the resistance of the harness between
secondary air pump connector and chassis
ground.
circuit of the har-
ness between sec-
ondary air pump
connector and
chassis ground.
8 CHECK SECONDARY AIR PUMP RELAY.
No. 13 of the secondary air pump relay.
2) Measure the resistance between secondary
air pump relay terminals.
Terminals
No. 14 No. 11:
Is the resistance less than 1 ? Go to step 9. Replace the sec-
ondary air pump
relay. <Ref. to
EN(H4DOTC)(diag
)-8, Electrical
Component Loca-
tion.>
9 CHECK SECONDARY AIR PUMP RELAY
POWER SOURCE.
2) Measure the voltage between the second-
ary air pump relay connector and chassis
ground.
of power supply
circuit.
SECONDARY AIR PUMP RELAY CONNEC-
TOR.
2) Disconnect the connector of ECM.
ECM and secondary air pump relay connector.
(B136) No. 8 (F9) No. 13:
contact of the ECM
connector.
Repair the open
circuit of harness
between ECM and
secondary air
pump relay con-
nector.
Step Check Yes No
BD:DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW
DETECTED
TEM INCORRECT FLOW DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
1 CHECK SECONDARY AIR COMBINATION
VALVE.
Inspection of the pipe between the secondary
air combination valve and cylinder head.
Is there damage or disconnec-
tion of the pipe?
Replace the pipe
between second-
ary air combination
valve and cylinder
head.
Go to step 2.
VALVE.
Race the engine at 2,000 rpm to check whether
or not the exhaust leak is heard.
Is there any exhaust leak? Replace the pipe
between second-
ary air combination
valve and cylinder
head.
Repair the poor
contact of the ECM
connector.
BE:DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A
CIRCUIT OPEN
TEM SWITCHING VALVE A CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
SECONDARY AIR COMBINATION VALVE
RELAY 1.
secondary air combination valve relay 1.
ECM and secondary air combination valve relay 1.
(B136) No. 30 (F9) No. 2:
Is the resistance less than 1 ? Go to step 2. Repair the open cir-
cuit of harness
between ECM and
secondary air combi-
nation valve relay 1.
RELAY 1.
chassis ground.
more?
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Repair the ground
ness between
ECM and second-
ary air combination
valve relay 1.
BF:DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A
CIRCUIT SHORTED
TEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
RELAY 1.
chassis ground.
harness between
ECM and second-
ary air combination
valve relay 1.
Repair the poor
contact of the ECM
connector.
BG:DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE "B"
CIRCUIT OPEN
TEM SWITCHING VALVE "B" CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
RELAY 2.
ECM and secondary air combination valve relay 2.
(B136) No. 19 (F9) No. 9:
cuit of harness
between ECM and
secondary air combi-
nation valve relay 2.
RELAY 2.
chassis ground.
more?
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Repair the ground
ness between
ECM and second-
ary air combination
valve relay 2.
BH:DTC P0417 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE "B"
CIRCUIT SHORTED
TEM SWITCHING VALVE "B" CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
RELAY 2.
chassis ground.
harness between
ECM and second-
ary air combination
valve relay 2.
Repair the poor
contact of the ECM
connector.
BI: DTC P0418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT
TEM CONTROL A CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
SECONDARY AIR PUMP RELAY.
and secondary air pump relay.
ECM and secondary air pump relay.
(B136) No. 8 (F9) No. 13:
circuit of harness
between ECM and
secondary air
pump relay.
chassis ground.
more?
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Repair the ground
ness between
ECM and second-
ary air pump relay.
BJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD
(BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-137, DTC P0420 CATALYST SYSTEM EFFICIENCY
BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05670
B83
1 2 3 4
5 6 7 8
B138
B47
1
2
4
6
3
5
E
*
* B138
B83
3 4
1 2
5 6
B135
B47
B19
B136
B:
C:
B137 D:
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B19
T5
2
2
T5
B19
3 14
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
T6
SBF-5
*
1
*
2
1
1
*
*
2
2
C
4
B
4
B
3
0
B
1
B134
T6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
1 2
3 4
3 14
MAIN RELAY
REAR
OXYGEN SENSOR
BATTERY
ECM
ARRANGEMENT
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
NOTE:
pipe
converter
catalytic converter
system?
Repair or replace
the exhaust sys-
tem. <Ref. to
EX(H4DOTC)-2,
General Descrip-
tion.>
Go to step 2.
112 km/h (50 70 MPH).
played?
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the failure,
and then perform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector
may be the cause.
Go to step 3.
RrO2 SENSOR
RrO2 SENSOR
A/F LAMBDA 1
A/F LAMBDA 1
EN-04895
played?
aged?
Replace the cata-
lytic converter.
<Ref. to
EC(H4DOTC)-5,
Front Catalytic
Converter.>
Go to step 5.
tor?
Completely
remove any water
inside.
Go to step 6.
rear oxygen sensor.
(B135) No. 4 (T6) No. 3:
(B135) No. 30 (T6) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
Step Check Yes No
RrO2 SENSOR
RrO2 SENSOR
EN-04896
and connector.
NOTE:
Repair the follow-
ing locations.
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the ECM and rear
oxygen sensor
Poor contact in
ECM connector
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Rear Oxygen Sen-
sor.>
Repair the open
circuit in the rear
oxygen sensor har-
ness.
Step Check Yes No
BK:DTC P0441 EVAPORATIVE EMISSION SYSTEM INCORRECT PURGE FLOW
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-139, DTC P0441 EVAPORATIVE EMISSION SYS-
TEM INCORRECT PURGE FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
2 CHECK PURGE LINE OF THE PURGE CON-
TROL SOLENOID VALVE 2.
Is there any clogging, flattened
part or bent in the purge line of
purge control solenoid valve 2?
Repair or replace
the purge line of
purge control sole-
noid valve 2.
Go to step 3.
VALVE 2.
3) Operate the purge control solenoid valve 2
NOTE:
Purge control solenoid valve 2 can be operated
using the Subaru Select Monitor. Regarding the
procedures, refer to Compulsory Valve Opera-
tion Check Mode. <Ref. to EN(H4DOTC)(di-
ag)-57, Compulsory Valve Operation Check
Mode.>
noid valve 2 operate?
Repair the poor
contact of the ECM
connector.
Replace the purge
control solenoid
valve 2. <Ref. to
EC(H4DOTC)-8,
Purge Control
Solenoid Valve.>
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-140, DTC P0442 EVAPORATIVE EMISSION CON-
TROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Fuel odor
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
DRAIN VALVE PRESSURE
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
Step Check Yes No
NOTE:
tightening.
securely?
cap securely.
genuine fuel filler
cap.
filler pipe?
Repair or replace
the fuel filler cap
<Ref. to
FU(H4DOTC)-59,
Fuel Filler Pipe.>
Go to step 4.
Select Monitor.
NOTE:
Check Mode. <Ref. to EN(H4DOTC)(diag)-57,
valve. <Ref. to
EC(H4DOTC)-18,
Drain Valve.>
VALVE.
NOTE:
noid valve operate?
control solenoid
valve. <Ref. to
EC(H4DOTC)-8,
Purge Control
Solenoid Valve.>
VALVE.
NOTE:
noid valve operate?
sure control sole-
EC(H4DOTC)-15,
Pressure Control
Solenoid Valve.>
TROL SYSTEM LINE.
tor.
ration line?
Repair or replace
the evaporation
line. <Ref. to
FU(H4DOTC)-69,
Fuel Delivery,
Return and Evapo-
ration Lines.>
Go to step 8.
Repair or replace
the canister. <Ref.
to EC(H4DOTC)-7,
Canister.>
Go to step 9.
9 CHECK FUEL TANK.
Remove the fuel tank. <Ref. to FU(H4DOTC)-
52, Fuel Tank.>
Repair or replace
to FU(H4DOTC)-
52, Fuel Tank.>
Go to step 10.
TROL SYSTEM.
Repair or replace
the hoses or pipes.
Repair the poor
contact of the ECM
connector.
Step Check Yes No
BM:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL
CIRCUIT OPEN
TROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
Step Check Yes No
chassis ground.
contact of the ECM
connector.
Go to step 2.
DRAIN VALVE.
and drain valve.
more?
ness between
ECM and drain
valve connector.
DRAIN VALVE.
(B136) No. 17 (R144) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and drain
valve connector
Poor contact of
coupling connector
terminals.
Terminals
No. 1 No. 2:
100 ?
valve. <Ref. to
EC(H4DOTC)-18,
Drain Valve.>
and chassis ground.
contact of drain
valve connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
main relay and
drain valve
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
BN:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL
CIRCUIT SHORTED
TROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
Step Check Yes No
DRAIN VALVE.
and drain valve.
chassis ground.
circuit to power in
the harness
between ECM and
drain valve con-
nector.
Go to step 2.
2) Measure the resistance between drain valve
terminals.
Terminals
No. 1 No. 2:
valve. <Ref. to
EC(H4DOTC)-18,
Drain Valve.>
Repair the poor
contact of the ECM
connector.
BO:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR
TROL SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05095
B83
31 2
2
2
3
2
3
0
ECM B135
R47
R213
R15
R1
B97
B97
1 2 3
R47
B135
74 6
6
1
3
1
7
B83 R213
FUEL
TANK
PRESSURE
SENSOR
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
3 4
5 6
1 2
7 8
1 2 3
4 5 6 7 8
ARRANGEMENT
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
Step Check Yes No
securely?
cap securely.
NOTE:
Disconnection, leakage and clogging of air
ventilation hoses and pipes between fuel filler
pipe and fuel tank
vacuum line?
Repair or replace
the hoses and
pipes.
Replace the fuel
tank pressure sen-
sor. <Ref. to
EC(H4DOTC)-14,
Fuel Tank Pres-
sure Sensor.>
BP:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR LOW INPUT
TROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05095
B83
31 2
2
2
3
2
3
0
ECM B135
R47
R213
R15
R1
B97
B97
1 2 3
R47
B135
74 6
6
1
3
1
7
B83 R213
FUEL
TANK
PRESSURE
SENSOR
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
3 4
5 6
1 2
7 8
1 2 3
4 5 6 7 8
ARRANGEMENT
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
7.45 kPa (55.89 mmHg,
2.2003 inHg) ?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
POWER SOURCE.
pressure sensor.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel tank
pressure sensor
connector
Poor contact in
ECM connector
Poor contact of
coupling connector
TOR.
tor.
(B135) No. 32 (R47) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel tank
pressure sensor
connector
Poor contact of
coupling connector
TOR.
chassis ground.
more?
ness between
ECM and fuel tank
pressure sensor
connector.
sor connector?
Repair the poor
contact in the ECM
or fuel tank pres-
sure sensor con-
nector.
Replace the fuel
tank pressure sen-
sor. <Ref. to
EC(H4DOTC)-14,
Fuel Tank Pres-
sure Sensor.>
BQ:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR HIGH INPUT
TROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05095
B83
31 2
2
2
3
2
3
0
ECM B135
R47
R213
R15
R1
B97
B97
1 2 3
R47
B135
74 6
6
1
3
1
7
B83 R213
FUEL
TANK
PRESSURE
SENSOR
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
3 4
5 6
1 2
7 8
1 2 3
4 5 6 7 8
ARRANGEMENT
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
(59.86 mmHg, 2.357 inHg) or
more?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
TOR.
pressure sensor.
eral scan tool.
NOTE:
tor.>
General scan tool
(59.86 mmHg, 2.357 inHg) or
more?
Repair the short
circuit to power in
the harness
between ECM and
fuel tank pressure
sensor connector.
Go to step 3.
TOR.
ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel tank
pressure sensor
connector
Poor contact in
ECM connector
Poor contact of
coupling connector
sensor connector.
Repair the poor
contact in fuel tank
pressure sensor
connector.
Replace the fuel
tank pressure sen-
sor. <Ref. to
EC(H4DOTC)-14,
Fuel Tank Pres-
sure Sensor.>
BR:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK
DETECTED (VERY SMALL LEAK)
TROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
TROUBLE SYMPTOM:
Fuel odor
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
Step Check Yes No
NOTE:
tightening.
securely?
cap securely.
genuine fuel filler
cap.
filler pipe?
Repair or replace
the fuel filler cap
<Ref. to
FU(H4DOTC)-59,
Fuel Filler Pipe.>
Go to step 4.
Select Monitor.
NOTE:
Drain valve can be operated using the Subaru
Select Monitor. Regarding the procedures, re-
fer to Compulsory Valve Operation Check
Mode. <Ref. to EN(H4DOTC)(diag)-57, Com-
pulsory Valve Operation Check Mode.>
valve. <Ref. to
EC(H4DOTC)-18,
Drain Valve.>
VALVE.
NOTE:
noid valve operate?
control solenoid
valve. <Ref. to
EC(H4DOTC)-8,
Purge Control
Solenoid Valve.>
VALVE.
NOTE:
noid valve operate?
sure control sole-
EC(H4DOTC)-15,
Pressure Control
Solenoid Valve.>
TROL SYSTEM LINE.
tor.
oration line?
Repair or replace
the evaporation
line. <Ref. to
FU(H4DOTC)-69,
Fuel Delivery,
Return and Evapo-
ration Lines.>
Go to step 8.
Repair or replace
the canister. <Ref.
to EC(H4DOTC)-7,
Canister.>
Go to step 9.
9 CHECK FUEL TANK.
52, Fuel Tank.>
Repair or replace
to FU(H4DOTC)-
52, Fuel Tank.>
Go to step 10.
TROL SYSTEM.
Repair or replace
the hoses or pipes.
Repair the poor
contact of the ECM
connector.
Step Check Yes No
BS:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK
DETECTED (FUEL CAP LOOSE/OFF)
TROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
TROUBLE SYMPTOM:
Fuel odor
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
Step Check Yes No
NOTE:
tightening.
securely?
cap securely.
genuine fuel filler
cap.
filler pipe?
Repair or replace
the fuel filler cap
<Ref. to
FU(H4DOTC)-59,
Fuel Filler Pipe.>
Go to step 4.
Select Monitor.
NOTE:
valve. <Ref. to
EC(H4DOTC)-18,
Drain Valve.>
VALVE.
NOTE:
noid valve operate?
control solenoid
valve. <Ref. to
EC(H4DOTC)-8,
Purge Control
Solenoid Valve.>
VALVE.
NOTE:
noid valve operate?
sure control sole-
EC(H4DOTC)-15,
Pressure Control
Solenoid Valve.>
TROL SYSTEM LINE.
tor.
Is there any disconnection,
damage or clogging on the
evaporation line?
Repair or replace
the evaporation
line. <Ref. to
FU(H4DOTC)-69,
Fuel Delivery,
Return and Evapo-
ration Lines.>
Go to step 8.
the canister. <Ref.
to EC(H4DOTC)-7,
Canister.>
Go to step 9.
9 CHECK FUEL TANK.
52, Fuel Tank.>
to FU(H4DOTC)-
52, Fuel Tank.>
Go to step 10.
TROL SYSTEM.
system?
Repair or replace
the hoses or pipes.
Repair the poor
contact of the ECM
connector.
Step Check Yes No
BT:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT LOW
TEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
Step Check Yes No
chassis ground.
contact of the ECM
connector.
Go to step 2.
ground.
more?
ness between
ECM and purge
control solenoid
valve connector.
(B137) No. 29 (E4) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and purge
control solenoid
valve connector
Poor contact of
coupling connector
VALVE.
Terminals
No. 1 No. 2:
100 ?
control solenoid
valve. <Ref. to
EC(H4DOTC)-8,
Purge Control
Solenoid Valve.>
contact of purge
control solenoid
valve connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the main relay and
purge control sole-
noid valve
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
BU:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT HIGH
TEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
BV:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-171, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT
CAUTION:
BW:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW
NOTE:
For the diagnostic procedure, refer to DTC P0463. <Ref. to EN(H4DOTC)(diag)-241, DTC P0463 FUEL LEV-
EL SENSOR A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Step Check Yes No
chassis ground.
circuit to power in
the harness
between the ECM
and purge control
solenoid valve con-
nector.
Go to step 2.
VALVE.
Terminals
No. 1 No. 2:
control solenoid
valve. <Ref. to
EC(H4DOTC)-8,
Purge Control
Solenoid Valve.>
Repair the poor
contact of the ECM
connector.
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Replace the fuel
level sensor and
fuel sub level sen-
sor. <Ref. to
FU(H4DOTC)-65,
Fuel Level Sen-
sor.> <Ref. to
FU(H4DOTC)-66,
Fuel Sub Level
Sensor.>
BX:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-175, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT
CAUTION:
BY:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-177, DTC P0464 FUEL LEVEL SENSOR CIRCUIT IN-
CAUTION:
Step Check Yes No
Monitor?
Check the combi-
nation meter. <Ref.
to IDI-13, CHECK
FUEL LEVEL
SENSOR,
INSPECTION,
Combination Meter
System.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Step Check Yes No
display?
Check the combi-
nation meter. <Ref.
to IDI-13, CHECK
FUEL LEVEL
SENSOR,
INSPECTION,
Combination Meter
System.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
BZ:DTC P0500 VEHICLE SPEED SENSOR A
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-180, DTC P0500 VEHICLE SPEED SENSOR A, Di-
CAUTION:
Step Check Yes No
1 CHECK DTC OF ABS.
Check DTC of ABS.
nosis according to
DTC. <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Repair poor con-
tact of the ECM
connector.
CA:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-182, DTC P0506 IDLE AIR CONTROL SYSTEM RPM
TROUBLE SYMPTOM:
Hard to start the engine.
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05673
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4 5 6
E57 B47
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
4
0
3
4
3
5
3
7
E2
B21
C
2
1
C
1
A
2
9
6
A
1
8
C
6
A
2
8
6 4
2
5
*
*
B122
2
4
E
3
8
3
9
2
8
D
5
D
4
A
1
9
A
5
D
7
D
1
D
2
D
3
3
E57
2 1 5
B134
B362
B47
5
7
6
A: B137 B136 D: C:
*
E
SBF-7
8
6 4
E
3 4
1 2
5 6
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
Replace the air
cleaner element.
<Ref. to
IN(H4DOTC)-7, Air
Cleaner Element.>
Go to step 3.
TROL.
1) Remove the electronic throttle control. <Ref.
to FU(H4DOTC)-11, REMOVAL, Throttle
Body.>
Remove foreign
matter from elec-
trol.
Perform the diag-
nosis of DTC
P2101. <Ref. to
EN(H4DOTC)(diag
)-320, DTC P2101
THROTTLE
ACTUATOR CON-
TROL MOTOR
CIRCUIT RANGE/
PERFORMANCE,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
CB:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-184, DTC P0507 IDLE AIR CONTROL SYSTEM RPM
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
EN-05673
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4 5 6
E57 B47
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
4
0
3
4
3
5
3
7
E2
B21
C
2
1
C
1
A
2
9
6
A
1
8
C
6
A
2
8
6 4
2
5
*
*
B122
2
4
E
3
8
3
9
2
8
D
5
D
4
A
1
9
A
5
D
7
D
1
D
2
D
3
3
E57
2 1 5
B134
B362
B47
5
7
6
A: B137 B136 D: C:
*
E
SBF-7
8
6 4
E
3 4
1 2
5 6
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
throttle body
body gasket
system?
Repair air suction
and leaks.
Go to step 3.
TROL.
2) Remove the electronic throttle control. <Ref.
to FU(H4DOTC)-11, REMOVAL, Throttle
Body.>
Remove foreign
matter from elec-
trol.
Perform the diag-
nosis of DTC
P2101. <Ref. to
EN(H4DOTC)(diag
)-320, DTC P2101
THROTTLE
ACTUATOR CON-
TROL MOTOR
CIRCUIT RANGE/
PERFORMANCE,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
CC:DTC P0512 STARTER REQUEST CIRCUIT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-186, DTC P0512 STARTER REQUEST CIRCUIT, Di-
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
EN-05680
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
No.21
B225
B106
MAIN SBF SBF-6
E
1
5
1
3
1
6
1
4
B136
B136
B72 B226
2
0
3
2
B72
B14
3 2
M
1 3
4 5 6
2
B106
1
2
B226
1
1
1
0
MT
AT
B225
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
1
2
AT MT
AT MT
2
3
1 7 8 9
4
6
5 11
10
IGNITION
SWITCH
BATTERY
CLUTCH
SWITCH
INHIBITOR
RELAY
STARTER
RELAY
STARTER MOTOR
ECM
: AT MODEL
: MT MODEL
CD:DTC P0600 SERIAL COMMUNICATION LINK
NOTE:
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
NITION SWITCH.
chassis ground.
circuit to power in
the harness
between ECM and
ignition switch.
Repair the poor
contact of the ECM
connector.
CE:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY
(RAM) ERROR
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-190, DTC P0604 INTERNAL CONTROL MODULE
RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05666
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
SBF-6 MAIN SBF
SBF-7
B72
A
7
B
2
C
2
3
D
2
A
5
D
3
B
5
B
1
9
No.12 B47
E2
B21
1
2
4
6
5
3
E
E
B134
B135
A:
C: B136
D: B137
B:
3
5
3
4
4
0
3 4
1 2
5 6
B47
No.13
D
7
3
6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B72
1 3
4 5 6
2
A: B:
D:
SBF-5
D
1
3
7
3 1
MAIN RELAY
TO OXYGEN SENSOR
IGNITION
SWITCH BATTERY
ECM
CF:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)
ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4DOTC)(diag)-251, DTC P0607 CONTROL
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
CG:DTC P0607 CONTROL MODULE PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-192, DTC P0607 CONTROL MODULE PERFOR-
MANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05681
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135 B: B134 A: B137 B136 D: C:
E
3
8
3
9
2
8
6
2
4
2
5
*
*
E2
B21
E57
46 123 5
D
4
D
5
A
2
9
A
1
9
D
7
A
5
D
2
D
1
D
3
3
5
3
4
3
7
4
0
3
6
A
2
8
C
6
A
1
8
B21 B72 E57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
B122
1 2 3 4
5 6 7 8
1 2
3 4
5 6
B47
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B136 C:
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
B137 D:
1 2 3 4 5 6
B122
*
B134 A:
4 5 6 7
8
2 1
9
3
10 11 12 13 16 17
26 27
28
18 19
20 21 22 23
34 35 29 30 31
25
14 15
24
33 32
B135 B:
SBF-6 MAIN SBF
SBF-7
B72
A
7
B
2
C
2
3
B
5
B
1
9
No.12
B47
1
2
4
6
5
3
E
No.13
SBF-5
1 3
E
1 3
4 5 6
2
MAIN RELAY
TO OXYGEN SENSOR
ECM
IGNITION
SWITCH
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
CH:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE
(BANK 1)
NOTE:
For the diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4DOTC)(diag)-320, DTC P2101 THROT-
TLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Di-
agnostic Trouble Code (DTC).>
CI: DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
NOTE:
CJ:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)
NOTE:
Step Check Yes No
chassis ground.
of power supply
circuit.
chassis ground.
of power supply
circuit.
(B134) No. 19 (E57) No. 5:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
chassis ground.
contact of the ECM
connector.
Repair the follow-
ing item.
Further tighten-
ing of the engine
ground terminal
Poor contact of
coupling connector
CK:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-199, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05682
3
1
B128
B128
T9
1
B55
B136
B122
11 B55
6
1
3 4
2
T12
1 2 3 4
5 6 7 8
B122
*
*
*
3
T12
1 2
T12 1
AT
MT
6M
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
5M
5M :
T12 6M :
2 1
1 2
M
T
AT
2
M
T
6M
6M
5
M
5
M
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
ECM
TCM
NEUTRAL
POSITION
SWITCH
NEUTRAL
POSITION
SWITCH
: AT MODEL
: MT MODEL
: 5MT MODEL
: 6MT MODEL
ARRANGEMENT
CL:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)
NOTE:
Step Check Yes No
2) Place the shift lever in a position except for
neutral.
chassis ground.
contact of the ECM
connector.
Go to step 2.
NEUTRAL POSITION SWITCH CONNEC-
TOR.
chassis ground.
more?
Repair the short
sion harness, or
replace the neutral
position switch.
Repair the ground
ness between
ECM and transmis-
sion harness con-
nector.
CM:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-202, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EN-05682
3
1
B128
B128
T9
1
B55
B136
B122
11 B55
6
1
3 4
2
T12
1 2 3 4
5 6 7 8
B122
*
*
*
3
T12
1 2
T12 1
AT
MT
6M
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
5M
5M :
T12 6M :
2 1
1 2
M
T
AT
2
M
T
6M
6M
5
M
5
M
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
ECM
TCM
NEUTRAL
POSITION
SWITCH
NEUTRAL
POSITION
SWITCH
: AT MODEL
: MT MODEL
: 5MT MODEL
: 6MT MODEL
ARRANGEMENT
Step Check Yes No
chassis ground.
contact of the ECM
connector.
Go to step 2.
(B136) No. 31 (B128) No. 1:
circuit of harness
between ECM and
transmission har-
ness connector.
(B128) No. 3 (B136) No. 6:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and trans-
mission harness
connector
Poor contact of
coupling connector
4 CHECK NEUTRAL SWITCH.
sion harness connector terminals.
(T9) No. 1 No. 3:
contact of trans-
mission harness
connector.
Repair the open
sion harness, or
replace the neutral
switch.
CN:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1
SENSOR1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-204, DTC P1152 O2 SENSOR CIRCUIT RANGE/
PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05669
SBF-5
B47
B21
E2
B21
E2
1
2
4
6
3
5
E
E
C
2
C
3
B
8
B
9
B
1
B134
4
3 21
E79
3 4
1 2
3 4
1 2
5 6
B21
B47
E79
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
B138
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B:
D:
1 2 3 4
5 6 7 8
B138
4
2
2
6
4
3
1
5
MAIN RELAY
BATTERY
FRONT
OXYGEN (A/F)
SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
(B135) No. 9 (E79) No. 1:
(B135) No. 8 (E79) No. 3:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
connector.
tor?
Repair the poor
oxygen (A/F) sen-
sor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>
CO:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1
SENSOR1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-207, DTC P1153 O2 SENSOR CIRCUIT RANGE/
PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05669
SBF-5
B47
B21
E2
B21
E2
1
2
4
6
3
5
E
E
C
2
C
3
B
8
B
9
B
1
B134
4
3 21
E79
3 4
1 2
3 4
1 2
5 6
B21
B47
E79
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
B138
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B:
D:
1 2 3 4
5 6 7 8
B138
4
2
2
6
4
3
1
5
MAIN RELAY
BATTERY
FRONT
OXYGEN (A/F)
SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
CP:DTC P1160 RETURN SPRING FAILURE
NOTE:
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
1) Connect the connector to ECM.
chassis ground.
ground.
oxygen (A/F) sen-
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>
ground.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
nector. After repair,
replace the ECM.
<Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
Repair poor con-
tact of the ECM
connector.
CQ:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT
LOW
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-212, DTC P1400 FUEL TANK PRESSURE CONTROL
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
Step Check Yes No
chassis ground.
contact of the ECM
connector.
Go to step 2.
more?
ness between
ECM and pressure
control solenoid
valve connector.
nector.
(B136) No. 28 (R68) No. 2:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and pressure
control solenoid
valve connector
Poor contact of
coupling connector
VALVE.
Terminals
No. 1 No. 2:
100 ?
sure control sole-
EC(H4DOTC)-15,
Pressure Control
Solenoid Valve.>
contact of pressure
control solenoid
valve connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
main relay and
pressure control
solenoid valve
connector
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
CR:DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
STUCK OPEN
TEM SWITCHING VALVE STUCK OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
VALVE.
1) Remove the secondary air combination
valve. <Ref. to EC(H4DOTC)-21, Secondary Air
Combination Valve.>
2) Blow in air from the secondary air combina-
tion valve air inlet, and check whether there are
leaks at the pipe connections.
Are there air leaks from the pipe
connections?
Replace the sec-
ondary air combi-
nation valve on the
side with the air
leak. <Ref. to
EC(H4DOTC)-21,
Secondary Air
Combination
Valve.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
CS:DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT
SHORTED
TEM CONTROL A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
and secondary air pump relay.
chassis ground.
circuit to power in
the harness
between ECM and
secondary air
pump relay.
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the failure,
and then perform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector
may be the cause.
CT:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-217, DTC P1420 FUEL TANK PRESSURE CONTROL
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
Step Check Yes No
chassis ground.
circuit to power in
the harness
between ECM and
pressure control
solenoid valve con-
nector.
Go to step 2.
VALVE.
Terminals
No. 1 No. 2:
sure control sole-
EC(H4DOTC)-15,
Pressure Control
Solenoid Valve.>
Repair the poor
contact of the ECM
connector.
CU:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-219, DTC P1443 VENT CONTROL SOLENOID
VALVE FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
2 CHECK DRAIN HOSE.
hose?
Replace the drain
hose.
Go to step 3.
drivers side).
NOTE:
contact of the ECM
connector.
Replace the drain
valve. <Ref. to
EC(H4DOTC)-18,
Drain Valve.>
CV:DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION
PROBLEM
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-221, DTC P1491 POSITIVE CRANKCASE VENTILA-
TION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05683
E80
1 2
A
3
0
D
6
D
2
6
4
5
4
1
B21
E2
B137 D:
B134 A:
D:
A:
B137
B134
B21
E80
1 2
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
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 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
ECM
PCV HOSE
ASSY
Step Check Yes No
1 CHECK BLOW-BY HOSE.
Check the blow-by hose condition.
Is there any disconnection or
crack in blow-by hose?
Repair or replace
the blow-by hose.
Go to step 2.
PCV HOSE ASSEMBLY.
and PCV hose assembly.
ECM and PCV hose assembly.
(B134) No. 30 (E80) No. 2:
circuit of harness
between ECM and
PCV hose assem-
bly.
PCV HOSE ASSEMBLY.
Measure the resistance between PCV hose
assembly and chassis ground.
more?
ness between
ECM and PCV
hose assembly.
4 CHECK GROUND CIRCUIT OF PCV HOSE
ASSEMBLY.
PCV hose assembly and engine ground.
circuit of harness
between PCV hose
assembly and
engine ground.
5 CHECK THE PCV HOSE ASSEMBLY.
Measure the resistance between the PCV hose
assembly terminals.
Terminals
No. 1 No. 2:
contact in ECM
and PCV hose
assembly connec-
tor.
Replace the PCV
hose assembly.
CW:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-223, DTC P1560 BACK-UP VOLTAGE CIRCUIT MAL-
CAUTION:
WIRING DIAGRAM:
EN-05666
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
SBF-6 MAIN SBF
SBF-7
B72
A
7
B
2
C
2
3
D
2
A
5
D
3
B
5
B
1
9
No.12 B47
E2
B21
1
2
4
6
5
3
E
E
B134
B135
A:
C: B136
D: B137
B:
3
5
3
4
4
0
3 4
1 2
5 6
B47
No.13
D
7
3
6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B72
1 3
4 5 6
2
A: B:
D:
SBF-5
D
1
3
7
3 1
MAIN RELAY
TO OXYGEN SENSOR
IGNITION
SWITCH BATTERY
ECM
Step Check Yes No
chassis ground.
tact of the ECM
connector.
Go to step 2.
chassis ground.
more?
ness between
ECM and battery
terminal.
3 CHECK FUSE NO. 13. Is the fuse blown out? Replace the fuse. Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and battery
Poor contact in
ECM connector
Poor contact of
battery terminal
CX:DTC P1602 CONTROL MODULE PROGRAMMING ERROR
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-225, DTC P1602 CONTROL MODULE PROGRAM-
MING ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05668
E
#4
1 2
SBF-7
#3
1 2
#2
1 2
B21
#1
1 2
4
8
5
4
5
3
5
2
5
1
89
1
0
1
1
1 2
5
3
6
4
2
1
B21 B137
E5
E5
E2
E6
E6
E16
E16
E17
B47
E17
B47
3 4
1 2
5 6
B137
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
MAIN RELAY
ECM
BATTERY
FUEL INJECTOR
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
engine oil?
<Ref. to
LU(H4SO)-9,
REPLACEMENT,
Engine Oil.>
on exhaust system?
Repair the exhaust
system.
Go to step 4.
EN-05673
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4 5 6
E57 B47
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
4
0
3
4
3
5
3
7
E2
B21
C
2
1
C
1
A
2
9
6
A
1
8
C
6
A
2
8
6 4
2
5
*
*
B122
2
4
E
3
8
3
9
2
8
D
5
D
4
A
1
9
A
5
D
7
D
1
D
2
D
3
3
E57
2 1 5
B134
B362
B47
5
7
6
A: B137 B136 D: C:
*
E
SBF-7
8
6 4
E
3 4
1 2
5 6
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
intake system?
Repair the air
intake system.
Go to step 5.
WARNING:
working area.
CAUTION:
Measure the fuel pressure while disconnecting
pressure regulator vacuum hose from intake
manifold. <Ref. to ME(H4DOTC)-24, INSPEC-
TION, Fuel Pressure.>
CAUTION:
NOTE:
pressure again.
314 kPa (2.9 3.2 kg/cm
2
, 41
46 psi)?
ing item.
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
sure.>
CAUTION:
NOTE:
pressure again.
260 kPa (2.35 2.65 kg/cm
2
,
33 38 psi)?
ing item.
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
SENSOR.
NOTE:
tor.>
General scan tool
engine coolant
temperature sen-
sor. <Ref. to
FU(H4DOTC)-25,
Engine Coolant
Temperature Sen-
sor.>
Step Check Yes No
TEMPERATURE SENSOR.
(158F).
NOTE:
tor.>
General scan tool
5.0 g/s (0.26 0.66 lb/m)?
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
TEMPERATURE SENSOR.
(158F).
NOTE:
tor.>
General scan tool
(18 90F)?
flow and intake air
temperature sen-
sor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Step Check Yes No
FUEL INJECTOR.
cylinders.
more?
ness between
ECM and fuel
injector.
FUEL INJECTOR.
#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:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel in-
jector connector
Poor contact of
coupling connector
Terminals
No. 1 No. 2:
20 ?
to FU(H4DOTC)-
32, Fuel Injector.>
contact of all con-
nectors in fuel
injector circuit.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the main relay and
fuel injector con-
nector on faulty
cylinders
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
Poor contact of
fuel injector con-
nector on faulty
cylinders
Step Check Yes No
FUEL INJECTOR.
circuit to power in
the harness
between the ECM
and fuel injector.
Go to step 16.
Terminals
No. 1 No. 2:
to FU(H4DOTC)-
32, Fuel Injector.>
Go to step 17.
SENSOR.
loosely installed?
Tighten the cam-
shaft position sen-
sor or crankshaft
position sensor.
Go to step 18.
Replace the crank
sprocket. <Ref. to
ME(H4DOTC)-52,
Crank Sprocket.>
Go to step 19.
TIMING BELT.
der block.
tion condition of
ME(H4DOTC)-42,
Timing Belt.>
Go to step 20.
TROL RELAY.
Terminals
No. 7 No. 8:
trol relay. <Ref. to
FU(H4DOTC)-48,
Electronic Throttle
Control Relay.>
of power supply
circuit.
LAY.
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 23.
Step Check Yes No
LAY.
ground.
more?
ness between
ECM and elec-
trol relay.
LAY.
(B136) No. 21 (B362) No. 6:
(B136) No. 1 (B362) No. 8:
circuit of harness
between ECM and
electronic throttle
control relay.
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
more?
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
Step Check Yes No
1) Connect the ECM.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 30.
nectors.
(B134) No. 19 (B134) No. 18:
(B134) No. 19 (B134) No. 28:
more?
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
NOTE:
tor.>
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4DOTC)-11,
Throttle Body.>
NOTE:
tor.>
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4DOTC)-11,
Throttle Body.>
Step Check Yes No
TOR.
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
circuit of harness
between ECM and
electronic throttle
control.
TOR.
circuit to power in
the harness
between the ECM
and electronic
throttle control.
Go to step 35.
TOR.
more?
ness between the
ECM and elec-
trol.
TROL MOTOR HARNESS.
(E57) No. 2 (E57) No. 1:
more?
circuit of harness
between ECM and
electronic throttle
control.
chassis ground.
circuit of the har-
ness between the
ECM and engine
ground.
TROL.
Terminals
No. 1 No. 2:
trol. <Ref. to
FU(H4DOTC)-11,
Throttle Body.>
TROL.
closed position
Repair the poor
contact of the ECM
connector.
Replace the elec-
trol. <Ref. to
FU(H4DOTC)-11,
Throttle Body.>
Step Check Yes No
CY:DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-227, DTC P2004 INTAKE MANIFOLD RUNNER CON-
TROL STUCK OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
CZ:DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2)
TROL STUCK OPEN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
2 CHECK TUMBLE GENERATOR VALVE RH.
1) Remove the tumble generator valve assem-
bly.
2) Check the tumble generator valve body.
Is there any dirt or clogging with
foreign objects in the tumble
generator valve?
Clean the tumble
generator valve.
Replace the tum-
ble generator valve
assembly. <Ref. to
FU(H4DOTC)-35,
Tumble Generator
Valve Assembly.>
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
2 CHECK TUMBLE GENERATOR VALVE LH.
bly.
generator valve?
Clean the tumble
generator valve.
Replace the tum-
ble generator valve
assembly. <Ref. to
FU(H4DOTC)-35,
Tumble Generator
Valve Assembly.>
DA:DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED
(BANK 1)
TROL STUCK CLOSED (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
DB:DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED
(BANK 2)
TROL STUCK CLOSED (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
2 CHECK TUMBLE GENERATOR VALVE RH.
bly.
generator valve?
Clean the tumble
generator valve.
Replace the tum-
ble generator valve
assembly. <Ref. to
FU(H4DOTC)-35,
Tumble Generator
Valve Assembly.>
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
2 CHECK TUMBLE GENERATOR VALVE LH.
bly.
generator valve?
Clean the tumble
generator valve.
Replace the tum-
ble generator valve
assembly. <Ref. to
FU(H4DOTC)-35,
Tumble Generator
Valve Assembly.>
DC:DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN
(BANK 1)
TROL CIRCUIT / OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05684
E55 B21
E2
E55
B21
B137
2
3
2
2
8
1
9
54
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
1 3 2
4 5
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
TUMBLE GENERATOR
VALVE ASSY RH
(WITH BUILT-IN SENSOR)
ECM
Step Check Yes No
TUMBLE GENERATOR VALVE ASSEMBLY
CONNECTOR.
and tumble generator valve assembly.
ECM and tumble generator valve assembly.
(B137) No. 22 (E55) No. 5:
(B137) No. 23 (E55) No. 4:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and tumble
generator valve
assembly connec-
tor
Poor contact of
coupling connector
CONNECTOR.
chassis ground.
more?
ness between
ECM and tumble
generator valve
assembly connec-
tor.
Check for poor contact of tumble generator
valve assembly connector.
Is there poor contact in the tum-
ble generator valve assembly
connector?
Repair the poor
contact of tumble
generator valve
assembly connec-
tor.
Replace the tum-
ble generator valve
assembly. <Ref. to
FU(H4DOTC)-36,
Tumble Generator
Valve Actuator.>
DD:DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW
(BANK 1)
TROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05684
E55 B21
E2
E55
B21
B137
2
3
2
2
8
1
9
54
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
1 3 2
4 5
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
TUMBLE GENERATOR
VALVE ASSY RH
ECM
Step Check Yes No
CONNECTOR.
chassis ground.
circuit to power in
the harness
between ECM and
tumble generator
valve assembly.
Replace the tum-
ble generator valve
assembly. <Ref. to
FU(H4DOTC)-36,
Tumble Generator
Valve Actuator.>
DE:DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN
(BANK 2)
TROL CIRCUIT / OPEN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05685
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
E2
E51
B21
B137
1
3
1
2
2
9
3
0
54
E51 B21
1 2 3 4 5 6 7 8 9 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
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
1 3 2
4 5
TUMBLE GENERATOR
VALVE ASSY LH
ECM
Step Check Yes No
CONNECTOR.
and tumble generator valve assembly.
ECM and tumble generator valve assembly.
(B137) No. 12 (E51) No. 5:
(B137) No. 13 (E51) No. 4:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and tumble
generator valve
assembly connec-
tor
Poor contact of
coupling connector
CONNECTOR.
chassis ground.
more?
ness between
ECM and tumble
generator valve
assembly connec-
tor.
Check for poor contact of tumble generator
valve assembly connector.
ble generator valve assembly
connector?
Repair the poor
contact of tumble
generator valve
assembly connec-
tor.
Replace the tum-
ble generator valve
assembly. <Ref. to
FU(H4DOTC)-36,
Tumble Generator
Valve Actuator.>
DF:DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW
(BANK 2)
TROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05685
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
E2
E51
B21
B137
1
3
1
2
2
9
3
0
54
E51 B21
1 2 3 4 5 6 7 8 9 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
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
1 3 2
4 5
TUMBLE GENERATOR
VALVE ASSY LH
ECM
Step Check Yes No
CONNECTOR.
chassis ground.
circuit to power in
the harness
between ECM and
tumble generator
valve assembly.
Replace the tum-
ble generator valve
assembly. <Ref. to
FU(H4DOTC)-36,
Tumble Generator
Valve Actuator.>
DG:DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH
CIRCUIT LOW (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-239, DTC P2016 INTAKE MANIFOLD RUNNER PO-
SITION SENSOR / SWITCH CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05686
E55
1 2 3
4 5
B21
E2
B21
312
B134
1
9
2
9
2
6
2
8
6
1
6
E55
1 2 3 4 5 6 7 8 9 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
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
TUMBLE GENERATOR
VALVE ASSY RH
POSITION SENSOR
ECM
Step Check Yes No
2) Read the data of tumble generator valve
position sensor signal using Subaru Select
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
2 CHECK POWER SUPPLY OF TUMBLE GEN-
ERATOR VALVE POSITION SENSOR.
2) Disconnect the connector from tumble gen-
erator valve position sensor.
4) Measure the voltage between tumble gener-
ator valve position sensor connector and engine
ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and tumble
generator valve
position sensor
connector
Poor contact in
ECM connector
Poor contact of
coupling connector
TUMBLE GENERATOR VALVE POSITION
SENSOR CONNECTOR.
ECM and tumble generator valve position sen-
sor connector.
(B134) No. 26 (E55) No. 1:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and tumble
generator valve
position sensor
connector
Poor contact of
coupling connector
SENSOR CONNECTOR.
chassis ground.
more?
ness between
ECM and tumble
generator valve
position sensor
connector.
Check for poor contact in ECM and tumble gen-
erator valve position sensor connector.
and tumble generator valve
position sensor connector?
Repair the poor
contact in ECM or
tumble generator
valve position sen-
sor connector.
Replace the tum-
ble generator valve
position sensor.
<Ref. to
FU(H4DOTC)-37,
Tumble Generator
Valve Position
Sensor.>
DH:DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH
CIRCUIT HIGH (BANK 1)
SITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05686
E55
1 2 3
4 5
B21
E2
B21
312
B134
1
9
2
9
2
6
2
8
6
1
6
E55
1 2 3 4 5 6 7 8 9 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
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
TUMBLE GENERATOR
VALVE ASSY RH
POSITION SENSOR
ECM
Step Check Yes No
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
SENSOR CONNECTOR.
NOTE:
tor.>
General scan tool
circuit to power in
the harness
between ECM and
tumble generator
valve position sen-
sor connector.
Go to step 3.
SENSOR CONNECTOR.
tumble generator valve position sensor connec-
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and tumble
generator valve
position sensor
connector
Poor contact in
ECM connector
Poor contact of
coupling connector
Check for poor contact in the tumble generator
valve position sensor connector.
ble generator valve position
sensor connector?
Repair the poor
contact of the tum-
ble generator valve
position sensor
connector.
Replace the tum-
ble generator valve
position sensor.
<Ref. to
FU(H4DOTC)-37,
Tumble Generator
Valve Position
Sensor.>
DI: DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH
SITION SENSOR / SWITCH CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05687
E51
B21
E2
B21
312
B134
1
9
2
9
1
6
2
8
6
2
7
E51
1 2 3 4 5 6 7 8 9 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
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3
4 5
POSITION SENSOR
TUMBLE GENERATOR
VALVE ASSY LH
ECM
Step Check Yes No
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
2 CHECK POWER SUPPLY OF TUMBLE GEN-
ERATOR VALVE POSITION SENSOR.
4) Measure the voltage between tumble gener-
ator valve position sensor connector and engine
ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and tumble
generator valve
position sensor
connector
Poor contact in
ECM connector
Poor contact of
coupling connector
SENSOR CONNECTOR.
ECM and tumble generator valve position sen-
sor connector.
(B134) No. 16 (E51) No. 1:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and tumble
generator valve
position sensor
connector
Poor contact of
coupling connector
SENSOR CONNECTOR.
chassis ground.
more?
ness between
ECM and tumble
generator valve
position sensor
connector.
Check for poor contact in ECM and tumble gen-
erator valve position sensor connector.
and tumble generator valve
position sensor connector?
Repair the poor
contact in ECM or
tumble generator
valve position sen-
sor connector.
Replace the tum-
ble generator valve
position sensor.
<Ref. to
FU(H4DOTC)-37,
Tumble Generator
Valve Position
Sensor.>
DJ:DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH
SITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05687
E51
B21
E2
B21
312
B134
1
9
2
9
1
6
2
8
6
2
7
E51
1 2 3 4 5 6 7 8 9 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
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3
4 5
POSITION SENSOR
TUMBLE GENERATOR
VALVE ASSY LH
ECM
Step Check Yes No
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
SENSOR CONNECTOR.
NOTE:
tor.>
General scan tool
circuit to power in
the harness
between ECM and
tumble generator
valve position sen-
sor connector.
Go to step 3.
SENSOR CONNECTOR.
tumble generator valve position sensor connec-
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and tumble
generator valve
position sensor
connector
Poor contact in
ECM connector
Poor contact of
coupling connector
Check for poor contact in the tumble generator
valve position sensor connector.
ble generator valve position
sensor connector?
Repair the poor
contact of the tum-
ble generator valve
position sensor
connector.
Replace the tum-
ble generator valve
position sensor.
<Ref. to
FU(H4DOTC)-37,
Tumble Generator
Valve Position
Sensor.>
DK:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
LOW (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-247, DTC P2088 INTAKE CAMSHAFT POSITION AC-
TUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05688
B21
E2
B137
E38
1
6
2 1
2
2
2
1
E38
B21
1 2
1
7
B137
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
ECM
OIL FLOW CONTROL SOLENOID VALVE RH
Step Check Yes No
FLOW CONTROL SOLENOID VALVE.
oil flow control solenoid valve.
ECM and oil flow control solenoid valve.
(B137) No. 17 (E38) No. 1:
(B137) No. 16 (E38) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
the harness be-
tween the ECM
and oil flow control
solenoid valve
connector
Poor contact of
coupling connector
chassis ground.
more?
ness between
ECM and oil flow
control solenoid
valve connector.
3 CHECK OIL FLOW CONTROL SOLENOID
VALVE.
Measure the resistance between oil flow control
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of the ECM
solenoid valve con-
nector.
Replace the oil
flow control sole-
ME(H4DOTC)-53,
Camshaft.>
DL:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
HIGH (BANK 1)
TUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05688
B21
E2
B137
E38
1
6
2 1
2
2
2
1
E38
B21
1 2
1
7
B137
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
ECM
OIL FLOW CONTROL SOLENOID VALVE RH
Step Check Yes No
chassis ground.
circuit to power in
the harness
between the ECM
solenoid valve con-
nector.
ECM and oil flow control solenoid valve connec-
tor.
(B137) No. 17 (E38) No. 1:
(B137) No. 16 (E38) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
the harness be-
tween the ECM
solenoid valve
connector
Poor contact of
coupling connector
VALVE.
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of the ECM
solenoid valve con-
nector.
Replace the oil
flow control sole-
ME(H4DOTC)-53,
Camshaft.>
DM:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
LOW (BANK 2)
TUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05689
B21
E2
B137
E37
1
4
2 1
3
3
3
2
E37
B21
1 2
1
5
B137
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
ECM
OIL FLOW CONTROL SOLENOID VALVE LH
Step Check Yes No
(B137) No. 15 (E37) No. 1:
(B137) No. 14 (E37) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
the harness be-
tween the ECM
solenoid valve
connector
Poor contact of
coupling connector
chassis ground.
more?
ness between
ECM and oil flow
control solenoid
valve connector.
VALVE.
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of the ECM
solenoid valve con-
nector.
Replace the oil
flow control sole-
ME(H4DOTC)-53,
Camshaft.>
DN:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
HIGH (BANK 2)
TUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05689
B21
E2
B137
E37
1
4
2 1
3
3
3
2
E37
B21
1 2
1
5
B137
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
ECM
OIL FLOW CONTROL SOLENOID VALVE LH
DO:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1
Refer to DTC P2097 for diagnostic procedure. <Ref. to EN(H4DOTC)(diag)-313, DTC P2097 POST CATA-
LYST FUEL TRIM SYSTEM TOO RICH BANK 1, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Step Check Yes No
chassis ground.
circuit to power in
the harness
between the ECM
solenoid valve con-
nector.
tor.
(B137) No. 15 (E37) No. 1:
(B137) No. 14 (E37) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
the harness be-
tween the ECM
solenoid valve
connector
Poor contact of
coupling connector
VALVE.
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of the ECM
solenoid valve con-
nector.
Replace the oil
flow control sole-
ME(H4DOTC)-53,
Camshaft.>
DP:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-253, DTC P2097 POST CATALYST FUEL TRIM SYS-
CAUTION:
WIRING DIAGRAM:
EN-05669
SBF-5
B47
B21
E2
B21
E2
1
2
4
6
3
5
E
E
C
2
C
3
B
8
B
9
B
1
B134
4
3 21
E79
3 4
1 2
3 4
1 2
5 6
B21
B47
E79
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
B138
*
*
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B:
D:
1 2 3 4
5 6 7 8
B138
4
2
2
6
4
3
1
5
MAIN RELAY
BATTERY
FRONT
OXYGEN (A/F)
SENSOR
ECM
ARRANGEMENT
AMONG 1, 2, 5 AND 6
EN-05670
B83
1 2 3 4
5 6 7 8
B138
B47
1
2
4
6
3
5
E
*
* B138
B83
3 4
1 2
5 6
B135
B47
B19
B136
B:
C:
B137 D:
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B19
T5
2
2
T5
B19
3 14
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
T6
SBF-5
*
1
*
2
1
1
*
*
2
2
C
4
B
4
B
3
0
B
1
B134
T6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B135 B:
B136 C:
B137 D:
A:
D
2
A
5
D
3
E2
B21
E
3
5
3
4
4
0
D
7
3
6
D
1
3
7
1 2
3 4
3 14
MAIN RELAY
REAR
OXYGEN SENSOR
BATTERY
ECM
ARRANGEMENT
ARRANGEMENT
AMONG 1, 2, 5 AND 6
Step Check Yes No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
TOR.
tor?
Completely
remove any water
inside.
Go to step 3.
TOR.
(B135) No. 9 (E79) No. 1:
(B135) No. 8 (E79) No. 3:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Poor contact of
coupling connector
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
1) Connect the ECM.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
replace the ECM.
<Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
Repair poor con-
tact of the ECM
connector.
on exhaust system?
Repair the exhaust
system.
Go to step 9.
intake system?
Repair the air
intake system.
Go to step 10.
WARNING:
working area.
CAUTION:
nector.
2) Measure the fuel pressure while discon-
necting pressure regulator vacuum hose from
intake manifold. <Ref. to ME(H4DOTC)-24,
INSPECTION, Fuel Pressure.>
CAUTION:
NOTE:
pressure again.
314 kPa (2.9 3.2 kgf/cm
2
, 41
46 psi)?
ing item.
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
sure.>
CAUTION:
NOTE:
pressure again.
260 kPa (2.35 2.65 kgf/cm
2
,
33 38 psi)?
ing item.
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 Yes No
SENSOR.
NOTE:
tor.>
General scan tool
engine coolant
temperature sen-
sor. <Ref. to
FU(H4DOTC)-25,
Engine Coolant
Temperature Sen-
sor.>
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
5.0 g/s (0.26 0.66 lb/s) ?
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Step Check Yes No
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
(18 90F)?
flow and intake air
temperature sen-
sor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
maximum)
tool.
NOTE:
tor.>
General scan tool
rpm.
tool.
NOTE:
tor.>
General scan tool
Step Check Yes No
tor?
Completely
remove any water
inside.
Go to step 19.
tool.
NOTE:
tor.>
General scan tool
more?
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>
Go to step 19.
rear oxygen sensor.
(B135) No. 4 (T6) No. 3:
(B135) No. 30 (T6) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact in
ECM connector
Poor contact of
coupling connector
Step Check Yes No
DQ:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/
PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-255, DTC P2101 THROTTLE ACTUATOR CONTROL
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05673
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4 5 6
E57 B47
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
4
0
3
4
3
5
3
7
E2
B21
C
2
1
C
1
A
2
9
6
A
1
8
C
6
A
2
8
6 4
2
5
*
*
B122
2
4
E
3
8
3
9
2
8
D
5
D
4
A
1
9
A
5
D
7
D
1
D
2
D
3
3
E57
2 1 5
B134
B362
B47
5
7
6
A: B137 B136 D: C:
*
E
SBF-7
8
6 4
E
3 4
1 2
5 6
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
Step Check Yes No
TROL RELAY.
Terminals
No. 7 No. 8:
FU(H4DOTC)-48,
Electronic Throttle
Control Relay.>
of power supply
circuit.
LAY.
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 4.
LAY.
ground.
more?
ness between
ECM and elec-
trol relay.
LAY.
(B136) No. 21 (B362) No. 6:
(B136) No. 1 (B362) No. 8:
circuit of harness
between ECM and
electronic throttle
control relay.
throttle control.
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
1) Connect the ECM.
more?
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
1) Connect the ECM.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 11.
nectors.
(B134) No. 19 (B134) No. 18:
(B134) No. 19 (B134) No. 28:
more?
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
NOTE:
tor.>
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4DOTC)-11,
Throttle Body.>
Step Check Yes No
NOTE:
tor.>
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4DOTC)-11,
Throttle Body.>
TOR.
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
circuit of harness
between ECM and
electronic throttle
control.
TOR.
1) Connect the ECM.
circuit to power in
the harness
between the ECM
and electronic
throttle control.
Go to step 16.
TOR.
more?
ness between the
ECM and elec-
trol.
TROL MOTOR HARNESS.
(E57) No. 2 (E57) No. 1:
more?
circuit of harness
between ECM and
electronic throttle
control control.
chassis ground.
circuit of the har-
ness between the
ECM and engine
ground.
Step Check Yes No
TROL.
Terminals
No. 2 No. 1:
trol. <Ref. to
FU(H4DOTC)-11,
Throttle Body.>
TROL.
closed position
Repair the poor
contact of the ECM
connector.
Replace the elec-
trol. <Ref. to
FU(H4DOTC)-11,
Throttle Body.>
Step Check Yes No
DR:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EN-05673
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4 5 6
E57 B47
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
4
0
3
4
3
5
3
7
E2
B21
C
2
1
C
1
A
2
9
6
A
1
8
C
6
A
2
8
6 4
2
5
*
*
B122
2
4
E
3
8
3
9
2
8
D
5
D
4
A
1
9
A
5
D
7
D
1
D
2
D
3
3
E57
2 1 5
B134
B362
B47
5
7
6
A: B137 B136 D: C:
*
E
SBF-7
8
6 4
E
3 4
1 2
5 6
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
Step Check Yes No
TROL RELAY.
Terminals
No. 7 No. 8:
FU(H4DOTC)-48,
Electronic Throttle
Control Relay.>
of power supply
circuit.
LAY.
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 4.
LAY.
ground.
more?
ness between
ECM and elec-
trol relay.
LAY.
(B136) No. 21 (B362) No. 6:
(B136) No. 1 (B362) No. 8:
contact of the ECM
connector.
Repair the open
circuit of harness
between ECM and
electronic throttle
control relay.
DS:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
CAUTION:
WIRING DIAGRAM:
EN-05673
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4 5 6
E57 B47
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
4
0
3
4
3
5
3
7
E2
B21
C
2
1
C
1
A
2
9
6
A
1
8
C
6
A
2
8
6 4
2
5
*
*
B122
2
4
E
3
8
3
9
2
8
D
5
D
4
A
1
9
A
5
D
7
D
1
D
2
D
3
3
E57
2 1 5
B134
B362
B47
5
7
6
A: B137 B136 D: C:
*
E
SBF-7
8
6 4
E
3 4
1 2
5 6
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
DT:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP
PERFORMANCE
NOTE:
Step Check Yes No
TROL RELAY.
Terminals
No. 7 No. 8:
more?
FU(H4DOTC)-48,
Electronic Throttle
Control Relay.>
PLY.
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 3.
LAY.
chassis ground.
more?
Repair the poor
contact of the ECM
connector.
Repair the ground
ness between
ECM and elec-
trol relay.
DU:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT
LOW INPUT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-263, DTC P2122 THROTTLE/PEDAL POSITION
SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05690
B315
C: B136
B137 D:
B83
B315
*
*
465132
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
D
2
B21
E2
D
1
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
C:
D:
B122
B83
D
3
A
5
C
6
B: B135
A: B134
D
7
3
7
3
5
3
4
4
0
3
6
B122
1 2 3 4 5 6
*
*
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
E *
ACCELERATOR PEDAL
POSITION SENSOR
ECM
ARRANGEMENT
Step Check Yes No
chassis ground.
(B135) No. 23 (B136) No. 6:
more?
short of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
1) Connect the ECM.
ground.
more?
Replace the accel-
erator pedal. <Ref.
to SP(H4SO)-3,
Accelerator
Pedal.>
Repair the ground
short of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
Replace the ECM if
defective. <Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
DV: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:
EN-05690
B315
C: B136
B137 D:
B83
B315
*
*
465132
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
D
2
B21
E2
D
1
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
C:
D:
B122
B83
D
3
A
5
C
6
B: B135
A: B134
D
7
3
7
3
5
3
4
4
0
3
6
B122
1 2 3 4 5 6
*
*
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
E *
ACCELERATOR PEDAL
POSITION SENSOR
ECM
ARRANGEMENT
Step Check Yes No
connector.
(B135) No. 23 (B315) No. 6:
(B135) No. 29 (B315) No. 5:
circuit of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
1) Connect the ECM.
ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
ground.
circuit to power
source in the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
Go to step 4.
nectors.
(B135) No. 21 (B135) No. 23:
more?
Repair the poor
contact of acceler-
ator pedal position
sensor connector.
Replace the accel-
erator pedal if
defective. <Ref. to
SP(H4SO)-3,
Accelerator
Pedal.>
Repair the short
circuit to power
source in the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
DW: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:
EN-05690
B315
C: B136
B137 D:
B83
B315
*
*
465132
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
D
2
B21
E2
D
1
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
C:
D:
B122
B83
D
3
A
5
C
6
B: B135
A: B134
D
7
3
7
3
5
3
4
4
0
3
6
B122
1 2 3 4 5 6
*
*
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
E *
ACCELERATOR PEDAL
POSITION SENSOR
ECM
ARRANGEMENT
Step Check Yes No
chassis ground.
more?
short of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
1) Connect the ECM.
ground.
more?
Replace the accel-
erator pedal. <Ref.
to SP(H4SO)-3,
Accelerator
Pedal.>
Repair the ground
short of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
Replace the ECM if
defective. <Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
DX: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:
EN-05690
B315
C: B136
B137 D:
B83
B315
*
*
465132
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
D
2
B21
E2
D
1
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
C:
D:
B122
B83
D
3
A
5
C
6
B: B135
A: B134
D
7
3
7
3
5
3
4
4
0
3
6
B122
1 2 3 4 5 6
*
*
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
E *
ACCELERATOR PEDAL
POSITION SENSOR
ECM
ARRANGEMENT
Step Check Yes No
connector.
(B135) No. 31 (B315) No. 3:
(B135) No. 30 (B315) No. 2:
circuit of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
1) Connect the ECM.
ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
ground.
circuit to power
source in the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
Go to step 4.
nectors.
(B135) No. 22 (B135) No. 31:
more?
Repair the poor
contact of acceler-
ator pedal position
sensor connector.
Replace the accel-
erator pedal if
defective. <Ref. to
SP(H4SO)-3,
Accelerator
Pedal.>
Repair the short
circuit to power
source in the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
DY: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:
EN-05673
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 31 32 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4 5 6
E57 B47
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
4
0
3
4
3
5
3
7
E2
B21
C
2
1
C
1
A
2
9
6
A
1
8
C
6
A
2
8
6 4
2
5
*
*
B122
2
4
E
3
8
3
9
2
8
D
5
D
4
A
1
9
A
5
D
7
D
1
D
2
D
3
3
E57
2 1 5
B134
B362
B47
5
7
6
A: B137 B136 D: C:
*
E
SBF-7
8
6 4
E
3 4
1 2
5 6
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
Step Check Yes No
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
1) Connect the ECM.
more?
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
1) Connect the ECM.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 6.
nectors.
(B134) No. 19 (B134) No. 18:
(B134) No. 19 (B134) No. 28:
more?
Repair poor con-
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H4DOTC)-11,
Throttle Body.>
Repair the short
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Step Check Yes No
DZ: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:
EN-05690
B315
C: B136
B137 D:
B83
B315
*
*
465132
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
D
2
B21
E2
D
1
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
C:
D:
B122
B83
D
3
A
5
C
6
B: B135
A: B134
D
7
3
7
3
5
3
4
4
0
3
6
B122
1 2 3 4 5 6
*
*
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
E *
ACCELERATOR PEDAL
POSITION SENSOR
ECM
ARRANGEMENT
Step Check Yes No
SENSOR OUTPUT.
chassis ground.
Main accelerator pedal position sensor
signal
Sub accelerator pedal position sensor
signal
SENSOR OUTPUT.
ground.
Replace the accel-
erator pedal. <Ref.
to SP(H4SO)-3,
Accelerator
Pedal.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and ac-
celerator pedal po-
sition sensor
connector.
Ground short cir-
cuit of harness be-
tween the ECM
and accelerator
pedal position sen-
sor connectors.
CONNECTOR.
and chassis ground.
Is the resistance less than 5 ? Repair poor con-
tact of the ECM
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and ac-
celerator pedal po-
sition sensor
connector.
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
EA:DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE
CONTROL CIRCUIT LOW
TEM SWITCHING VALVE CONTROL CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
Step Check Yes No
chassis ground.
contact of the ECM
connector.
Go to step 2.
PURGE CONTROL SOLENOID VALVE 2.
purge control solenoid valve 2.
control solenoid valve 2 connector and engine
ground.
more?
ness between
ECM and purge
control solenoid
valve 2 connector.
ECM and purge control solenoid valve 2.
(B136) No. 7 (E52) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and purge
control solenoid
valve 2 connector
Poor contact of
coupling connector
VALVE 2.
1) Remove the purge control solenoid valve 2.
trol solenoid valve 2 terminals.
Terminals
No. 1 No. 2:
100 ?
control solenoid
valve 2. <Ref. to
EC(H4DOTC)-8,
Purge Control
Solenoid Valve.>
TROL SOLENOID VALVE 2.
solenoid valve 2 and engine ground.
contact in the
purge control sole-
noid valve 2 con-
nector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the main relay and
purge control sole-
noid valve 2
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
EB:DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE
CONTROL CIRCUIT HIGH
TEM SWITCHING VALVE CONTROL CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
EN-05679
SBF-7
E4
B47
E
5
3
6
4
2
1
2 1
C
1
7
C
2
8
D
2
9
C
7
R15
R213
R68 R144
R1
B97
1
4
1
5
22 11
7
15
E52
2 1
E52
R144 E4
B47
R67 B97 R213
R68
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
B21
E2
1
1
4
8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
4
4
MAIN RELAY
ECM
BATTERY
CONTROL
SOLENOID VALVE
PURGE CONTROL
SOLENOID VALVE 1
PURGE CONTROL
SOLENOID VALVE 2
Step Check Yes No
purge control solenoid valve 2.
chassis ground.
Is the voltage 10 V or more? Repair the short to
power in the har-
ness between
ECM and purge
control solenoid
valve 2 connector.
Go to step 2.
VALVE 2.
trol solenoid valve 2 terminals.
Terminals
No. 1 No. 2:
control solenoid
valve 2. <Ref. to
EC(H4DOTC)-8,
Purge Control
Solenoid Valve.>
Repair the poor
contact of the ECM
connector.
EC:DTC P2431 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE
SENSOR CIRCUIT RANGE/PERFORMANCE
TEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
2) Using the Subaru Select Monitor, read sec-
ondary air piping pressure, intake pipe absolute
pressure and atmospheric pressure, and com-
pare with the actual atmospheric pressure.
NOTE:
tor.>
Is the actual difference with
atmospheric pressure 200
mmHg (27 kPa, 8 inHg, 3.9
psig) or more?
Replace the sec-
ondary air combi-
nation valve RH.
<Ref. to
EC(H4DOTC)-21,
Secondary Air
Combination
Valve.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
ED:DTC P2432 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE
SENSOR CIRCUIT LOW
TEM AIR FLOW /PRESSURE SENSOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
2) Read the data of secondary air pipe pres-
sure signal using the Subaru Select Monitor or
general scan tool.
NOTE:
tor.>
General scan tool
53.3 kPa (400 mmHg, 15.8
inHg) ?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector con-
tact failure.
VALVE RH POWER SOURCE.
2) Disconnect the connector from the second-
ary air combination valve RH.
ary air combination valve RH connector and
chassis ground.
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and second-
ary air combination
valve RH connec-
tor
Poor contact in
ECM connector
Poor contact of
coupling connector
RH CONNECTOR.
between the ECM and secondary air combina-
tion valve RH connector.
(B134) No. 27 (E41) No. 2:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and second-
ary air combination
valve RH connec-
tor
Poor contact of
coupling connector
RH CONNECTOR.
chassis ground.
more?
ness between
ECM and second-
ary air combination
valve RH connec-
tor.
Check for poor contact in the ECM and second-
ary air combination valve RH connector.
ECM or secondary air combi-
nation valve RH connector?
Repair the poor
contact in the ECM
or secondary air
combination valve
RH connector.
Replace the sec-
ondary air combi-
nation valve RH.
<Ref. to
EC(H4DOTC)-21,
Secondary Air
Combination
Valve.>
EE:DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE
SENSOR CIRCUIT HIGH
TEM AIR FLOW /PRESSURE SENSOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
general scan tool.
NOTE:
tor.>
General scan tool
kPa (1000 mmHg, 39.4 inHg) or
more?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
RH CONNECTOR.
general scan tool.
NOTE:
tor.>
General scan tool
kPa (1000 mmHg, 39.4 inHg) or
more?
Repair the short
circuit to power in
the harness
between ECM and
secondary air com-
bination valve RH
connectors.
Go to step 3.
RH CONNECTOR.
between the secondary air combination valve
RH connector and engine ground.
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and second-
ary air combination
valve RH connec-
tor
Poor contact in
ECM connector
Poor contact of
coupling connector
Check for poor contact of the secondary air
combination valve RH connector.
Is there poor contact of the sec-
ondary air combination valve
RH connector?
Repair the poor
contact of the sec-
ondary air combi-
nation valve RH
connector.
Replace the sec-
ondary air combi-
nation valve RH.
<Ref. to
EC(H4DOTC)-21,
Secondary Air
Combination
Valve.>
EF:DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
STUCK OPEN (BANK 1)
TEM SWITCHING VALVE STUCK OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
VALVE FUSE.
Check if the secondary air combination valve
fuse (10 A) is blown out.
AND SECONDARY AIR COMBINATION
VALVE RH.
valve fuse (10 A) from the fuse box.
ondary air combination valve fuse and second-
ary air combination valve RH connector, and
chassis ground.
more?
Replace the fuse
with a new part,
and connect the
secondary air com-
bination valve RH
connector.
Go to step 3.
Repair the ground
ness between the
fuse box and the
secondary air com-
bination valve RH.
VALVE RH OPERATION.
air combination valve RH using the Subaru
Select Monitor.
NOTE:
Mode for more operation procedures. <Ref. to
Does the secondary air combi-
nation valve RH repeatedly
switch to ON and OFF?
PUMP AND SECONDARY AIR COMBINA-
TION VALVE RH.
pump and secondary air combination valve RH.
Replace, clean or
connect the duct.
Go to step 5.
5 CHECK PIPE BETWEEN SECONDARY AIR
COMBINATION VALVE RH AND CYLINDER
HEAD.
Check the pipe between the secondary air com-
bination valve RH and cylinder head.
connection of the pipe?
Replace, clean or
connect the pipe.
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
AIR COMBINATION VALVE RH.
age between the secondary air combination
valve RH and the chassis ground.
Does the voltage repeatedly
change between 10 V and 0 V?
Replace the sec-
ondary air combi-
nation valve RH.
<Ref. to
EC(H4DOTC)-21,
Secondary Air
Combination
Valve.>
Go to step 7.
AIR COMBINATION VALVE RH AND CHAS-
SIS GROUND.
Measure the resistance between the secondary
air combination valve RH connector and chas-
sis ground.
circuit of harness
between second-
ary air combination
valve RH and
chassis ground.
AIR COMBINATION VALVE RELAY 1 AND
RH CONNECTOR.
valve relay 1 from the relay box.
relay 1 and secondary air combination valve RH
connector.
(F9) No. 3 (E41) No. 6:
circuit of the har-
ness between the
secondary air com-
bination valve relay
1 and secondary
air combination
valve RH connec-
tor.
VALVE RELAY 1.
No. 2 of the secondary air combination valve
relay 1.
ondary air combination valve relay 1 terminals.
Terminals
No. 3 No. 4:
ondary air combi-
nation valve relay
1. <Ref. to
EN(H4DOTC)(diag
)-8, Electrical
Component Loca-
tion.>
VALVE RELAY 1.
air combination valve relay 1 terminals with the
battery disconnected.
Terminals
No. 3 No. 4:
more?
Go to step 11. Replace the sec-
ondary air combi-
nation valve relay
1. <Ref. to
EN(H4DOTC)(diag
)-8, Electrical
Component Loca-
tion.>
VALVE RELAY 1 POWER SOURCE.
ary air combination valve relay 1 connector and
chassis ground.
of power supply
circuit.
Step Check Yes No
EG: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)-355, DTC P2440 SECOND-
ARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK 1), Diagnostic Procedure with
RELAY 1 CONNECTOR.
ECM and secondary air combination valve relay
1 connector.
(B136) No. 30 (F9) No. 2:
circuit of harness
between ECM and
secondary air com-
1 connector.
RELAY 1 CONNECTOR.
air combination valve relay 1 connector and
chassis ground.
more?
Repair the poor
contact of the ECM
connector.
Repair the ground
ness between
ECM and second-
ary air combination
valve relay 1 con-
nector.
Step Check Yes No
EH:DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
STUCK OPEN (BANK2)
TEM SWITCHING VALVE STUCK OPEN (BANK2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
VALVE FUSE.
Check if the secondary air combination valve
fuse (10 A) is blown out.
AND SECONDARY AIR COMBINATION
VALVE LH.
valve fuse (10 A) from the fuse box.
ary air combination valve LH.
ondary air combination valve fuse and second-
ary air combination valve LH connector, and
chassis ground.
more?
Replace the fuse
with a new part,
and connect the
secondary air com-
bination valve LH
connector.
Go to step 3.
Repair the ground
ness between the
fuse box and the
secondary air com-
bination valve LH.
VALVE LH OPERATION.
air combination valve LH using the Subaru
Select Monitor.
NOTE:
Mode for more operation procedures. <Ref. to
Does the secondary air combi-
nation valve LH repeatedly
switch to ON and OFF?
PUMP AND SECONDARY AIR COMBINA-
TION VALVE LH.
pump and secondary air combination valve LH.
Replace, clean or
connect the duct.
Go to step 5.
5 CHECK PIPE BETWEEN SECONDARY AIR
COMBINATION VALVE LH AND CYLINDER
HEAD.
Check the pipe between the secondary air com-
bination valve LH and cylinder head.
connection of the pipe?
Replace, clean or
connect the pipe.
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
AIR COMBINATION VALVE LH.
ary air combination valve LH.
age between the secondary air combination
valve LH and the chassis ground.
Does the voltage repeatedly
change between 10 V and 0 V?
Replace the sec-
ondary air combi-
nation valve LH.
<Ref. to
EC(H4DOTC)-21,
Secondary Air
Combination
Valve.>
Go to step 7.
AIR COMBINATION VALVE LH AND CHAS-
SIS GROUND.
air combination valve LH connector and chassis
ground.
circuit of harness
between second-
ary air combination
valve LH and chas-
sis ground.
AIR COMBINATION VALVE RELAY 2 AND
LH CONNECTOR.
valve relay 2 from the relay box.
relay 2 and secondary air combination valve LH
connector.
(F9) No. 8 (E40) No. 2:
circuit of the har-
ness between the
secondary air com-
2 and secondary
air combination
valve LH connec-
tor.
VALVE RELAY 2.
No. 9 of the secondary air combination valve
relay 2.
ondary air combination valve relay 2 terminals.
Terminals
No. 7 No. 8:
ondary air combi-
nation valve relay
2. <Ref. to
EN(H4DOTC)(diag
)-8, Electrical
Component Loca-
tion.>
VALVE RELAY 2.
air combination valve relay 2 terminals with the
battery disconnected.
Terminals
No. 7 No. 8:
more?
ondary air combi-
nation valve relay
2. <Ref. to
EN(H4DOTC)(diag
)-8, Electrical
Component Loca-
tion.>
VALVE RELAY 2 POWER SOURCE.
ary air combination valve relay 2 connector and
chassis ground.
of power supply
circuit.
Step Check Yes No
EI: DTC P2443 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
STUCK CLOSED (BANK2)
NOTE:
For the diagnostic procedure, refer to DTC P2442. <Ref. to EN(H4DOTC)(diag)-360, DTC P2442 SECOND-
ARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK2), Diagnostic Procedure with
RELAY 2 CONNECTOR.
ECM and secondary air combination valve relay
2 connector.
(B136) No. 19 (F9) No. 9:
circuit of harness
between ECM and
secondary air com-
2 connector.
RELAY 2 CONNECTOR.
air combination valve relay 2 connector and
chassis ground.
more?
Repair the poor
contact of the ECM
connector.
Repair the ground
ness between
ECM and second-
ary air combination
valve relay 2 con-
nector.
Step Check Yes No
EJ:DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON
TEM PUMP STUCK ON, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
EN-05678
B47
1
2
4
6
3
5
SBF-7
E
F9
13
12
11
14
1
2
2
1
3
4
16
15
5
6
B143 F37
B144
B21
E2
E41 E40
B134 A:
B136 C:
F37
F11
B21 E40 B47
B144 F9 B143 F37
E41
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
MAIN
SBF
10A
60A
9
10
8
7
E
E
11
5
20
8
C30
C19
C8
A19
A27
A29
61
2
8
4
7
3216412
9
2
16
18
14
12
10
4
14 4
F11
1 2
3 4
1 2
5 6
1 3
4 5 6
2
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136
1
5 7 6
2
8
3 4
9
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
5
6 3
1
2
9
10
12
11
13
14
4 7 8
15 16
4
6
MAIN RELAY
BATTERY
RELAY HOLDER
SECONDARY
AIR
COMBINATION
VALVE RELAY1
SECONDARY
AIR
COMBINATION
VALVE RELAY2
SECONDARY
AIR PUMP
RELAY
SECONDARY
AIR PUMP
MAIN FUSE
BOX (M/B)
ECM
SECONDARY AIR
SECONDARY AIR
COMBINATION
VALVE LH
Step Check Yes No
1 CHECK SECONDARY AIR PIPING PRES-
SURE.
2) Using the Subaru Select Monitor, read sec-
ondary air piping pressure data, and compare
with the actual barometric pressure.
NOTE:
tor.>
Is the actual difference with
atmospheric pressure 50
mmHg (6.7 kPa, 2.0 inHg, 0.97
psig) or more?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
2 CHECK SECONDARY AIR PUMP.
(167F).
2) Check whether or not the secondary air
pump is operating.
Is the secondary air pump oper-
ating?
ondary air combi-
nation valve LH.
<Ref. to
EC(H4DOTC)-21,
INSPECTION,
Secondary Air
Combination
Valve.>
SECONDARY AIR PUMP RELAY CONNEC-
TOR.
2) Remove the secondary air pump relay from
the relay box.
ondary air pump relay connector and engine
ground terminals.
(F9) No. 13 Engine ground:
more?
ness between
ECM and second-
ary air pump relay
connector.
4 CHECK SECONDARY AIR PUMP RELAY.
air pump relay terminals.
Terminals
No. 14 No. 11:
more?
Repair the short
circuit to power in
the harness
between second-
ary air pump relay
and secondary air
pump connector.
Replace the sec-
ondary air pump
relay. <Ref. to
EN(H4DOTC)(diag
)-8, Electrical
Component Loca-
tion.>
Diagnostic Procedure without Diagnostic Trouble Code (DTC)
20.Diagnostic Procedure without Diagnostic Trouble Code (DTC)
A: CHECK SI-DRIVE (SUBARU Intelligent Drive) SYSTEM
DIAGNOSIS:
SI-DRIVE mode will not change.
CAUTION:
Note that the SI-DRIVE system performs the following control when changing modes.
1. When the engine is cold, the low coolant temperature display will light in the multi-information dis-
play meter. In this case, it will not be possible to change to the S# (sports sharp) mode.
2. If the engine is stopped in the S# (sports sharp) mode, it will be in the S (sports) mode when the
engine is restarted.
3. If the engine is stopped in the S (sports) or I (intelligent) mode, then restarted, it will enter the mode
it was on before stopping the engine.
4. If the malfunction indicator light becomes lit while the engine is running, it will enter the S (sports)
mode. In this case, it will not be possible to change to the S# (sports sharp) or I (intelligent) mode.
5. If there is a possible engine coolant temperature overheat condition, it will not be possible to
switch to the S# (sports sharp) mode. When driving in the S# (sports sharp) mode, it will enter the S
(sports) mode.
1. EVEN WHEN THE SI-DRIVE MODE IS CHANGED, THE MULTI INFORMATION DISPLAY
DOES NOT CHANGE, AND THE MODE DOES NOT SWITCH
WIRING DIAGRAM:
Step Check Yes No
1 CHECK SI-DRIVE SELECTOR.
1) Disconnect the connector from the multi
information display meter.
2) Measure the resistance between connec-
tors when the SI-DRIVE selector is operated.
(i11) No. 9 (i11) No. 12:
Does the resistance change as
shown below?
S#: 2.14 3.2 k
I: 0.8 1.2 k
S: less than 10
2 CHECK SI-DRIVE S# SWITCH.
1) Hold down the SI-DRIVE S# switch on the
steering wheel.
the multi-information display meter connector
and chassis ground.
(i11) No. 8 Chassis ground:
?
EN-05720
i1
5 6 7 8
2 1
9
4 3
10
24
22
23 25 27 26 28
11 12 13 14 15 16
17 18 19 20 21
C7
1 2 3 4 5
B68
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
B: i11
A: i10
3 4 5 6 7 8 9
19 20 21 14 15 16 17 18
1 2 10
12 11 13 22
i54
1
9
2 3 8
10
4
11 12 13 14 15 16
5 6 7
17 18
R43
2 3 4 5 6 7 8 9
11 12 13 14 17 18 19 20
1
10 15 16
ST4
2 3 4 5 1 6
i10 A: i11 B:
A
1
1
A
1
2
B
9
B
1
2
i1
B36
9
2
4
i54
R99
21
R43
C1
1
5
1
6
B
8
3 2
ST1
ST4
B68
1
2
5
4 3
C7
I
S#
S
E
4 5ST5
ST5
2 3 4 5 1
COMBINATION
METER
ROLL
CONNECTOR
SI-DRIVE
SELECTOR
SI-DRIVE S#
SWITCH
Cracked or improperly connected connector
Broken connector pin
Disconnection of connector terminal
Is there any abnormal condi-
tion?
Correct the cause
of trouble.
Go to step 4.
4 RECHECK FAULT.
2) Change the SI-DRIVE mode.
tion?
Replace the multi
information dis-
play meter. <Ref.
to IDI-19, Combi-
nation Meter.>
The circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
5 CHECK SI-DRIVE SELECTOR HARNESS
AND CONNECTOR.
Short or open circuit in the harness
Improperly connected or loose terminal in the
SI-DRIVE selector connector
Improperly connected or loose terminal in
coupling connector
tion?
Correct the cause
of trouble.
Go to step 7.
6 CHECK SI-DRIVE S# SWITCH HARNESS
AND CONNECTOR.
steering roll connector
coupling connector
tion?
Correct the cause
of trouble.
Go to step 7.
7 RECHECK FAULT.
tion?
Replace the SI-
DRIVE selector.
<Ref. to
FU(H4DOTC)-43,
SI-DRIVE (SUB-
ARU Intelligent
Drive) Selector.>
The circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Step Check Yes No
2. WHEN THE SI-DRIVE MODE IS CHANGED, MODE CHANGE ERROR APPEARS IN THE
MULTI INFORMATION DISPLAY APPROXIMATELY 5 SECONDS LATER
3. WHEN THE SI-DRIVE MODE IS CHANGED, MODE CHANGE ERROR IS NOT DISPLAYED
IN MULTI INFORMATION DISPLAY, AND S#, I, S FLASHES
NOTE:
In this case, there may be a problem outside the SI-DRIVE system.
Step Check Yes No
1 CHECK DTC. Is DTC displayed? Check for the cor-
responding DTC
using the List of
Diagnostic Trouble
Code (DTC) for
each unit.
Go to step 2.
2 CHECK DISPLAY OF MULTI INFORMATION
DISPLAY METER.
Check whether there are other errors displayed
other than the Mode Change Error.
Example:
Err is displayed in the external temperature
or fuel consumption displays.
FUEL gauge, TEMP gauge or ECO gauge
does not move.
Is there other errors displayed
other than the Mode Change
Error?
For the diagnostic
procedure, refer to
LAN section. <Ref.
to LAN(diag)-2,
Basic Diagnostic
Procedure.>
Go to step 3.
3 CHECK MULTI INFORMATION DISPLAY
METER AND ECM.
Is the multi information display
meter and ECM part numbers
correct?
Replace the multi-
information dis-
play meter. <Ref.
to IDI-19, Combi-
nation Meter.>
Replace the multi
information dis-
play meter and/or
ECM to that of the
correct part num-
ber. <Ref. to IDI-
19, Combination
Meter.> or <Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
Step Check Yes No
1 CHECK MALFUNCTION INDICATOR LIGHT.
2) Check whether the malfunction indicator
light is lit or not.
light illuminate?
Check the appro-
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
)-83, List of Diag-
nostic Trouble
Code (DTC).>
Go to step 2.
GAUGE.
2) Check the engine coolant temperature
gauge.
Is it overheating? Investigate and
repair the cause of
the overheating.
Go to step 3.
3 CHECK DISPLAY OF MULTI INFORMATION
DISPLAY.
3) Check the display of the multi information
display.
Do the displays S#, I, S of
the multi information display
flash?
Replace the multi
information dis-
play meter. <Ref.
to IDI-19, Combi-
nation Meter.>
Perform test opera-
tion, and check the
malfunction indica-
tor and the coolant
temperature
gauge. If they are
operating normally,
end the diagnosis.
A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H4DOTC)-95, Engine Trouble in
General.>
2. Rough idling
10) Oxygen sensor
4) Mass air flow sensor
5. Engine stalls, hesitates, or sputters at acceleration.
6. Surging
7) Throttle position sensor
*1: Check ignition coil and spark plug.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
7. Spark knock
4) Knock sensor
GD(H4DOTC)-2
GENERAL DESCRIPTION
A: LIST
DTC Item Index
mance (Bank 1)
<Ref. to GD(H4DOTC)-10, DTC P0011 INTAKE CAMSHAFT POSITION -
TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1),
P0016 Crankshaft Position - Camshaft
Position Correlation (Bank1)
<Ref. to GD(H4DOTC)-13, DTC P0016 CRANKSHAFT POSITION - CAM-
SHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code
P0018 Crankshaft Position - Camshaft
Position Correlation (Bank2)
<Ref. to GD(H4DOTC)-15, DTC P0018 CRANKSHAFT POSITION - CAM-
mance (Bank 2)
<Ref. to GD(H4DOTC)-15, DTC P0021 INTAKE CAMSHAFT POSITION -
P0030 HO2S Heater Control Circuit (Bank
1 Sensor 1)
<Ref. to GD(H4DOTC)-16, DTC P0030 HO2S HEATER CONTROL CIRCUIT
(Bank 1 Sensor 1)
ria.>
(Bank 1 Sensor 1)
ria.>
(Bank 1 Sensor 2)
ria.>
(Bank 1 Sensor 2)
ria.>
P0068 MAP/MAF - Throttle Position Cor-
relation
<Ref. to GD(H4DOTC)-26, DTC P0068 MAP/MAF - THROTTLE POSITION
Range/Performance
<Ref. to GD(H4DOTC)-29, DTC P0101 MASS OR VOLUME AIR FLOW CIR-
CUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
Low Input
High Input
<Ref. to GD(H4DOTC)-36, DTC P0107 MANIFOLD ABSOLUTE PRES-
SURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trou-
ble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-38, DTC P0108 MANIFOLD ABSOLUTE PRES-
SURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trou-
<Ref. to GD(H4DOTC)-40, DTC P0111 INTAKE AIR TEMPERATURE SEN-
SOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC)
Circuit Low
SOR 1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
Circuit High
SOR 1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0117 Engine Coolant Temperature Cir-
cuit Low
<Ref. to GD(H4DOTC)-46, DTC P0117 ENGINE COOLANT TEMPERA-
TURE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0118 Engine Coolant Temperature Cir-
cuit High
<Ref. to GD(H4DOTC)-48, DTC P0118 ENGINE COOLANT TEMPERA-
TURE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-3
GENERAL DESCRIPTION
<Ref. to GD(H4DOTC)-50, DTC P0122 THROTTLE/PEDAL POSITION
SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC)
SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC)
P0125 Insufficient Coolant Temperature
for Closed Loop Fuel Control
<Ref. to GD(H4DOTC)-54, DTC P0125 INSUFFICIENT COOLANT TEM-
PERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble
P0126 Insufficient Engine Coolant Tem-
perature for Stable Operation
<Ref. to GD(H4DOTC)-57, DTC P0126 INSUFFICIENT ENGINE COOLANT
TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code
P0128 Coolant Thermostat (Engine Cool-
ant Temperature Below Thermo-
stat Regulating Temperature)
<Ref. to GD(H4DOTC)-59, DTC P0128 COOLANT THERMOSTAT (ENGINE
(Bank 1 Sensor 1)
<Ref. to GD(H4DOTC)-61, DTC P0131 O2 SENSOR CIRCUIT LOW VOLT-
AGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
(Bank 1 Sensor 1)
<Ref. to GD(H4DOTC)-63, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLT-
ria.>
(Bank 1 Sensor 1)
<Ref. to GD(H4DOTC)-65, DTC P0133 O2 SENSOR CIRCUIT SLOW
RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
<Ref. to GD(H4DOTC)-68, DTC P0134 O2 SENSOR CIRCUIT NO ACTIV-
ITY DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC)
(Bank 1 Sensor 2)
<Ref. to GD(H4DOTC)-70, DTC P0137 O2 SENSOR CIRCUIT LOW VOLT-
ria.>
(Bank 1 Sensor 2)
<Ref. to GD(H4DOTC)-73, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLT-
ria.>
(Bank 1 Sensor 2)
<Ref. to GD(H4DOTC)-74, DTC P0139 O2 SENSOR CIRCUIT SLOW
ing Criteria.>
<Ref. to GD(H4DOTC)-81, DTC P0140 O2 SENSOR CIRCUIT NO ACTIV-
ITY DETECTED (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC)
P0171 System Too Lean (Bank 1) <Ref. to GD(H4DOTC)-83, DTC P0171 SYSTEM TOO LEAN (BANK 1),
P0172 System Too Rich (Bank 1) <Ref. to GD(H4DOTC)-84, DTC P0172 SYSTEM TOO RICH (BANK 1),
P0181 Fuel Temperature Sensor A Cir-
<Ref. to GD(H4DOTC)-86, DTC P0181 FUEL TEMPERATURE SENSOR A
ing Criteria.>
cuit Low Input
cuit High Input
SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC)
SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC)
DTC Item Index
GD(H4DOTC)-4
GENERAL DESCRIPTION
P0230 Fuel Pump Primary Circuit <Ref. to GD(H4DOTC)-97, DTC P0230 FUEL PUMP PRIMARY CIRCUIT,
Solenoid A Range/Performance
<Ref. to GD(H4DOTC)-99, DTC P0244 TURBO/SUPER CHARGER
WASTEGATE SOLENOID A RANGE/PERFORMANCE, Diagnostic Trouble
Solenoid A Low
WASTEGATE SOLENOID A LOW, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
Solenoid A High
WASTEGATE SOLENOID A HIGH, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
P0301 Cylinder 1 Misfire Detected <Ref. to GD(H4DOTC)-105, DTC P0301 CYLINDER 1 MISFIRE
DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-112, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW
Criteria.>
<Ref. to GD(H4DOTC)-114, DTC P0328 KNOCK SENSOR 1 CIRCUIT
HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC)
cuit
<Ref. to GD(H4DOTC)-116, DTC P0335 CRANKSHAFT POSITION SEN-
SOR A CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-118, DTC P0336 CRANKSHAFT POSITION SEN-
SOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code
P0340 Camshaft Position Sensor A Cir-
cuit (Bank 1 or Single Sensor)
<Ref. to GD(H4DOTC)-120, DTC P0340 CAMSHAFT POSITION SENSOR
A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code
P0345 Camshaft Position Sensor A Cir-
cuit (Bank 2)
<Ref. to GD(H4DOTC)-122, DTC P0345 CAMSHAFT POSITION SENSOR
A CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0410 Secondary Air Injection System <Ref. to GD(H4DOTC)-123, DTC P0410 SECONDARY AIR INJECTION
SYSTEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
Incorrect Flow Detected
<Ref. to GD(H4DOTC)-132, DTC P0411 SECONDARY AIR INJECTION
SYSTEM INCORRECT FLOW DETECTED, Diagnostic Trouble Code (DTC)
Switching Valve A Circuit Open
SYSTEM SWITCHING VALVE A CIRCUIT OPEN, Diagnostic Trouble Code
Switching Valve A Circuit Shorted
SYSTEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic Trouble
Switching Valve B Circuit Open
SYSTEM SWITCHING VALVE "B" CIRCUIT OPEN, Diagnostic Trouble Code
Switching Valve B Circuit Shorted
SYSTEM SWITCHING VALVE "B" CIRCUIT SHORTED, Diagnostic Trouble
Control A Circuit Open
SYSTEM CONTROL A CIRCUIT, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
DTC Item Index
GD(H4DOTC)-5
GENERAL DESCRIPTION
Threshold (Bank 1)
<Ref. to GD(H4DOTC)-137, DTC P0420 CATALYST SYSTEM EFFICIENCY
Criteria.>
Incorrect Purge Flow
<Ref. to GD(H4DOTC)-139, DTC P0441 EVAPORATIVE EMISSION SYS-
TEM INCORRECT PURGE FLOW, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
<Ref. to GD(H4DOTC)-140, DTC P0442 EVAPORATIVE EMISSION CON-
TROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble
TROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble
TROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble
tem Pressure Sensor
TROL SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC)
TROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble
TROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble
Leak)
TROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trou-
tem Leak Detected (Fuel Cap
Loose/Off)
Purge Control Valve Circuit Low
TEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code
Purge Control Valve Circuit High
TEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code
P0461 Fuel Level Sensor A Circuit
Range/Performance
<Ref. to GD(H4DOTC)-171, DTC P0461 FUEL LEVEL SENSOR A CIR-
Criteria.>
P0462 Fuel Level Sensor A Circuit Low <Ref. to GD(H4DOTC)-173, DTC P0462 FUEL LEVEL SENSOR A CIR-
CUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0463 Fuel Level Sensor A Circuit High <Ref. to GD(H4DOTC)-175, DTC P0463 FUEL LEVEL SENSOR A CIR-
CUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0464 Fuel Level Sensor Circuit Intermit-
tent
<Ref. to GD(H4DOTC)-177, DTC P0464 FUEL LEVEL SENSOR CIRCUIT
P0500 Vehicle Speed Sensor A <Ref. to GD(H4DOTC)-180, DTC P0500 VEHICLE SPEED SENSOR A,
P0506 Idle Air Control System RPM
Lower Than Expected
<Ref. to GD(H4DOTC)-182, DTC P0506 IDLE AIR CONTROL SYSTEM
RPM LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0507 Idle Air Control System RPM
Higher Than Expected
<Ref. to GD(H4DOTC)-184, DTC P0507 IDLE AIR CONTROL SYSTEM
RPM HIGHER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0512 Starter Request Circuit <Ref. to GD(H4DOTC)-186, DTC P0512 STARTER REQUEST CIRCUIT,
DTC Item Index
GD(H4DOTC)-6
GENERAL DESCRIPTION
P0513 Incorrect Immobilizer Key <Ref. to GD(H4DOTC)-187, DTC P0513 INCORRECT IMMOBILIZER KEY,
P0600 Serial Communication Link <Ref. to GD(H4DOTC)-188, DTC P0600 SERIAL COMMUNICATION LINK,
<Ref. to GD(H4DOTC)-190, DTC P0604 INTERNAL CONTROL MODULE
RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code
Memory (ROM) Error
<Ref. to GD(H4DOTC)-191, DTC P0605 INTERNAL CONTROL MODULE
READ ONLY MEMORY (ROM) ERROR, Diagnostic Trouble Code (DTC)
P0607 Control Module Performance <Ref. to GD(H4DOTC)-192, DTC P0607 CONTROL MODULE PERFOR-
P0638 Throttle Actuator Control Range/
Performance (Bank 1)
<Ref. to GD(H4DOTC)-195, DTC P0638 THROTTLE ACTUATOR CON-
TROL RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC)
(MIL Request)
<Ref. to GD(H4DOTC)-197, DTC P0700 TRANSMISSION CONTROL SYS-
TEM (MIL REQUEST), Diagnostic Trouble Code (DTC) Detecting Criteria.>
Low (AT Model)
<Ref. to GD(H4DOTC)-198, DTC P0851 PARK/NEUTRAL SWITCH INPUT
CIRCUIT LOW (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
P0851 Neutral Switch Input Circuit Low
(MT Model)
<Ref. to GD(H4DOTC)-199, DTC P0851 NEUTRAL SWITCH INPUT CIR-
CUIT LOW (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
High (AT Model)
<Ref. to GD(H4DOTC)-201, DTC P0852 PARK/NEUTRAL SWITCH INPUT
CIRCUIT HIGH (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
(MT Model)
<Ref. to GD(H4DOTC)-202, DTC P0852 NEUTRAL SWITCH INPUT CIR-
CUIT HIGH (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
<Ref. to GD(H4DOTC)-204, DTC P1152 O2 SENSOR CIRCUIT RANGE/
PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code
<Ref. to GD(H4DOTC)-207, DTC P1153 O2 SENSOR CIRCUIT RANGE/
PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code
P1160 Return Spring Failure <Ref. to GD(H4DOTC)-210, DTC P1160 RETURN SPRING FAILURE, Diag-
P1400 Fuel Tank Pressure Control Sole-
noid Valve Circuit Low
<Ref. to GD(H4DOTC)-212, DTC P1400 FUEL TANK PRESSURE CON-
TROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC)
SYSTEM SWITCHING VALVE STUCK OPEN, Diagnostic Trouble Code
Control A Circuit Shorted
SYSTEM CONTROL A CIRCUIT SHORTED, Diagnostic Trouble Code
Valve Circuit High
<Ref. to GD(H4DOTC)-217, DTC P1420 FUEL TANK PRESSURE CON-
TROL SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
P1443 Vent Control Solenoid Valve Func-
tion Problem
<Ref. to GD(H4DOTC)-219, DTC P1443 VENT CONTROL SOLENOID
VALVE FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4DOTC)-221, DTC P1491 POSITIVE CRANKCASE VENTI-
LATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code
DTC Item Index
GD(H4DOTC)-7
GENERAL DESCRIPTION
P1560 Back-up voltage circuit malfunction <Ref. to GD(H4DOTC)-223, DTC P1560 BACK-UP VOLTAGE CIRCUIT
MALFUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1570 Antenna <Ref. to GD(H4DOTC)-224, DTC P1570 ANTENNA, Diagnostic Trouble
P1571 Reference Code Incompatibility <Ref. to GD(H4DOTC)-224, DTC P1571 REFERENCE CODE INCOMPATI-
BILITY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
(Except Antenna Curcuit)
<Ref. to GD(H4DOTC)-224, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
P1574 Key Communication Failure <Ref. to GD(H4DOTC)-224, DTC P1574 KEY COMMUNICATION FAILURE,
P1576 EGI Control Module EEPROM <Ref. to GD(H4DOTC)-224, DTC P1576 EGI CONTROL MODULE
EEPROM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1577 IMM Control Module EEPROM <Ref. to GD(H4DOTC)-224, DTC P1577 IMM CONTROL MODULE
EEPROM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1578 Meter Failure <Ref. to GD(H4DOTC)-224, DTC P1578 METER FAILURE, Diagnostic Trou-
P1602 Control Module Programming Error <Ref. to GD(H4DOTC)-225, DTC P1602 CONTROL MODULE PROGRAM-
Stuck Open (Bank 1)
<Ref. to GD(H4DOTC)-227, DTC P2004 INTAKE MANIFOLD RUNNER
CONTROL STUCK OPEN (BANK 1), Diagnostic Trouble Code (DTC)
Stuck Open (Bank 2)
CONTROL STUCK OPEN (BANK 2), Diagnostic Trouble Code (DTC)
CONTROL STUCK CLOSED (BANK 1), Diagnostic Trouble Code (DTC)
CONTROL STUCK CLOSED (BANK 2), Diagnostic Trouble Code (DTC)
Circuit / Open (Bank 1)
CONTROL CIRCUIT / OPEN (BANK 1), Diagnostic Trouble Code (DTC)
Circuit Low (Bank 1)
CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC)
Circuit / Open (Bank 2)
CONTROL CIRCUIT / OPEN (BANK 2), Diagnostic Trouble Code (DTC)
Circuit Low (Bank 2)
CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC)
Sensor / Switch Circuit Low
(Bank 1)
POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1), Diagnostic Trou-
Sensor / Switch Circuit High
(Bank 1)
POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1), Diagnostic Trou-
Sensor / Switch Circuit Low
(Bank 2)
POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2), Diagnostic Trou-
Sensor / Switch Circuit High
(Bank 2)
POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2), Diagnostic Trou-
DTC Item Index
GD(H4DOTC)-8
GENERAL DESCRIPTION
<Ref. to GD(H4DOTC)-247, DTC P2088 INTAKE CAMSHAFT POSITION
ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code
ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code
P2096 Post Catalyst Fuel Trim System
Too Lean Bank 1
<Ref. to GD(H4DOTC)-251, DTC P2096 POST CATALYST FUEL TRIM
SYSTEM TOO LEAN BANK 1, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P2097 Post Catalyst Fuel Trim System
Too Rich Bank 1
<Ref. to GD(H4DOTC)-253, DTC P2097 POST CATALYST FUEL TRIM
SYSTEM TOO RICH BANK 1, Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
TROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble
cuit Low
TROL MOTOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
cuit High
TROL MOTOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Trouble Code
SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code
SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code
SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code
SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code
SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble
SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble
Switching Valve Control Circuit
Low
TEM SWITCHING VALVE CONTROL CIRCUIT LOW, Diagnostic Trouble
Switching Valve Control Circuit
High
TEM SWITCHING VALVE CONTROL CIRCUIT HIGH, Diagnostic Trouble
Flow/Pressure Sensor Circuit
Range/Performance
SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/PERFOR-
DTC Item Index
GD(H4DOTC)-9
GENERAL DESCRIPTION
Flow/Pressure Sensor Circuit Low
SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT LOW, Diagnostic
Flow /Pressure Sensor Circuit High
SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT HIGH, Diagnostic
(Bank 1)
SYSTEM SWITCHING VALVE STUCK OPEN (BANK 1), Diagnostic Trouble
(Bank 1)
SYSTEM SWITCHING VALVE STUCK CLOSED (BANK 1), Diagnostic Trou-
(Bank 2)
SYSTEM SWITCHING VALVE STUCK OPEN (BANK2), Diagnostic Trouble
(Bank 2)
SYSTEM SWITCHING VALVE STUCK CLOSED (BANK2), Diagnostic Trou-
Pump Stuck On
SYSTEM PUMP STUCK ON, Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
DTC Item Index
GD(H4DOTC)-10
GENERAL DESCRIPTION
Detect the AVCS system malfunction.
Judge NG when the amount of AVCS actual timing advance does not approach to the amount of AVCS target
timing advance.
3. ENABLE CONDITION
Perform the diagnosis continuously after warming up when the engine speed increases and AVCS operates.
(1) AVCS timing controller (3) Engine control module (ECM) (5) Oil pressure
(2) Vane (4) Oil flow control solenoid valve
Time of establishing all secondary
parameter conditions
> 3000 ms
Engine speed > 1300 rpm
Engine coolant temperature > 60 C (140 F)
AVCS control Operation
Target advance angle > 0 CA
Target timing advance change amount
(per 64 ms)
< 1.07 CA
EN-01852
(3)
(4)
(1)
(5)
(2)
GD(H4DOTC)-11
GENERAL DESCRIPTION
1) When the conditions during which the differences of AVCS target timing advance amount and AVCS ac-
tual timing advance amount is large continues for certain amount of time.
2) When the differences of target timing advance amount and actual timing advance amount is calculated
during AVCS control, and the difference per predetermined time is the specified value or larger.
Judge as NG when the following conditions are established within the predetermined time.
AT model: 30000 ms
MT model: 20000 ms
cles.
Normality Judgment
Judge as OK and clear the NG if the following conditions are established within the predetermined time.
AT model: 30000 ms
MT model: 20000 ms
Judgment Value
E(Target position Actual position) > 8000 CA (AT model)
(Bank 1)
> 8000 CA (AT model)
(Bank 2)
> 5300 CA (MT
model) (Bank 1)
> 5300 CA (MT
model) (Bank 2)
or
E(Target position Actual position) < 8000 CA (AT
model) (Bank 1)
< 8000 CA (AT
model) (Bank 2)
< 5300 CA (MT
model) (Bank 1)
< 5300 CA (MT
model) (Bank 2)
Judgment Value
E(Target position Actual position) s 8000 CA (AT model)
(Bank 1)
s 8000 CA (AT model)
(Bank 2)
s 5300 CA (MT
model) (Bank 1)
s 5300 CA (MT
model) (Bank 2)
and
> 8000 CA (AT
model) (Bank 1)
> 8000 CA (AT
model) (Bank 2)
> 5300 CA (MT
model) (Bank 1)
> 5300 CA (MT
model) (Bank 2)
GD(H4DOTC)-12
GENERAL DESCRIPTION
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 (0 CA) to the compensation value of partial learning zone with IG OFF.
Enter the initial value (0 CA) to the compensation value of the partial learning zone when making a nor-
mality judgment abnormality judgment.
AVCS control: Maximum timing retard learning is not complete or maximum timing retard learning comple-
tion 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%).
GD(H4DOTC)-13
GENERAL DESCRIPTION
CORRELATION (BANK1)
Judge as NG when the timing advance is outside the normal range.
3. ENABLE CONDITION
Perform the diagnosis continuously after starting engine and while AVCS is not operating.
AVCS control Not in operation
Target timing advance 0CA
EN-01852
(3)
(4)
(1)
(5)
(2)
GD(H4DOTC)-14
GENERAL DESCRIPTION
Judge as NG when the camshaft sensor input position is not within the normal range.
cles.
Normality Judgment
Judgment Value
Camshaft input position < BTDC 17 CA
(Bank 1)
< BTDC 17 CA
(Bank 2)
or
> BTDC 55 CA
(Bank 1)
> BTDC 55 CA
(Bank 2)
Judgment Value
Camshaft input position > BTDC 17 CA
(Bank 1)
> BTDC 17 CA
(Bank 2)
and
s BTDC 55 CA
(Bank 1)
s BTDC 55 CA
(Bank 2)
GD(H4DOTC)-15
GENERAL DESCRIPTION
8. FAIL SAFE
ISC feedback compensation: Do not perform the AVCS actual timing advance compensation. Determine
the OCV Driving Duty is the given value (9.36%).
C: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELA-
TION (BANK2)
NOTE:
For the detection standard, refer to DTC P0016. <Ref. to GD(H4DOTC)-13, DTC P0016 CRANKSHAFT PO-
SITION - CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
NOTE:
For the detection standard, refer to DTC P0011. <Ref. to GD(H4DOTC)-10, DTC P0011 INTAKE CAM-
SHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic
GD(H4DOTC)-16
GENERAL DESCRIPTION
E: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
3. ENABLE CONDITION
(2) Ceramic heater
Condition established time > 42000 ms
Control duty > 35 % Experienced
After fuel cut > 20000 ms
EN-02181
( 1 ) ( 2 )
( 3 ) ( 4 )
GD(H4DOTC)-17
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Correction when re-starting at high temperature: Normally minimum value 0.06 0.
Judgment Value
Front oxygen (A/F) sensor impedance > 50 O
Judgment Value
Front oxygen (A/F) sensor impedance s 50 O
GD(H4DOTC)-18
GENERAL DESCRIPTION
3. ENABLE CONDITION
output voltage

EN-01792
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H4DOTC)-19
GENERAL DESCRIPTION
Normality Judgment
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.
Judgment Value
duty
< 87.5 %
Judgment Value
GD(H4DOTC)-20
GENERAL DESCRIPTION
3. ENABLE CONDITION
output voltage

EN-01793
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H4DOTC)-21
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
duty
> 12.5 %
Judgment Value
GD(H4DOTC)-22
GENERAL DESCRIPTION
3. ENABLE CONDITION
sensor heater

Elapsed time after engine starting > 1 second
EN-01792
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H4DOTC)-23
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-24
GENERAL DESCRIPTION
3. ENABLE CONDITION
sensor heater

EN-01793
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H4DOTC)-25
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
Rear oxygen sensor heater control duty > 25 %
Judgment Value
GD(H4DOTC)-26
GENERAL DESCRIPTION
J: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
3. ENABLE CONDITION
EN-01765
(B)
(A)
(2)
(3)
(1)
GD(H4DOTC)-27
GENERAL DESCRIPTION
Low side: 3000 msec
cles.
Normality Judgment
Judgment Value
Low
Throttle position > 10 deg
Output voltage < 1 V
Engine load > 1.356 g/rev (0.048
oz/rev)
High
Engine load < 0.4 g/rev (0.014 oz/
rev)
Judgment Value
Low
Output voltage > 1 V
Engine load > 1.356 g/rev (0.048
oz/rev)
High
Engine load < 0.4 g/rev (0.014 oz/
rev)
GD(H4DOTC)-28
GENERAL DESCRIPTION
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)-29
GENERAL DESCRIPTION
K: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE
3. ENABLE CONDITION
EN-01766
(3)
(4)
(2)
(1)
(A)
GD(H4DOTC)-30
GENERAL DESCRIPTION
Low: 3000 ms
High: 10000 ms
cles.
Judgment Value
Low
Throttle opening angle > 15 deg
Intake manifold pressure > 53.32 kPa (400
mmHg, 15.748 inHg)
High (1)
mmHg, 15.551 inHg)
High (2)
mmHg, 15.551 inHg)
GD(H4DOTC)-31
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Low
mmHg, 15.748 inHg)
High
Intake manifold pressure < 52.65 kPa (395
mmHg, 15.551 inHg)
GD(H4DOTC)-32
GENERAL DESCRIPTION
L: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Output voltage s 0.2 V
Judgment Value
EN-01766
(3)
(4)
(2)
(1)
(A)
GD(H4DOTC)-33
GENERAL DESCRIPTION
8. FAIL SAFE
Air flow meter: Engine load is normally calculated by manifold pressure and engine speed; however, cal-
culated 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 0 CA (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 (0.04 oz)/s). Stop calculation of throttle sensor temper-
ature compensation (hold previous value)
GD(H4DOTC)-34
GENERAL DESCRIPTION
M: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-01766
(3)
(4)
(2)
(1)
(A)
GD(H4DOTC)-35
GENERAL DESCRIPTION
8. FAIL SAFE
Knock compensation:
GD(H4DOTC)-36
GENERAL DESCRIPTION
N: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT LOW INPUT
3. ENABLE CONDITION
None
EN-01765
(B)
(A)
(2)
(3)
(1)
GD(H4DOTC)-37
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-38
GENERAL DESCRIPTION
O: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT HIGH INPUT
3. ENABLE CONDITION
None
EN-01765
(B)
(A)
(2)
(3)
(1)
GD(H4DOTC)-39
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-40
GENERAL DESCRIPTION
P: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/
PERFORMANCE
3. ENABLE CONDITION
(1) Air flow sensor (3) Resistance value (O) (A) Air
starting
< 30 C (86 F)
is less than 60 km/h (37.3 MPH
> 600 sec
EN-01767
(3)
(4)
(2)
(1)
(A)
GD(H4DOTC)-41
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
and Min.
approximately 0.5C
(0.9F) near 25C)
Judgment Value
and Min.
> 0.02 V
GD(H4DOTC)-42
GENERAL DESCRIPTION
Q: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-01767
(3)
(4)
(2)
(1)
(A)
GD(H4DOTC)-43
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4DOTC)-44
GENERAL DESCRIPTION
R: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-01767
(3)
(4)
(2)
(1)
(A)
GD(H4DOTC)-45
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4DOTC)-46
GENERAL DESCRIPTION
S: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
3. ENABLE CONDITION
Normality Judgment
(1) Connector (A) Resistance value (kO)
None
Judgment Value
Judgment Value
EN-02917
(A)
(2)
(1)
(B)
GD(H4DOTC)-47
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 %.
Tumble generator valve control: Open the tumble generator valve.
GD(H4DOTC)-48
GENERAL DESCRIPTION
T: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-02917
(A)
(2)
(1)
(B)
GD(H4DOTC)-49
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4DOTC)-50
GENERAL DESCRIPTION
U: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT
LOW
3. ENABLE CONDITION
Ignition switch ON
Battery voltage > 6 V
EN-01859
(1)
(2)
(3)
(4)
GD(H4DOTC)-51
GENERAL DESCRIPTION
Time Needed for Diagnosis: 24 msec
Normality Judgment
8. FAIL SAFE
Judgment Value
Sensor 1 input voltage s 0.224 V
Judgment Value
GD(H4DOTC)-52
GENERAL DESCRIPTION
V: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT
HIGH
3. ENABLE CONDITION
Ignition switch ON
EN-01859
(1)
(2)
(3)
(4)
GD(H4DOTC)-53
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-54
GENERAL DESCRIPTION
W: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP
FUEL CONTROL
3. ENABLE CONDITION
EN-02917
(A)
(2)
(1)
(B)
GD(H4DOTC)-55
GENERAL DESCRIPTION
t = 451056 ms 25870 ms/C Ti
cles.
Normality Judgment
Judgment Value
Timer for diagnosis after engine start > Judgment value of
0 (0) 8 (5) 16 (9.9) 24 (14.9) 32 (19.9) 40 (24.9) 48 (29.8) 56 (34.8)
Tempera-
ture
C (F)
20
(4)
0.000 ms 37.136 ms 74.272 ms 111.41 ms 126.66 ms 141.91 ms 163.59 ms 185.26 ms
10
(14)
0.000 ms 27.391 ms 54.782 ms 82.173 ms 99.65 ms 117.13 ms 135.96 ms 154.8 ms
Judgment Value
GD(H4DOTC)-56
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4DOTC)-57
GENERAL DESCRIPTION
X: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE
OPERATION
3. ENABLE CONDITION
(A) Resistance value (kO) (B) Temperature C (F)

None
Fuel level > 15 L (3.963 US gal,
3.3 Imp gal)
engine stop
> 70 C (158 F)
EN-02917
(A)
(2)
(1)
(B)
GD(H4DOTC)-58
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
< 2.5 C (36.5 F)
fuel temperature
> 5 C (41 F)
ture
< 2.5 C (36.5 F)
Judgment Value
> 2.5 C (36.5 F)
GD(H4DOTC)-59
GENERAL DESCRIPTION
Y: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE
3. ENABLE CONDITION
None
EN-01692
(9)
(2)
(6)
(8)
(7)
(5)
(4)
(3)
(1)
(2)
GD(H4DOTC)-60
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Estimate ambient temperature > 7 C (19.4 F)
starting
< 55 C (131 F)
Estimated coolant temperature > 70 C (158 F)
Engine coolant temperature s 70 C (158 F)
temperature
> 30 C (86 F)
Judgment Value
starting
< 55 C (131 F)
temperature
s 30 C (86 F)
GD(H4DOTC)-61
GENERAL DESCRIPTION
Z: DTC P0131 O2 SENSOR CIRCUIT LOW 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. ENABLE CONDITION
(3) ZrO
2
(C) Lean
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4DOTC)-62
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Input voltage < 1.8 V
or
Input current < 0.01 A
Judgment Value
Input voltage > 1.8 V
Input current > 0.01 A
GD(H4DOTC)-63
GENERAL DESCRIPTION
AA:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
3. ENABLE CONDITION
(3) ZrO
2
(C) Lean
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4DOTC)-64
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
or
Judgment Value
Input voltage s 3.8 V
Input current s 0.01 A
GD(H4DOTC)-65
GENERAL DESCRIPTION
AB:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
diagnosed.
(3) ZrO
2
(C) Lean
EN-01694
(1)
(2)
(3)
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4DOTC)-66
GENERAL DESCRIPTION
3. ENABLE CONDITION
Calculate faf difference and the value difference every 32ms 4 . Calculate the diagnosis value after cal-
culating 1640 time.
cles.
> 1024 ms
Barometric pressure > 75.05 kPa
(563 mmHg, 22.165 inHg)
Front oxygen (A/F) sensor impedance 0 O 50 O
Elapsed time after starting the engine > 120000 ms
Vehicle speed 10 km/h 120 km/h
(6.2 MPH 74.6 MPH)
Amount of intake air 10 g/s 31 g/s
(0.353 oz/s 1.093 oz/s)
purge
< 0.2
Total time of operating canister purge > 19.9 sec
Judgment Value
parafca = td2faf/td2lmd > 0.644 (AT model)
> 0.444 (MT model)
where,
faf (n2))
(n1) lmd (n2))
onds
GD(H4DOTC)-67
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
parafca = td2faf/td2lmd s 0.644 (AT model)
s 0.444 (MT model)
where,
faf (n2))
(n1) lmd (n2))
onds
GD(H4DOTC)-68
GENERAL DESCRIPTION
AC:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 1)
3. ENABLE CONDITION
(3) ZrO
2
(C) Lean
None
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4DOTC)-69
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
more
> 36000 ms
Front oxygen (A/F) sensor impedance. > 500 O
Judgment Value
Front oxygen (A/F) sensor impedance. s 500 O
GD(H4DOTC)-70
GENERAL DESCRIPTION
AD:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H4DOTC)-71
GENERAL DESCRIPTION
3. ENABLE CONDITION
High
Front oxygen (A/F) sensor compensation coefficient Not in limit value
Low (1)
Amount of intake air > 10 g/s (0.353 oz/s)
Low (2)
Current continuation time of the rear oxygen sensor heater > 25000 ms
Low (3)
GD(H4DOTC)-72
GENERAL DESCRIPTION
High: 2500 ms
Low (1): 20000 ms
Low (2): 150000 ms
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
High P0138
Low P0137
Map
Judgment Value
High P0138
Sensor output voltage s 1.2 V P0158
Low P0137
GD(H4DOTC)-73
GENERAL DESCRIPTION
AE:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
NOTE:
For the detection standard, refer to DTC P0137. <Ref. to GD(H4DOTC)-70, DTC P0137 O2 SENSOR CIR-
CUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-74
GENERAL DESCRIPTION
AF:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
cut.
DIAGNOSTIC METHOD
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H4DOTC)-75
GENERAL DESCRIPTION
3. ENABLE CONDITION
more.
Experienced
gen sensor heater
> 60000 ms
gen sensor heater
> 30000 ms
Estimated catalyst temperature > 400 C (752 F)
Number of deceleration fuel cut > 1 time
GD(H4DOTC)-76
GENERAL DESCRIPTION
(D) 0.15 V
(A)
(B)
(C)
(D)
(E)
(G)
(F)
(H)
EN-05566
GD(H4DOTC)-77
GENERAL DESCRIPTION
NOTE:
cles.
Normality Judgment
condition.
Response time (diagnosis value) s threshold value normal
8. FAIL SAFE
Judgment Value
2
> 837 ms
or
Longest time over 0.55 V > 2000 ms
Judgment Value
2
s 837 ms
GD(H4DOTC)-78
GENERAL DESCRIPTION
10.ENABLE CONDITION
Deceleration fuel cut time is 6000 ms or more. Experienced
Current calculation time of the rear oxygen sen-
sor heater
> 0 ms
Current continuation time of the rear oxygen
sensor heater
> 0 ms
GD(H4DOTC)-79
GENERAL DESCRIPTION
(A) 0.55 V (G) More than 120000 ms (J) Judge NG when the voltage of
tion.
(B) 0.5 V (H) Measure the response time
(diagnostic value).
(C) 0.3 V
(D) 0.25 V (I) Execute the malfunction judg-
(E) 0 V
(I)
(E)
(F)
(G)
(D)
(C)
(B)
(A)
(H)
(J)
EN-05567
GD(H4DOTC)-80
GENERAL DESCRIPTION
judge as NG.
cles.
Normality Judgment
condition.
15.FAIL SAFE
Judgment Value
O
2
> 2000 ms
or
Longest time under 0.25 V > 120000 ms
Judgment Value
O
2
s 2000 ms
GD(H4DOTC)-81
GENERAL DESCRIPTION
AG:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 2)

sensor
In operation
sor
> 0.55 V + 0.05 V
coefficient
Not in limit value
more.
Experienced
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H4DOTC)-82
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
or
Judgment Value
age low side
Incomplete
Minimum output voltage s 0.15 V
Maximum output voltage > 0.55 V
GD(H4DOTC)-83
GENERAL DESCRIPTION
AH:DTC P0171 SYSTEM TOO LEAN (BANK 1)
DIAGNOSTIC METHOD
measured by sensor.
2. ENABLE CONDITION
cles.
Engine load > Value of Map 1
Map1
Engine speed (rpm) Idling 800 1200 1600 2000 2400 2800 3200 3600 4000 4400
Measured value
(g(oz)/rev)
Non-turbo
0.228
(0.008)
0.22
(0.008)
0.22
(0.008)
0.22
(0.008)
0.228
(0.008)
0.23
(0.008)
0.234
(0.008)
0.242
(0.009)
0.25
(0.009)
0.25
(0.009)
Judgment Value
fsobd = (sglmd tglmda) + faf + flaf > Value of Map 2
tion coefficient
Map2
2.34375
(0.083)
4.6875
(0.165)
7.03125
(0.248)
9.375
(0.331)
11.71875
(0.413)
14.0625
(0.496)
fsobdL1 (%) 1.4 1.4 1.368623 1.319185 1.26975 1.265 1.265
GD(H4DOTC)-84
GENERAL DESCRIPTION
Normality Judgment
7. FAIL SAFE
Rich side malfunction
AI: DTC P0172 SYSTEM TOO RICH (BANK 1)
Diagnostic method
measured by sensor.
2. ENABLE CONDITION
Judgment Value
Engine load change s 0.02 g/rev (0.001 oz/
rev)
Cumulative time of canister purge after engine start > 20 sec
Continuous period after canister purge starting > 29884 ms
Map1
Engine speed
(rpm)
Idling 800 1200 1600 2000 2400 2800 3200 3600 4000 4400
Measured value
(g(oz)/rev)
Non-turbo
0.228
(0.008)
0.22
(0.008)
0.22
(0.008)
0.22
(0.008)
0.228
(0.008)
0.23
(0.008)
0.234
(0.008)
0.242
(0.009)
0.25
(0.009)
0.25
(0.009)
GD(H4DOTC)-85
GENERAL DESCRIPTION
cles.
Normality Judgment
7. FAIL SAFE
Rich side malfunction
Judgment Value
faf = main feedback compensation coefficient every 64
milliseconds
flaf = main feedback learning compensation coefficient
Map2
2.34375
(0.083)
4.6875
(0.165)
7.03125
(0.248)
9.375
(0.331)
11.71875
(0.413)
14.0625
(0.496)
fsobdL1 (%) 0.6 0.6 0.63137 0.68082 0.73025 0.73025 0.73025
Judgment Value
fsobd = (sglmd tglmda) + faf + flaf > 0.8
GD(H4DOTC)-86
GENERAL DESCRIPTION
AJ:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/
PERFORMANCE
Diagnosis is performed in two methods (drift diagnosis and stack diagnosis). If either is NG, judge as NG. If
Drift Diagnosis
Stuck Diagnosis
3. ENABLE CONDITION
DRIFT DIAGNOSIS
(A) Resistance value (O) (B) Fuel temperature C (F)
None
EN-01700
(A)
(B)
GD(H4DOTC)-87
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
10.ENABLE CONDITION
Stuck Diagnosis
Judgment Value
Fuel level > 9.6 L (2.536 US gal,
2.112 Imp gal)
Elapsed time after starting the engine > 20 sec
> 10 C (50 F)
perature
> 10 C (50 F)
Judgment Value
2.112 Imp gal)
> 10 C (50 F)
perature
< 10 C (50 F)
GD(H4DOTC)-88
GENERAL DESCRIPTION
cles.
Normality Judgment
15.FAIL SAFE
None
Judgment Value
Accumulated amount of intake air > 551043 g
(19435.287 oz)
Max. and Min.
< 2 C (35.6 F)
Judgment Value
Max. and Min.
> 2 C (35.6 F)
GD(H4DOTC)-89
GENERAL DESCRIPTION
AK:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT
3. ENABLE CONDITION
None
EN-01700
(A)
(B)
GD(H4DOTC)-90
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4DOTC)-91
GENERAL DESCRIPTION
AL:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT
3. ENABLE CONDITION
None
EN-01700
(A)
(B)
GD(H4DOTC)-92
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4DOTC)-93
GENERAL DESCRIPTION
AM:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
LOW
3. ENABLE CONDITION
Ignition switch ON
EN-01859
(1)
(2)
(3)
(4)
GD(H4DOTC)-94
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-95
GENERAL DESCRIPTION
AN:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
HIGH
3. ENABLE CONDITION
Ignition switch ON
EN-01859
(1)
(2)
(3)
(4)
GD(H4DOTC)-96
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-97
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.
3. ENABLE CONDITION
(1) Engine control module (ECM) (3) Fuel pump (4) Battery
(2) Fuel pump control unit
None
EN-01771
E
E
(3)
(4)
(2)
FPC
DI
FP+
FP-
+B
(1)
GD(H4DOTC)-98
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
OFF setting may be needed depending on the NG portion.
Judgment Value
Fuel pump control ON
Fuel pump control unit output diagnosis
signal
Low
2.2 Imp gal)
Judgment Value
signal
High
2.2 Imp gal)
GD(H4DOTC)-99
GENERAL DESCRIPTION
AP:DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID A
RANGE/PERFORMANCE
Detect the malfunction of wastegate control solenoid valve function.
Judge as NG when becoming high wastegate pressure.
3. ENABLE CONDITIONS
EN-01772
(1)
(1) Coil
None
GD(H4DOTC)-100
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Intake manifold pressure > Value from Map
Map
Pa (kPa (mmHg, inHg))
58.65 kPa
(440 mmHg,
17.323 inHg)
77.31 kPa
(580 mmHg,
22.835 inHg)
89.31 kPa
(670 mmHg,
26.378 inHg)
95.98 kPa
(720 mmHg,
28.346 inHg)
98.64 kPa
(740 mmHg,
29.134 inHg)
101.31 kPa
(760 mmHg,
29.921 inHg)
Abnormal threshold
(kPa (mmHg, inHg))
143.43 kPa
(1076 mmHg,
42.362 inHg)
172.62 kPa
(1295 mmHg,
50.984 inHg)
204.54 kPa
(1534 mmHg,
60.411 inHg)
216.22 kPa
(1622 mmHg,
63.86 inHg)
221.28 kPa
(1660 mmHg,
65.354 inHg)
221.28 kPa
(1660 mmHg,
65.354 inHg)
Judgment Value
Intake manifold pressure < Value from Map 22.39 kPa
(168 mmHg, 6.614 inHg)
GD(H4DOTC)-101
GENERAL DESCRIPTION
AQ:DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID A LOW
Detect open or short circuit of the wastegate control solenoid valve.
Judge as NG when the terminal output voltage remains Low during outputting the duty signal.
3. ENABLE CONDITION
Normality Judgment
EN-01772
(1)
(1) Coil
Elapsed time after starting the engine > 1 second
Judgment Value
Duty ratio of wastegate control < 75%
Judgment Value
GD(H4DOTC)-102
GENERAL DESCRIPTION
8. FAIL SAFE
None
GD(H4DOTC)-103
GENERAL DESCRIPTION
AR:DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID A HIGH
Detect open or short circuit of the wastegate control solenoid valve.
Judge as NG when the terminal output voltage remains Low or High during outputting the duty signal.
3. ENABLE CONDITION
Normality Judgment
EN-01772
(1)
(1) Coil
Judgment Value
Duty ratio of wastegate control > 25%
Judgment Value
GD(H4DOTC)-104
GENERAL DESCRIPTION
8. FAIL SAFE
None
GD(H4DOTC)-105
GENERAL DESCRIPTION
AS:DTC P0301 CYLINDER 1 MISFIRE DETECTED
1.5 times misfire
fire
180 Interval Difference Method (MT: 1,800 rpm or less, AT: None)
2. ENABLE CONDITION
Map1
AT model
MT model
All secondary parameters enable condi-
tions
> 1024 ms
Intake manifold pressure change at 180
CA
< Value of Map 1
Throttle position change during 16 milli-
seconds
< 14 deg (AT model)
< 14 deg (MT model)
2.112 Imp gal)
Vehicle dynamic control or AT torque
control
Not in operation
Intake manifold pressure > Value from Map 2
Fuel parameter determination Not extremely low vol-
atility
Engine load change during 32 millisec-
onds
< 1000 rpm
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700
kPa
(mmHg,
inHg)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700
kPa
(mmHg,
inHg)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
13.33
(100,
3.937)
GD(H4DOTC)-106
GENERAL DESCRIPTION
Map2
AT model (Tumble generator valve open)
AT model (Tumble generator valve closed)
MT model (Tumble generator valve open)
MT model (Tumble generator valve closed)
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700
kPa
(mmHg,
inHg)
29.33
(220,
8.661)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
27.33
(205,
8.071)
27.99
(210,
8.268)
29.53
(221.5,
8.72)
31.33
(235,
9.252)
32.73
(245.5,
9.665)
34.12
(256,
10.079)
38.19
(286.5,
11.28)
43.99
(330,
12.992)
49.52
(371.5,
14.626)
53.32
(400,
15.748)
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700
kPa
(mmHg,
inHg)
29.33
(220,
8.661)
26.66
(200,
7.874)
26.66
(200,
7.874)
26.66
(200,
7.874)
27.33
(205,
8.071)
27.99
(210,
8.268)
29.53
(221.5,
8.72)
31.33
(235,
9.252)
32.73
(245.5,
9.665)
34.12
(256,
10.079)
38.19
(286.5,
11.28)
43.99
(330,
12.992)
49.52
(371.5,
14.626)
53.32
(400,
15.748)
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700
kPa
(mmHg,
inHg)
27.33
(205,
8.071)
23.33
(175,
6.89)
23.59
(177,
6.968)
23.33
(175,
6.89)
23.99
(180,
7.087)
24.39
(183,
7.205)
28.79
(216,
8.504)
29.99
(225,
8.858)
31.59
(237,
9.331)
32.53
(244,
9.606)
37.06
(278,
10.945)
41.86
(314,
12.362)
46.92
(352,
13.858)
51.05
(383,
15.079)
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700
kPa
(mmHg,
inHg)
25.06
(188,
7.402)
24.79
(186,
7.323)
25.59
(192,
7.559)
39.99
(300,
11.811)
40.79
(306,
12.047)
42.12
(316,
12.441)
43.99
(330,
12.992)
44.52
(334,
13.15)
47.32
(355,
13.976)
54.65
(410,
16.142)
54.65
(410,
16.142)
54.65
(410,
16.142)
54.65
(410,
16.142)
54.65
(410,
16.142)
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700
kPa
(mmHg,
inHg)
27.33
(205,
8.071)
23.33
(175,
6.89)
23.59
(177,
6.968)
23.33
(175,
6.89)
23.99
(180,
7.087)
24.39
(183,
7.205)
28.79
(216,
8.504)
29.99
(225,
8.858)
31.59
(237,
9.331)
32.53
(244,
9.606)
37.06
(278,
10.945)
41.86
(314,
12.362)
46.92
(352,
13.858)
51.05
(383,
15.079)
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700
kPa
(mmHg,
inHg)
25.06
(188,
7.402)
24.79
(186,
7.323)
25.59
(192,
7.559)
39.99
(300,
11.811)
40.79
(306,
12.047)
42.12
(316,
12.441)
43.99
(330,
12.992)
44.52
(334,
13.15)
47.32
(355,
13.976)
54.65
(410,
16.142)
54.65
(410,
16.142)
54.65
(410,
16.142)
54.65
(410,
16.142)
54.65
(410,
16.142)
GD(H4DOTC)-107
GENERAL DESCRIPTION
culation
speed)
ignition
Method
Method
Method
EN-01774
#3 #2 #4 #1 #3 #2 #4 #1 #3 #2 (A)
GD(H4DOTC)-108
GENERAL DESCRIPTION
Diagnostic
value
domg 180 = (omg 1 omg 0) (omg 5 omg 1)/4
domg 180 s judgment value of negative side
Judged as misfire.
Threshold valve (positive number)
Threshold valve (negative number)
domg180
domg180
EN-02877
Judged as misfire.
Threshold valve
domg360
domg360
EN-03273
GD(H4DOTC)-109
GENERAL DESCRIPTION
cles.
Normality Judgment
FTP emission judgment value > 20 100/2000% in
1000 revs.
Judgment Value
1000 revs.
Judged as misfire.
Threshold valve
domg720
domg720
EN-03274
GD(H4DOTC)-110
GENERAL DESCRIPTION
Map 3
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Catalyst damage misfire judgment value > Value from Map 3
0.2
(0.007)
0.4
(0.014)
0.6
(0.021)
0.8
(0.028)
1
(0.035)
1.2
(0.042)
1.4
(0.049)
1.6
(0.056)
1.8
(0.063)
2
(0.071)
Engine
speed
(rpm)
700 148 128 116 106 100 90 90 90 90 90
1000 148 128 114 104 92 85 85 85 85 85
1500 140 118 102 90 85 85 85 72 72 72
2000 128 90 90 73 58 43 40 36 32 20
2500 116 87 57 45 39 36 34 32 30 20
3000 108 87 58 39 36 36 32 30 28 20
3500 98 74 43 27 23 22 20 20 20 20
4000 69 61 40 27 22 20 20 20 20 20
4500 60 55 34 25 20 20 20 20 20 20
5000 55 55 34 23 20 20 20 20 20 20
5500 54 54 33 22 20 20 20 20 20 20
6000 52 52 32 21 20 20 20 20 20 20
6500 50 50 30 20 20 20 20 20 20 20
6700 50 50 30 20 20 20 20 20 20 20
Judgment Value
Catalyst damage misfire judgment value < Value from Map 3
GD(H4DOTC)-111
GENERAL DESCRIPTION
NOTE:
For the detection standard, refer to DTC P0301. <Ref. to GD(H4DOTC)-105, DTC P0301 CYLINDER 1 MIS-
NOTE:
NOTE:
GD(H4DOTC)-112
GENERAL DESCRIPTION
AW:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE
SENSOR)
3. ENABLE CONDITION
None
EN-01707
(1)
(2)
(3)
(4) (5)
(A)
GD(H4DOTC)-113
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Knock compensation:
Knock compensation final advance/delay angle value = knock compensation value + whole learning com-
pensation value + portional learning compensation value
Failure: Knock compensation value = 5CA (5CA retard)
Judgment Value
Judgment Value
GD(H4DOTC)-114
GENERAL DESCRIPTION
AX:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE
SENSOR)
3. ENABLE CONDITION
None
EN-01707
(1)
(2)
(3)
(4) (5)
(A)
GD(H4DOTC)-115
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Knock compensation:
Knock compensation final advance/delay angle value = knock compensation value + whole learning com-
pensation value + portional learning compensation value
Failure: Knock compensation value = 5CA (5CA retard)
Judgment Value
Judgment Value
GD(H4DOTC)-116
GENERAL DESCRIPTION
AY:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT
3. ENABLE CONDITION
(A) Camshaft signal (RH) (B) Camshaft signal (LH) (C) Crankshaft signal
None
EN-03269
(A)
(C)
10 C 30 C 30 C
(B)
50 CA 50 CA
50 CA
50 CA
50 CA 50 CA
EN-01780
(1)
(2)
(3)
GD(H4DOTC)-117
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Starter switch ON
Judgment Value
GD(H4DOTC)-118
GENERAL DESCRIPTION
AZ:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/
PERFORMANCE
3. ENABLE CONDITION
EN-03269
(A)
(C)
10 C 30 C 30 C
(B)
50 CA 50 CA
50 CA
50 CA
50 CA 50 CA
EN-01780
(1)
(2)
(3)
GD(H4DOTC)-119
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Amount of crank sensor signal during 1 rev. Not = 30
Judgment Value
Amount of crank sensor signal during 1 rev. = 30
GD(H4DOTC)-120
GENERAL DESCRIPTION
BA:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR
SINGLE SENSOR)
3. ENABLE CONDITION
Abnormality Judgment 1
Judge as NG when the condition where the number of camshaft position sensor signals are less than 3 time
during 2 engine revs. continues.
(A) Camshaft signal (RH) (C) Crankshaft signal (D) Number of camshaft position sig-
nals = When normal, there will be
3 cam signals for every 2 engine
revolutions.
(B) Camshaft signal (LH)
Judgment Value
2 revs.
< 3 time
EN-01853
(A)
(C)
10 C 30 C 30 C
(B)
50 CA 50 CA
50 CA
50 CA
50 CA 50 CA
(D)
GD(H4DOTC)-121
GENERAL DESCRIPTION
Normality Judgement 1
8. FAIL SAFE
AVCS control:
Maximum timing retard learning is not complete or maximum timing retard learning completion is not ex-
perienced.
ISC feedback compensation: Do not perform the AVCS actual timing advance compensation.
Make the OCV driving Duty to be the given value (9.36%).
Judgment Value
Camshaft position sensor signal > 3 time
Judgment Value
Starter ON
Camshaft position sensor signal No input
Judgment Value
Camshaft position sensor signal Input exists
GD(H4DOTC)-122
GENERAL DESCRIPTION
BB:DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)
NOTE:
For the detection standard, refer to DTC P0340. <Ref. to GD(H4DOTC)-120, DTC P0340 CAMSHAFT PO-
SITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
GD(H4DOTC)-123
GENERAL DESCRIPTION
BC:DTC P0410 SECONDARY AIR INJECTION SYSTEM
Detect NG judging from secondary air delivery pipe pressure, pulse of secondary air delivery pipe pressure
and secondary air pipe airflow amount.
2. ENABLE CONDITION
Perform diagnosis during secondary air pump operation
Pump supply pressure check
Estimate ambient temperature > 4.4 C
Barometric pressure > 75.05 kPa (563
mmHg, 22.165 inHg)
Engine In operation
Secondary air pump Operating
Combination valve Bank open (Except
with both banks
closed)
Combination valve both closed pulse
diagnosis
mmHg, 22.165 inHg)
Engine In operation
Engine load > 0.2 g/rev (0.007 oz/
rev)
Combination valve changeover pres-
sure diagnosis
mmHg, 22.165 inHg)
Engine In operation
and
< 25 g/s (0.882 oz/s)
Overflow diagnosis
mmHg, 22.165 inHg)
Engine In operation
GD(H4DOTC)-124
GENERAL DESCRIPTION
Measure secondary air delivery pipe pressure, pulse of secondary air delivery pipe pressure and secondary
air pipe airflow amount.
(1) IG (7) Diagnosis enable condition (11) Right bank all closed pressure
(POR) measurement
(2) Ne (8) Pump supply pressure check
(judgment)
(3) Secondary air pump operating
status
(12) Both banks all closed pressure
(PORL) measurement (9) Flow amount check (judgment)
(4) E-COMB valve (right hand) status (10) Barometric pressure (Pas) mea-
surement before secondary air
control
(13) Left bank all closed pressure
(POL) measurement
(5) E-COMB valve (left hand) status
(6) Secondary air delivery pipe pres-
sure (psi)
(2)
(7)
(8)
(6)
(12)
(11)
(10)
(13)
(9)
EN-05591
(3)
ON
OFF
(1)
ON
OFF
(4)
OPEN
CLOSE
(5)
OPEN
CLOSE
GD(H4DOTC)-125
GENERAL DESCRIPTION
Pump supply pressure check
Perform the system function diagnosis with how much the pressure rises when the secondary air pump is
turned from OFF to ON.
Judge as NG if delivery pipe pressure does not rise though it should when the secondary air pump turns OFF
ON.
cles.
Normality Judgment
Combination valve both closed pulse diagnosis
Perform open stuck diagnosis of both combination valves using delivery pipe pressure pulse when both com-
bination valves are closed. Determine which side of valves is stuck open by comparing secondary air flow
amount when RH combination valve is closed with that when LH combination valve is closed.
Calculate voltage pulse of the pump supply pipe pressure when both combination valves are closed. The cal-
culation should be small because there is no pulse from supply pipe pressure with both combination valves
closed. When the calculation is large, determine that either of the combination valves is stuck open.
Determine which side of valves is stuck open by comparing secondary air flow amount when the RH combi-
nation valve is closed with that when the LH combination valve is closed. Air flow amount is larger on the
open stuck valve.
Judgment Value
Secondary air supply pipe pressure
(after barometric pressure compensa-
tion)
< 0.93 kPa (7 mmHg,
0.276 inHg)
P0410
Judgment Value
Secondary air supply pipe pressure
(after barometric pressure compensa-
tion)
> 0.93 kPa (7 mmHg,
0.276 inHg)
P0410
GD(H4DOTC)-126
GENERAL DESCRIPTION
Time Needed for Diagnosis: 4000 ms + 992 ms + 992 ms + 992 ms
cles.
Normality Judgment
Combination valve changeover pressure diagnosis
Perform the RH combination valve stuck closed diagnosis with the variation of delivery pipe pressure when
the RH combination valve turns closed open.
Delivery pipe pressure should vary when the RH combination valve turns closed open. When the variation
is small, determine that the RH combination valve is stuck closed.
cles.
Judgment Value
Pulse calculation value when both com-
bination valves are closed
> Value of Map 1 P2440
Air flow amount when the right bank is
closed (value from Map 2)
> Air flow amount
when the left bank is
closed (value from
Map 3)
Air flow amount when the left bank is
> Air flow amount
when the right bank is
closed (value from
Map 2)
Judgment Value
s Value of Map 1 P2440, P2442
Judgment Value
Pressure variation value when the RH
combination valve is switched
< Value of Map 4 P2441
GD(H4DOTC)-127
GENERAL DESCRIPTION
Normality Judgment
Perform the LH combination valve stuck closed diagnosis with the variation of delivery pipe pressure when
the LH combination valve turns open closed.
Delivery pipe pressure should vary when the LH combination valve turns open closed. When the variation
is small, determine that the LH combination valve is stuck closed.
cles.
Normality Judgment
Overflow diagnosis
Perform secondary air system flow abnormality diagnosis using both sides of combination valves secondary
air amount when both are closed.
Judge as secondary air system flow abnormality either if there is excessive secondary air flow amount with
the RH combination valve closed, or if there is excessive secondary air flow amount with the LH combination
valve closed.
Judgment Value
Pressure variation value when the RH
Judgment Value
Pressure variation value when the LH
< Value of Map 5 P2443
Judgment Value
Pressure variation value when the LH
GD(H4DOTC)-128
GENERAL DESCRIPTION
PORL: Both banks all closed pressure
POR: Right bank all closed pressure
POL: Left bank all closed pressure
cles.
Normality Judgment
PORL: Both banks all closed pressure
POR: Right bank all closed pressure
POL: Left bank all closed pressure
Judgment Value
or
> Value of Map 7

Voltage at PORL measurement Volt-
age at POR measurement
s 4 V
age at POL measurement
s 4 V
Judgment Value
s Value of Map 6 P0411
or
s Value of Map 7

age at POR measurement
s 4 V
age at POL measurement
s 4 V
Map1
Intake air (g (oz)/rev)
0.1
(0.004)
0.25
(0.009)
0.3
(0.011)
1
(0.035)
Threshold value (V) 13 13 3.25 3.25
GD(H4DOTC)-129
GENERAL DESCRIPTION
Map2
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)
69.32
(520,
20.472)
74.65
(560,
22.047)
79.98
(600,
23.622)
85.31
(640,
25.197)
90.64
(680,
26.772)
95.98
(720,
28.346)
101.31
(760,
29.921)
106.64
(800,
31.496)
111.97
(840,
33.071)
117.3
(880,
34.646)
122.64
(920,
36.22)
127.97
(960,
37.795)
133.3
(1000,
39.37)
138.63
(1040,
40.945)
143.96
(1080,
42.52)
149.3
(1120,
44.094)
69.32
(520, 20.472)
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400 2400 2400
74.65
(560, 22.047)
200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400 2400
79.98
(600, 23.622)
400 200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400
85.31
(640, 25.197)
600 400 200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400
90.64
(680, 26.772)
800 600 400 200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
95.98
(720, 28.346)
1000 800 600 400 200 0 200 400 600 800 1000 1200 1400 1600 1800 2000
101.31
(760, 29.921)
1200 1000 800 600 400 200 0 200 400 600 800 1000 1200 1400 1600 1800
106.64
(800, 31.496)
1400 1200 1000 800 600 400 200 0 200 400 600 800 1000 1200 1400 1600
111.97
(840, 33.071)
1600 1400 1200 1000 800 600 400 200 0 200 400 600 800 1000 1200 1400
117.3
(880, 34.646)
1800 1600 1400 1200 1000 800 600 400 200 0 200 400 600 800 1000 1200
122.64
(920, 36.22)
2000 1800 1600 1400 1200 1000 800 600 400 200 0 200 400 600 800 1000
127.97
(960, 37.795)
2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 200 400 600 800
133.3
(1000, 39.37)
2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 200 400 600
138.63
(1040,
40.945)
2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 200 400
143.96
(1080, 42.52)
2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 200
149.3
(1120,
44.094)
2400 2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0
(L/min)
GD(H4DOTC)-130
GENERAL DESCRIPTION
Map 3
Secondary air
pressure in
the pipe when
both comb.
valve is clos-
ing kPa
(mmHg, inHg)
Secondary air
pressure in
the pipe when
RH comb.
valve is clos-
ing kPa
(mmHg, inHg)
69.32
(520,
20.472)
74.65
(560,
22.047)
79.98
(600,
23.622)
85.31
(640,
25.197)
90.64
(680,
26.772)
95.98
(720,
28.346)
101.31
(760,
29.921)
106.64
(800,
31.496)
111.97
(840,
33.071)
117.3
(880,
34.646)
122.64
(920,
36.22)
127.97
(960,
37.795)
133.3
(1000,
39.37)
138.63
(1040,
40.945)
143.96
(1080,
42.52)
149.3
(1120,
44.094)
69.32
(520, 20.472)
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400 2400 2400
74.65
(560, 22.047)
200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400 2400
79.98
(600, 23.622)
400 200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400
85.31
(640, 25.197)
600 400 200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400
90.64
(680, 26.772)
800 600 400 200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
95.98
(720, 28.346)
1000 800 600 400 200 0 200 400 600 800 1000 1200 1400 1600 1800 2000
101.31
(760, 29.921)
1200 1000 800 600 400 200 0 200 400 600 800 1000 1200 1400 1600 1800
106.64
(800, 31.496)
1400 1200 1000 800 600 400 200 0 200 400 600 800 1000 1200 1400 1600
111.97
(840, 33.071)
1600 1400 1200 1000 800 600 400 200 0 200 400 600 800 1000 1200 1400
117.3
(880, 34.646)
1800 1600 1400 1200 1000 800 600 400 200 0 200 400 600 800 1000 1200
122.64
(920, 36.22)
2000 1800 1600 1400 1200 1000 800 600 400 200 0 200 400 600 800 1000
127.97
(960, 37.795)
2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 200 400 600 800
133.3
(1000, 39.37)
2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 200 400 600
138.63
(1040,
40.945)
2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 200 400
143.96
(1080, 42.52)
2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 200
149.3
(1120,
44.094)
2400 2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0
(L/min)
GD(H4DOTC)-131
GENERAL DESCRIPTION
7. FAIL SAFE
None
Map4
Amount of intake air when RH comb. valve
switches (g (oz)/s)
Battery voltage when RH comb. valve
switches (V)
10
(0.353)
15
(0.529)
20
(0.705)
25
(0.882)
26
(0.917)
11 0.025 0.025 0.025 0.005 0
12 0.035 0.035 0.035 0.015 0
13 0.05 0.05 0.05 0.025 0
14 0.05 0.05 0.05 0.025 0
(V)
Map 5
Amount of intake air when LH comb. valve
switches (g (oz)/s)
Battery voltage when LH comb. valve
switches (V)
10
(0.353)
15
(0.529)
20
(0.705)
25
(0.882)
26
(0.917)
11 0.025 0.025 0.025 0.005 0
12 0.035 0.035 0.035 0.015 0
13 0.05 0.05 0.05 0.025 0
14 0.05 0.05 0.05 0.025 0
(V)
Map6
Amount of intake air when P0R is measuring
(g (oz)/s)
Battery voltage when P0R measuring (V)
2
(0.071)
25
(0.882)
11.5 345 345
12.5 345 345
13.5 345 345
14.5 390 390
15.5 420 420
(L/min)
Map7
Amount of intake air when P0L is measuring
(g (oz)/s)
Battery voltage when P0L measuring (V)
2
(0.071)
25
(0.882)
11.5 345 345
12.5 345 345
13.5 345 345
14.5 390 390
15.5 420 420
(L/min)
GD(H4DOTC)-132
GENERAL DESCRIPTION
BD:DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW
DETECTED
NOTE:
For the detection standard, refer to DTC P0410. <Ref. to GD(H4DOTC)-123, DTC P0410 SECONDARY AIR
INJECTION SYSTEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-133
GENERAL DESCRIPTION
BE:DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A
CIRCUIT OPEN
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Ignition ON
puts OFF signal
LOW
Judgment Value
Ignition ON
puts OFF signal
HIGH
GD(H4DOTC)-134
GENERAL DESCRIPTION
BF:DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A
CIRCUIT SHORTED
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Ignition ON
puts ON signal
HIGH
Judgment Value
Ignition ON
puts ON signal
LOW
GD(H4DOTC)-135
GENERAL DESCRIPTION
BG:DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE "B"
CIRCUIT OPEN
NOTE:
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:
INJECTION SYSTEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) De-
tecting Criteria.>
GD(H4DOTC)-136
GENERAL DESCRIPTION
BI: DTC P0418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Ignition ON
puts OFF signal
LOW
Judgment Value
Ignition ON
puts OFF signal
HIGH
GD(H4DOTC)-137
GENERAL DESCRIPTION
BJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD
(BANK 1)
(A) Normal (C) Output waveform from the front
oxygen (A/F) sensor
(D) Output waveform from the rear
oxygen Sensor
(B) Deterioration
(1) Front oxygen (A/F) sensor (2) Front oxygen sensor (3) Catalytic converter
EN-01713
(A)
(B)
(C) (D)
(1) (2)
(3)
(3)
GD(H4DOTC)-138
GENERAL DESCRIPTION
3. ENABLE CONDITION
lative value (E |(sglmd
n
sglmd
n1
)|) and rear oxygen sensor output voltage deviation cumulative value (E
|(ro2sad
n
ro2sad
n1
cumulative value (E |(sglmd
n
sglmd
n1
nostic value.
cles.
Normality Judgment
Barometric pressure > 75.05 kPa (563 mmHg, 22.165
inHg)
> 1000 ms
and
< 40 g/s (1.411 oz/s)
Engine load change every 0.5 engine revs. < 0.02 g/rev (0.001 oz/rev)
Purge execution calculated time > 5 sec
Judgment Value
E |(ro2sad
n
ro2sad
n1
)| / E |(sglmd
n

sglmd
n1
)|
> 11 (AT model)
> 9 (MT model)
Judgment Value
E |(ro2sad
n
ro2sad
n1
)| / E |(sglmd
n

sglmd
n1
)|
s 11 (AT model)
s 9 (MT model)
GD(H4DOTC)-139
GENERAL DESCRIPTION
8. FAIL SAFE
None
BK:DTC P0441 EVAPORATIVE EMISSION SYSTEM INCORRECT PURGE FLOW
NOTE:
For the detection standard, refer to DTC P0442. <Ref. to GD(H4DOTC)-140, DTC P0442 EVAPORATIVE
tecting Criteria.>
GD(H4DOTC)-140
GENERAL DESCRIPTION
(1) Fuel gauge (7) Canister (13) Fuel level sensor
(2) Intake manifold (8) Pressure control valve (14) Fuel tank
(3) Throttle body (9) Drain valve (15) Fuel cut valve
(4) Purge control solenoid valve (10) Drain filter (16) Fuel tank pressure sensor
(5) Purge control solenoid valve 2 (11) Shut-off valve (17) Vent valve
(6) Engine control module (ECM) (12) Fuel temperature sensor
(1)
(2)
(3)
(6)
(8)
(9)
(10)
(4)
(5)
(7)
(12)
(11)
(13)
(14)
(17)
(15)
(16)
EN-05372
GD(H4DOTC)-141
GENERAL DESCRIPTION
0.04-inch Diagnosis
Mode Z
(Purge control solenoid valve
opening failure diagnosis)
Perform purge control solenoid valve opening failure diagno-
sis from the size of tank pressure variation from diagnosis
start.
0 ms + 3000 ms 0 ms +
3000 ms + 13000 ms
Mode A
10000 ms
Mode B
(Sealed negative pressure,
large leakage 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.
0 10000 ms + 25000 ms
Mode C
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.
0 17000 ms
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.
0 ms + 10000 ms
Mode
Z
Mode
A
Mode
B
Mode
C
Mode
D
Parge control
solenoid velve2
blockade diagnosis
OK
NG
OK OK OK OK
NG
Early OK
Cancel
Mode
Z
Extend
NG
NG
OK
END
EN-05590
OK
GD(H4DOTC)-142
GENERAL DESCRIPTION
Mode
Behavior of tank internal pressure under
normal conditions
Diagnostic item DTC
Mode Z
Roughly the same as barometric pres-
sure (Same as 0 kPa (0 mmHg, 0 inHg))
Purge control solenoid valve is judged to
be open.
P0457
Mode A
Pressure is in proportion to amount of
evaporative emission.
None
Mode B
Negative pressure is formed due to
intake manifold negative pressure
Large leak
P0457
[1.0 mm (0.04 in)]
P0442
GD(H4DOTC)-143
GENERAL DESCRIPTION
0.02-inch Diagnosis
Mode A
When the pressure in the tank is not near 0 mmHg, wait until
it returns to 0 point (near 0 mmHg).
0 Value of Map 1
Mode B
Decrease the pressure in the tank to the target value by
introducing the intake manifold pressure to the fuel tank.
0 Value of Map 2
Mode C
Wait until the tank pressure returns to the target (start level
of P2 calculation).
0 20000 ms + 0 +
Value from Map 2
Mode D
(Negative pressure change calcu-
lated)
Calculate the time it takes for the tank pressure to change to
the Mode E shifting pressure. If the tank pressure does not
change to the Mode E shifting pressure, make advanced OK
judgment.
0 0 ms + 200000 ms
Mode E
calculation)
0 0 ms + 200000 ms +
Value from Map 3
Map1
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Map2
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Map 3
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
EN-02871
Cancel
Early OK 2
Early OK 1
OK OK OK OK
Cancel
Cancel
Cancel
Cancel
END
GD(H4DOTC)-144
GENERAL DESCRIPTION
(c) Canister
EN-01715
(a)
(b) (c)
(4)
(1)
(2)
(3)
GD(H4DOTC)-145
GENERAL DESCRIPTION
Solenoid ON B C
EN-01716
A
B C
X X Y
(a)
(b) (c)
EN-01717
A
B C
(a)
(b) (c)
GD(H4DOTC)-146
GENERAL DESCRIPTION
When Solenoid is ON
(b) Fuel tank
(c) Canister
EN-01718
A
B C
(a)
(b) (c)
(1)
EN-01719
A
B C
(a)
(b) (c)
GD(H4DOTC)-147
GENERAL DESCRIPTION
Drain valve
3. ENABLE CONDITION
0.04-inch Diagnosis
Barometric pressure > 75.05 kPa (563 mmHg, 22.165 inHg)
Total time of canister purge operation > 120000 ms
Fuel tank pressure > 4 kPa (30 mmHg, 1.181 inHg)
sure)
> 13.33 kPa ( 100 mmHg, 3.937 inHg)
Fuel level 9.6 L (2.536 US gal, 2.112 Imp gal) 54.4 L (14.372 US gal,
11.968 Imp gal)
Intake air temperature > 10 C (14 F)
< 1.7 mmHg (Mode D)
one second
< 1.7 mmHg (Mode A)
< 1.7 mmHg (Mode D)
EN-02293
GD(H4DOTC)-148
GENERAL DESCRIPTION
0.02-inch Diagnosis
0.04-inch Diagnosis
0.02-inch Diagnosis
Perform the diagnosis 125 seconds or more at a constant engine speed of 50 km/h (31 MPH) or higher to
judge as NG or OK.
Time since last incomplete 0.02-inch leakage
diagnosis
Fuel level 9.6 L (2.536 US gal, 2.112 Imp gal) 54.4 L
(14.372 US gal, 11.968 Imp gal)
sure)
> 13.33 kPa ( 100 mmHg, 3.937 inHg)
Fuel tank pressure 0.43 kPa (3.2 mmHg, 0.126 inHg) 1.43 kPa
(10.7 mmHg, 0.421 inHg)
Vehicle speed 50 km/h (31.1 MPH) 510 km/h (316.9 MPH) continues for
125000 ms
During diagnosis
Change of fuel level s Value of Map 4
Pressure change every one second < 0.06 kPa (0.44 mmHg, 0.017 inHg)
one second
< 0.07 kPa (0.51 mmHg, 0.02 inHg) (Mode D)
| Pressure change in tank every second | s 0.1 kPa (0.75 mmHg, 0.03 inHg)
Barometric pressure change 0.48 kPa (3.6 mmhg, 0.142 inHg) 0.32 kPa (2.4 mmhg,
0.094 inHg) (Mode D)
0.32 kPa (2.4 mmhg, 0.094 inHg) 0.32 kPa (2.4 mmhg,
0.094 inHg) (Mode E)
Map4
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
GD(H4DOTC)-149
GENERAL DESCRIPTION
DTC
Purpose of Mode Z
celled.
DIAGNOSTIC METHOD
If OK judgment cannot be made, extend Mode Z 16, and Judge as NG when the following conditions are es-
tablished after predetermined amount of time.
cles.
Normality Judgment
Judgment Value
evptez evptezha > 0.6 kPa (4.5 mmHg,
0.177 inHg)
P0457
evptezini s 1.43 kPa (10.7
mmHg, 0.421 inHg)
Time of 2 L (0.528 US gal, 0.44 Imp gal)
or more fuel no sloshing
> 40000 ms
Judgment Value
evptez evptezha s 0.4 kPa (3 mmHg,
0.118 inHg)
P0457
GD(H4DOTC)-150
GENERAL DESCRIPTION
Normal
evptez evptezha s 0.4 kPa (3 mmHg, 0.118 inHg) Normal when above is established
(2) 3000 ms (4) 0.4 kPa (3 mmHg, 0.118 inHg)
EN-02869
(1)
(2)
(4)
evptez
evptezini
evptezha
0
(3)
(5)
GD(H4DOTC)-151
GENERAL DESCRIPTION
evptezini s 1.43 kPa (10.7 mmHg, 0.421 inHg)
(1) Mode Z (5) 0.6 kPa (4.5 mmHg, 0.177 inHg) (7) 40000 ms no fuel sloshing
(2) Extended mode Z (6) 1.43 kPa
(10.7 mmHg, 0.421 inHg)
(8) NG judgment
(3) 3000 ms + 13000 ms
(4) Fuel tank pressure
EN-02870
(8)
(7)
(6)
(4)
(5)
evptez
evptezini
evptezha
0
(3)
(2) (1)
GD(H4DOTC)-152
GENERAL DESCRIPTION
Leak Diagnosis
DTC
P0441 Evaporative emission system incorrect purge flow
culation.)
Judgment Value
Time to reach target negative pressure > 10000 ms + 25000 ms P0457
or
Mode B time > 10000 ms
started)
> 0.33 kPa (2.5 mmHg,
0.098 inHg)
Tank pressure when starting cal-
culation of P2
judgment
1.3 kPa
(9.75 mmHg, 0.384 inHg)
17000 ms
GD(H4DOTC)-153
GENERAL DESCRIPTION
Purge control solenoid valve 2 stuck close diagnosis
Perform purge control solenoid valve 2 stuck close diagnosis using the variation gap between the tank pres-
sure at the end of mode C and after mode C.
cles.
Judgment Value
P2 1.5 - P1 > Value of Map 5 P0442
10000 ms in mode D
10000 ms in mode A
0.28 kPa
(2.1 mmHg,
0.083 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.35 mmHg,
0.093 inHg)
0.32 kPa
(2.4 mmHg,
0.094 inHg)
10 L (2.642 US gal, 2.2 Imp gal)
0.28 kPa
(2.1 mmHg,
0.083 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.35 mmHg,
0.093 inHg)
0.32 kPa
(2.4 mmHg,
0.094 inHg)
20 L (5.284 US gal, 4.4 Imp gal)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.32 kPa
(2.4 mmHg,
0.094 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
0.35 kPa
(2.6 mmHg,
0.102 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
30 L (7.926 US gal, 6.6 Imp gal)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.41 kPa
(3.05 mmHg,
0.12 inHg)
0.42 kPa
(3.15 mmHg,
0.124 inHg)
0.43 kPa
(3.25 mmHg,
0.128 inHg)
0.45 kPa
(3.35 mmHg,
0.132 inHg)
40 L (10.568 US gal, 8.8 Imp gal)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.42 kPa
(3.15 mmHg,
0.124 inHg)
0.44 kPa
(3.3 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
50 L (13.21 US gal, 11 Imp gal)
0.43 kPa
(3.2 mmHg,
0.126 inHg)
0.44 kPa
(3.3 mmHg,
0.13 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.48 kPa
(3.6 mmHg,
0.142 inHg)
0.49 kPa
(3.7 mmHg,
0.146 inHg)
60 L (15.852 US gal, 13.2 Imp gal)
0.43 kPa
(3.2 mmHg,
0.126 inHg)
0.44 kPa
(3.3 mmHg,
0.13 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.48 kPa
(3.6 mmHg,
0.142 inHg)
0.49 kPa
(3.7 mmHg,
0.146 inHg)
Elapsed time after completion of mode C
advanced OK judgement
= 3500 ms P0441
Tank pressure variation after completion
of mode C advanced OK judgement
< 0.758 mmHg
GD(H4DOTC)-154
GENERAL DESCRIPTION
Leak Diagnosis
DTC
culation.)
Normality Judgment
Judgment Value
Mode D time > 0 ms + 20000 ms
Tank internal pressure s Value of Map 6
P2 s Value of Map 7
Map6
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Tank pressure
(kPa, mmHg, inHgl)
1.85,
13.9,
0.547
1.85,
13.9,
0.547
1.84,
13.8,
0.543
1.83,
13.7,
0.539
1.81,
13.6,
0.535
1.8,
13.5,
0.531
1.8,
13.5,
0.531
Map7
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Tank pressure
(kPa, mmHg, inHgl)
0.93, 7,
0.276
0.93, 7,
0.276
0.94, 7.05,
0.278
0.95, 7.1,
0.28
1.09, 8.2,
0.323
1.28, 9.6,
0.378
1.28, 9.6,
0.378
GD(H4DOTC)-155
GENERAL DESCRIPTION
cles.
Judgment Value
P1 < Value of Map 8
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa
(1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
10 L (2.642 US gal, 2.2 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa
(1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
20 L (5.284 US gal, 4.4 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa
(1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
30 L (7.926 US gal, 6.6 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa
(1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
40 L (10.568 US gal, 8.8 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.25 kPa
(1.85 mmHg,
0.073 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
50 L (13.21 US gal, 11 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.27 kPa
(2 mmHg,
0.079 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0 kPa
(0 mmHg,
0 inHg)
60 L (15.852 US gal, 13.2 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.27 kPa
(2 mmHg,
0.079 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0 kPa
(0 mmHg,
0 inHg)
GD(H4DOTC)-156
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
P1 > Value of Map 9
0.13 kPa
(1 mmHg,
0.039 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
10 L (2.642 US gal, 2.2 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
20 L (5.284 US gal, 4.4 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.43 kPa
(3.25 mmHg,
0.128 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
30 L (7.926 US gal, 6.6 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.4 kPa
(3 mmHg,
0.118 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
40 L (10.568 US gal, 8.8 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.3 kPa
(2.25 mmHg,
0.089 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 L (13.21 US gal, 11 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.2 kPa
(1.5 mmHg,
0.059 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
60 L (15.852 US gal, 13.2 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.2 kPa
(1.5 mmHg,
0.059 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
GD(H4DOTC)-157
GENERAL DESCRIPTION
BM:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL
CIRCUIT OPEN
3. ENABLE CONDITION
(7) Yoke
None
(1) (2) (3)
(4) (5) (6) (7) (8)
(9) (10) (11) (12) (13) (17)
(14) (15) (16) (18) (19) (19)
EN-02294
GD(H4DOTC)-158
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
puts OFF signal
Low
Judgment Value
puts OFF signal
High
GD(H4DOTC)-159
GENERAL DESCRIPTION
BN:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL
CIRCUIT SHORTED
3. ENABLE CONDITION
(7) Yoke
None
(1) (2) (3)
(4) (5) (6) (7) (8)
(9) (10) (11) (12) (13) (17)
(14) (15) (16) (18) (19) (19)
EN-02294
GD(H4DOTC)-160
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
puts ON signal
High
Judgment Value
puts ON signal
Low
GD(H4DOTC)-161
GENERAL DESCRIPTION
BO:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR
tus.
3. ENABLE CONDITION
2.112 Imp gal)
mmHg, 22.165 inHg)
EN-04462
(A)
(B)
(2) (1)
(C)
GD(H4DOTC)-162
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
> 16 time
< 0.05 kPa (0.375 mmHg,
0.015 inHg)
> 7 C (44.6 F)
Judgment Value
Maximum Minimum tank pressure > 0.05 kPa (0.375 mmHg,
0.015 inHg)
GD(H4DOTC)-163
GENERAL DESCRIPTION
BP:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR LOW INPUT
3. ENABLE CONDITION
None
Judgment Value
2.199 inHg)
EN-04462
(A)
(B)
(2) (1)
(C)
GD(H4DOTC)-164
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Fuel tank pressure > 7.44 kPa (55.85 mmHg,
2.199 inHg)
GD(H4DOTC)-165
GENERAL DESCRIPTION
BQ:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR HIGH INPUT
3. ENABLE CONDITION
> 5000 ms
< 0.08
(left and right)
> 0.9
EN-04462
(A)
(B)
(2) (1)
(C)
GD(H4DOTC)-166
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
BR:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED
(VERY SMALL LEAK)
NOTE:
tecting Criteria.>
BS:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED
(FUEL CAP LOOSE/OFF)
NOTE:
tecting Criteria.>
Judgment Value
2.356 inHg)
22.165 inHg)
Judgment Value
2.356 inHg)
GD(H4DOTC)-167
GENERAL DESCRIPTION
BT:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT LOW
3. ENABLE CONDITION
(A) (B)
EN-02197
GD(H4DOTC)-168
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4DOTC)-169
GENERAL DESCRIPTION
BU:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT HIGH
3. ENABLE CONDITION
(A) (B)
EN-02197
GD(H4DOTC)-170
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Duty ratio of ON > 0.25
Judgment Value
GD(H4DOTC)-171
GENERAL DESCRIPTION
BV:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE
3. ENABLE CONDITION
None
EN-01734
0
(B)
(A)
GD(H4DOTC)-172
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
(11672.853 oz)
0.572 Imp gal)
Judgment Value
(11672.853 oz)
Max. min. values of fuel level output > 2.6 L (0.687 US gal,
0.572 Imp gal)
GD(H4DOTC)-173
GENERAL DESCRIPTION
BW:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW
3. ENABLE CONDITION
None
(5)
(4)
(1)
(2) (3)
EN-05371
GD(H4DOTC)-174
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4DOTC)-175
GENERAL DESCRIPTION
BX:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH
3. ENABLE CONDITION
None
(5)
(4)
(1)
(2) (3)
EN-05371
GD(H4DOTC)-176
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H4DOTC)-177
GENERAL DESCRIPTION
BY:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
2. ENABLE CONDITION
Idle switch ON
2.112 Imp gal)
and
< 54.4 L (14.372 US
gal, 11.968 Imp gal)
Vehicle speed = 0 km/h (0 MPH) > 10000 ms
GD(H4DOTC)-178
GENERAL DESCRIPTION
(B) NG at 4 time
Diagnosis condition
Diagnosis timer
(A)
Fuel level sensor
A/D value
Diagnosis counter
(B)
1
2
3
4
5
6
0
(C)
(D)
EN-05569
GD(H4DOTC)-179
GENERAL DESCRIPTION
cles.
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Integrated times of the condition reaching follows, > 4 time
DELFLMAX > Value from Map
or
SUMFL > 25.92 V
At this time,
DELFLMAX: Maximum difference of sensor output for 12288 ms
SUMFL: Integrated value of the sensor output deviation for12288 ms
Map
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Maximum value Minimum value of change of tank pressure for
12288 ms
> 0.05 kPa (0.375 mmHg,
0.015 inHg)
Maximum value Minimum value of battery voltage for12288 ms > 0.969 V
Judgment Value
SUMFL < 25.92 V
At this time,
GD(H4DOTC)-180
GENERAL DESCRIPTION
BZ:DTC P0500 VEHICLE SPEED SENSOR A
is impossible.
3. ENABLE CONDITION
Normality Judgment
Elapsed time after engine starting > 2000 ms
Judgment Value
Front left wheel speed > 300 km/h
(186.4 MPH)
Front right wheel speed > 300 km/h
(186.4 MPH)
Judgment Value
and
< 300 km/h
(186.4 MPH)
and
< 300 km/h
(186.4 MPH)
GD(H4DOTC)-181
GENERAL DESCRIPTION
8. FAIL SAFE
Accelerator sensor signal process: Not allowed full closed point learning (hold the previous value)
ABS wheel speed sensor signal process: Vehicle speed = 10 km/h (6 MPH)
condition (4400 rpm or more).
ISC control: Open loop compensation is set to (1 g (0.04 oz) oz/s) Not allowed ISC feedback volume cal-
culation.
Radiator fan control: Both main and sub fan ON drive
Gear ratio judgment: Gear = Control as fixed in sixth gear
GD(H4DOTC)-182
GENERAL DESCRIPTION
CA:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
2. ENABLE CONDITION
cles.
Normality Judgment
22.165 inHg)
2.112 Imp gal)
Elapsed time after starting the engine > 10.49 sec
Lambda value (left and right) > 0.9
and
< 1.1
OFF
> 5.1 sec
more.
> 5.1 sec
> 5.1 sec
Judgment Value
speed
< 100 rpm
Judgment Value
speed
> 100 rpm
GD(H4DOTC)-183
GENERAL DESCRIPTION
7. FAIL SAFE
None
GD(H4DOTC)-184
GENERAL DESCRIPTION
CB:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
2. ENABLE CONDITION
cles.
Normality Judgment
22.165 inHg)
2.112 Imp gal)
and
< 1.1
OFF
> 5.1 sec
more.
> 5.1 sec
> 5.1 sec
Judgment Value
Actual Target engine speed > 200 rpm
Judgment Value
GD(H4DOTC)-185
GENERAL DESCRIPTION
7. FAIL SAFE
None
GD(H4DOTC)-186
GENERAL DESCRIPTION
CC:DTC P0512 STARTER REQUEST CIRCUIT
2. ENABLE CONDITION
cles.
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Judgment Value
GD(H4DOTC)-187
GENERAL DESCRIPTION
CD:DTC P0513 INCORRECT IMMOBILIZER KEY
2. ENABLE CONDITION
DTC Item Outline of Diagnosis
Incorrect immobilizer key
(Use of unregistered key in body integrated unit)
ECM
P1572
Antenna Circuit)
P1578 Meter Failure
combination meter
GD(H4DOTC)-188
GENERAL DESCRIPTION
CE:DTC P0600 SERIAL COMMUNICATION LINK
(High speed CAN)
3. ENABLE CONDITION
None
Judgment Value
Starter switch OFF
Engine run
or
TCM, ABSCM or VDCCM
None during 500 milliseconds
or
TCM, ABSCM or VDCCM
GD(H4DOTC)-189
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Accelerator pedal position sensor request target throttle opening calculation: AT protection torque guard is
normally obtained from CAN communication. Preset value is 408 Nm (42 kgf-m, 301 ft-lb).
Judgment Value
Starter switch OFF
Engine run
Yes
Yes
GD(H4DOTC)-190
GENERAL DESCRIPTION
CF:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY
(RAM) ERROR
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Write the specified value to RAM and
then read.
The written value can-
not be read.
Judgment Value
then read.
The written value can
be read.
GD(H4DOTC)-191
GENERAL DESCRIPTION
CG:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)
ERROR
2. ENABLE CONDITION
Main CPU: 16 milliseconds 32 time
Sub CPU: 16 milliseconds 2 time
Normality Judgment
7. FAIL SAFE
Ignition switch ON
Judgment Value
Judgment Value
GD(H4DOTC)-192
GENERAL DESCRIPTION
CH:DTC P0607 CONTROL MODULE PERFORMANCE
(1) When the read value of throttle position sensor 1 signal is mismatched between main CPU and sub CPU.
(2) When the read value of accelerator pedal position sensor 1 signal is mismatched between main CPU and
sub CPU.
(3) When the sub CPU operates abnormally.
(4) When the communication between main CPU sub CPU is abnormal.
(5) When the input amplifier circuit of throttle position sensor 1 is abnormal.
(6) When the cruise control cannot be canceled correctly.
(7) When the signal of brake SW1 and 2 is mismatched.
EN-01862
(1)
(4)
(2)
(3)
(5)
(6)
(7)
(8)
(9)
(12)
(11) (10)
(10)
(10)
(10)
(13)
(14)
GD(H4DOTC)-193
GENERAL DESCRIPTION
3. ENABLE CONDITION
(1): 600 msec
(2): 830 msec
(3): 200 msec
(4): 200 msec
(5): 24 msec
(6): 250 msec
(7): 200 ms
(1) Battery voltage > 6 V
Judgment Value
(1) Difference of CPU reading value of the
throttle position sensor signal
> 0.4058 V
> 0.127542424 V
(3) WD pulse from sub CPU No WD pulse occur
(4) Communication between CPU Not possible to com-
municate
angle (Throttle position sensor 1 open-
ing angle after passing amplifier) 1/4|
> 3 deg
ON
signal OFF
(7) Brake switch 1, 2 signal SW 1 and 2 are not
matched
GD(H4DOTC)-194
GENERAL DESCRIPTION
Normality Judgment
(1): 2000 msec
(2): 2000 msec
(3): 2000 msec
(4): 2000 msec
(5): 24 msec
(6): 2000 msec
(7): 2000 ms
8. FAIL SAFE
Judgment Value
< 0.4058 V
< 0.127542424 V
(4) Communication between CPU Possible to communi-
cate
angle (Throttle position sensor 1 open-
ing angle after passing amplifier) 1/4|
< 3 deg
ON
signal ON
(7) Brake switch 1, 2 signal SW 1 and 2 are
matched
GD(H4DOTC)-195
GENERAL DESCRIPTION
CI: DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE
(BANK 1)
3. ENABLE CONDITION
Always perform the diagnosis continuously when the electric throttle control is operating.
Normal operation of electric throttle con-
trol
ON
Judgment Value
> Value of Map 1
Output duty to drive circuit > 95%
Map1
angle () = d
0 s d < 6.15 6.15 s d < 9.65 9.65 s d < 14.65 14.65 s d < 26.65 26.65 s d
Difference between target
opening angle and actual
opening angle ()
3.5 5 12 25 25
EN-01863
(3)
(4)
(1)
(2)
GD(H4DOTC)-196
GENERAL DESCRIPTION
Difference between target opening angle and actual opening angle: 1000 milliseconds (when target open-
ing angle > actual opening angle) or value of Map 2 (when target opening angle s actual opening angle)
Output duty to drive circuit: value of Map 3
Normality Judgment
Difference between target opening angle and actual opening angle: 2000 msec
Output duty to drive circuit: 2000 msec
8. FAIL SAFE
Map2
0 s d < 5.5 5.5 s d < 9 9 s d < 13 13 s d < 22 22 s d
Judgment time
(milliseconds)
1000 400 300 250 250
Map 3
Voltage to drive circuit (V) 6 8 10 12 14 16
Judgment time
(milliseconds)
2000 2000 2000 2000 2000 2000
Judgment Value
< Value of Map 1
Output duty to drive circuit < 95%
GD(H4DOTC)-197
GENERAL DESCRIPTION
CJ:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Judgment Value
GD(H4DOTC)-198
GENERAL DESCRIPTION
CK:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)
Judge as NG when the neutral terminal input in ECM differs from the received data from TCM.
2. ENABLE CONDITION
Perform the diagnosis continuously after two seconds have passed since the engine started.
cles.
Normality Judgment
7. FAIL SAFE
None
Starter relay OFF
Judgment Value
LOW (ON)
Judgment Value
HIGH (OFF)
GD(H4DOTC)-199
GENERAL DESCRIPTION
CL:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)
Judge as NG when there is no change in the neutral SW even if the driving shift was applied. (There is neutral
2. ENABLE CONDITION
change.
cles.
Normality Judgment
Starter relay OFF
Judgment Value
from a to b below)
LOW (ON) continues.
Vehicle speed > 0 km/h (0 MPH)
Judgment Value
from a to b below)
Changes to HIGH
(OFF).
GD(H4DOTC)-200
GENERAL DESCRIPTION
7. FAIL SAFE
Cruise control: Not allowed to command cruise control.
GD(H4DOTC)-201
GENERAL DESCRIPTION
CM:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)
2. ENABLE CONDITION
cles.
Normality Judgment
7. FAIL SAFE
None
Starter relay OFF
Judgment Value
HIGH (OFF)
Judgment Value
LOW (ON)
GD(H4DOTC)-202
GENERAL DESCRIPTION
CN:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)
Judge as NG when there is no change in the neutral SW even if the driving shift was applied. (There is neutral
2. ENABLE CONDITION
change.
cles.
Normality Judgment
Starter relay OFF
Judgment Value
from a to b below)
HIGH (OFF) contin-
ues.
Judgment Value
from a to b below)
Changes to LOW
(ON).
GD(H4DOTC)-203
GENERAL DESCRIPTION
7. FAIL SAFE
None
GD(H4DOTC)-204
GENERAL DESCRIPTION
CO:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW)
(BANK1 SENSOR1)
control, etc.
air fuel ratio
> 1: Lean
< 1: Rich
(3) ZrO
2
(C) Lean
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4DOTC)-205
GENERAL DESCRIPTION
3. ENABLE CONDITION
cles.
Normality Judgment
conditions
> 4096 ms
(563 mmHg, 22.165 inHg)
Targeted lambda value load compensation coefficient 1 1
Judgment Value
value < 0.85
Judgment Value
value > 0.85
GD(H4DOTC)-206
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4DOTC)-207
GENERAL DESCRIPTION
CP:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH)
(BANK1 SENSOR1)
control, etc.
air fuel ratio
> 1: Lean
< 1: Rich
(3) ZrO
2
(C) Lean
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H4DOTC)-208
GENERAL DESCRIPTION
3. ENABLE CONDITION
cles.
Normality Judgment
conditions
> 4096 ms
(563 mmHg, 22.165 inHg)
Targeted lambda value load compensation coefficient 1 1
Judgment Value
value > 1.15
Judgment Value
value s 1.15
GD(H4DOTC)-209
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H4DOTC)-210
GENERAL DESCRIPTION
CQ:DTC P1160 RETURN SPRING FAILURE
3. ENABLE CONDITION
(2) Return spring (5) Throttle valve (8) Main and sub throttle position sen-
sor
Throttle position sensor Normal
EN-04463
S S
(8)
(6)
(7)
(5)
(1)
(3)
(2)
(4)
GD(H4DOTC)-211
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
to OFF
< 2 deg
Judgment Value
to OFF
> 2 deg
GD(H4DOTC)-212
GENERAL DESCRIPTION
CR:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT
LOW
3. ENABLE CONDITION
None
EN-01759
(1)
(2)
(3)
(4)
(5)
(A)
(B) (C)
GD(H4DOTC)-213
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
puts OFF signal
Low
Judgment Value
puts OFF signal
High
GD(H4DOTC)-214
GENERAL DESCRIPTION
CS:DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
STUCK OPEN
Always detect abnormally that both combination valve electromagnetic valve and the reed valve are open
failure.
Calculate the integrated value of Max./Min. value and output voltage deviation of the secondary air delivery
pipe pressure sensor output voltage in a given time after engine start. Judge as NG if the integrated value
and the difference between Max. and Min. values are large.
Perform continuous diagnosis when air flow amount is large during the secondary air pump stop after engine
start.
and
< 10000 rpm
After secondary air system stops > 9000 ms
and
< 400 g/s (14.108 oz/s)
Engine load > 0 g/rev
GD(H4DOTC)-215
GENERAL DESCRIPTION
When both combination valve electromagnetic valve and the reed valve are open failure, the failure appears
as pulses in the secondary air delivery pipe pressure sensor output. Detect abnormality by capturing these
pulses using the following method.
Calculate Max./Min. value of the secondary air delivery pipe pressure sensor output voltage and the sum of
the output voltage deviation for the given time. Compare the difference between Max. and Min. values with
threshold value and also compare the sum value with the threshold value. If both values exceed the threshold
value, count up NG counter and then judge as NG if the counter reaches the given times.
Normality Judgment
Judge as OK and clear NG if neither exceeds the threshold value, or if either of the two exceeds the threshold
value.
7. FAIL SAFE
None
Judgment Value
Pipe inner pressure difference between
Max. and Min.
> 0.05 V
Sum of the pipe inner pressure variation
value every 4 milliseconds
> 5 V
Barometric pressure variation value < 26.66 kPa (200
mmHg, 7.874 inHg)
Judgment Value
Pipe inner pressure difference between
Max. and Min.
s 0.05 V
Sum of the pipe inner pressure variation
value every 4 milliseconds
s 5 V
GD(H4DOTC)-216
GENERAL DESCRIPTION
CT:DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT
SHORTED
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Ignition ON
puts ON signal
HIGH
Judgment Value
Ignition ON
puts ON signal
LOW
GD(H4DOTC)-217
GENERAL DESCRIPTION
CU:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
3. ENABLE CONDITION
None
EN-01759
(1)
(2)
(3)
(4)
(5)
(A)
(B) (C)
GD(H4DOTC)-218
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
puts ON signal
High
Judgment Value
puts ON signal
Low
GD(H4DOTC)-219
GENERAL DESCRIPTION
CV:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM
3. ENABLE CONDITION
(7) Yoke
Drain valve Open
22.165 inHg)
Tank pressure when starter is OFF
ON
0.43 kPa (3.2 mmHg,
0.126 inHg)
and
1.43 kPa (10.7 mmHg,
0.421 inHg)
(1) (2) (3)
(4) (5) (6) (7) (8)
(9) (10) (11) (12) (13) (17)
(14) (15) (16) (18) (19) (19)
EN-02294
GD(H4DOTC)-220
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Fuel tank pressure s 4 kPa (30 mmHg,
1.181 inHg)
Judgment Value
Fuel tank pressure > 4 kPa (30 mmHg,
1.181 inHg)
> 30000 ms
Fuel temperature 10 C (14 F) 55 C
(131 F)
Intake manifold relative pressure > 26.66 kPa (200 mmHg,
7.874 inHg)
GD(H4DOTC)-221
GENERAL DESCRIPTION
CW: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.
3. ENABLE CONDITION
(1) Engine control module (ECM) (3) PCV diagnosis connector (4) 5 V
(2) Detecting circuit
None
EN-01790
E
(1)
(2)
(3)
(4)
GD(H4DOTC)-222
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
voltage
High
Judgment Value
voltage
Low
GD(H4DOTC)-223
GENERAL DESCRIPTION
CX:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Judgment Value
GD(H4DOTC)-224
GENERAL DESCRIPTION
CY:DTC P1570 ANTENNA
NOTE:
For the detection standard, refer to DTC P0513. <Ref. to GD(H4DOTC)-187, DTC P0513 INCORRECT
IMMOBILIZER KEY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CZ:DTC P1571 REFERENCE CODE INCOMPATIBILITY
NOTE:
DA:DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)
NOTE:
DB:DTC P1574 KEY COMMUNICATION FAILURE
NOTE:
DC:DTC P1576 EGI CONTROL MODULE EEPROM
NOTE:
DD:DTC P1577 IMM CONTROL MODULE EEPROM
NOTE:
DE:DTC P1578 METER FAILURE
NOTE:
GD(H4DOTC)-225
GENERAL DESCRIPTION
DF:DTC P1602 CONTROL MODULE PROGRAMMING ERROR
control.
NG.
specified value.
control.
2. ENABLE CONDITION
cles.
22.165 inHg)
Judgment Value
Map
Coolant
temperature
after starting
the engine
40 C
(40 F)
30 C
(22 F)
20 C
(4 F)
10 C
(14 F)
0 C
(32 F)
10 C
(50 F)
20 C
(68 F)
30 C
(86 F)
40 C
(104 F)
45 C
(113 F)
Threshold
value
(AT model)
200 C
(392 F)
200 C
(392 F)
200 C
(392 F)
200 C
(392 F)
98 C
(208.4 F)
98 C
(208.4 F)
97 C
(206.6 F)
93 C
(199.4 F)
89 C
(192.2 F)
88 C
(190.4 F)
Threshold
value
(MT model)
200 C
(392 F)
200 C
(392 F)
200 C
(392 F)
200 C
(392 F)
86.45830052
C
(187.6 F)
83.45699292
C
(182.2 F)
82.13981981
C
(179.9 F)
77.22136721
C
(171 F)
74.07767676
C
(165.3 F)
73.24222051
C
(163.8 F)
GD(H4DOTC)-226
GENERAL DESCRIPTION
Normality Judgment
cles.
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Estimated exhaust gas temperature > Value from Map
Judgment Value
> 6000 ms
> 30 CA)
> 0 ms
Judgment Value
< 6000 ms
> 30 CA)
< 0 ms
GD(H4DOTC)-227
GENERAL DESCRIPTION
DG: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
Normality Judgment
7. FAIL SAFE
Tumble generator valve opening
For tumble generator valve full closing points learning, not allowed to update to closing side.
For tumble generator valve full opening points learning, not allowed to update to opening side.
Tumble generator valve control
Output the open signal.
Ambient air temperature > 30 C (22 F)
Judgment Value
Tumble generator valve opening > 64.3 deg
Tumble generator valve close signal output > 3200 ms
Judgment Value
Tumble generator valve opening < 64.3 deg
GD(H4DOTC)-228
GENERAL DESCRIPTION
DH: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
Normality Judgment
7. FAIL SAFE
Output the open signal.
Judgment Value
Judgment Value
GD(H4DOTC)-229
GENERAL DESCRIPTION
DI: 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
Normality Judgment
7. FAIL SAFE
Output the close signal.
Judgment Value
Tumble generator valve open signal output > 4600 ms
Judgment Value
GD(H4DOTC)-230
GENERAL DESCRIPTION
DJ: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
Normality Judgment
7. FAIL SAFE
Output the close signal.
Judgment Value
Judgment Value
GD(H4DOTC)-231
GENERAL DESCRIPTION
DK:DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN
(BANK 1)
Detect the open or short circuit of tumble generator valve motor.
Judge as NG when the open signal is sent from IC after tumble generator valve driving IC diagnosis.
3. ENABLE CONDITION
(1) Engine control module (ECM) (2) Tumble generator valve (3) Battery

EN-01789
E
E
(3)
M (2)
(1)
GD(H4DOTC)-232
GENERAL DESCRIPTION
At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve out-
put is set to ON OFF, and judge open NG when the open NG signal is sent 96 msec 20 time in a row.
Time Needed for Diagnosis: 96 msec 20 time
Normality Judgment
Judge as OK and clear the NG when the OK signal is sent.
8. FAIL SAFE
Tumble generator valve control: Not allowed to move tumble generator valve.
Judgment Value
Open NG signal input Low
Overcurrent NG signal input High
Judgment Value
Open NG signal input High
GD(H4DOTC)-233
GENERAL DESCRIPTION
DL:DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW
(BANK 1)
Judge as NG when the overcurrent signal is sent from IC after tumble generator valve driving IC diagnosis.
3. ENABLE CONDITION
EN-01789
E
E
(3)
M (2)
(1)
GD(H4DOTC)-234
GENERAL DESCRIPTION
put is set to ON OFF, and judge overcurrent NG when the overcurrent NG signal is sent 96 msec 10 time
in a row.
Normality Judgment
8. FAIL SAFE
Judgment Value
Overcurrent NG signal input Low
Judgment Value
GD(H4DOTC)-235
GENERAL DESCRIPTION
DM:DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN
(BANK 2)
Judge as NG when the open signal is sent from IC after tumble generator valve driving IC diagnosis.
3. ENABLE CONDITION
EN-01789
E
E
(3)
M (2)
(1)
GD(H4DOTC)-236
GENERAL DESCRIPTION
put is set to ON OFF, and judge open NG when the open NG signal is sent 96 msec 20 time in a row.
Normality Judgment
8. FAIL SAFE
Judgment Value
Open NG signal input Low
Judgment Value
GD(H4DOTC)-237
GENERAL DESCRIPTION
DN:DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW
(BANK 2)
Judge as NG when the overcurrent signal is sent from IC after tumble generator valve driving IC diagnosis.
3. ENABLE CONDITION
EN-01789
E
E
(3)
M (2)
(1)
GD(H4DOTC)-238
GENERAL DESCRIPTION
put is set to ON OFF, and judge overcurrent NG when the overcurrent NG signal is sent 96 msec 10 time
in a row.
Normality Judgment
8. FAIL SAFE
Judgment Value
Overcurrent NG signal input Low
Judgment Value
GD(H4DOTC)-239
GENERAL DESCRIPTION
DO:DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH
Detect open or short circuit of tumble generator valve position sensor.
3. ENABLE CONDITION
(1) Rotor (3) Voltage (V) (4) Tumble generator valve opening
()
(2) Return spring
None
EN-01768
(3)
(4)
(1) (2)
GD(H4DOTC)-240
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-241
GENERAL DESCRIPTION
DP:DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH
3. ENABLE CONDITION
(1) Rotor (3) Voltage (V) (4) Throttle valve opening angle ()
(2) Return spring
None
EN-01768
(3)
(4)
(1) (2)
GD(H4DOTC)-242
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-243
GENERAL DESCRIPTION
DQ:DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH
3. ENABLE CONDITION
()
(2) Return spring
None
EN-01768
(3)
(4)
(1) (2)
GD(H4DOTC)-244
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-245
GENERAL DESCRIPTION
DR:DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH
3. ENABLE CONDITION
()
(2) Return spring
None
EN-01768
(3)
(4)
(1) (2)
GD(H4DOTC)-246
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-247
GENERAL DESCRIPTION
DS:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
LOW (BANK 1)
Detect open or short circuit of the oil flow control solenoid valve.
Judge as NG when the current is small even though the duty signal is large.
2. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Oil flow control solenoid valve control
duty
> 99.61 %
Oil control solenoid valve control present
current
< 0.306 A
Judgment Value
Target current value of the oil flow control
solenoid valve
> 0.14 A
|Target current value of the oil flow con-
trol solenoid valve Oil flow control sole-
noid valve control current value|
< 0.08 A
GD(H4DOTC)-248
GENERAL DESCRIPTION
7. FAIL SAFE
learning compensation factor when making a normality judgment abnormality judgment, and then
Enter the initial value (0CA) to the compensation value of partial learning zone when making a normal-
ity judgment abnormality judgment.
AVCS control:
perienced.
Make the oil flow control solenoid valve driving duty a predetermined value (9.36%).
GD(H4DOTC)-249
GENERAL DESCRIPTION
DT:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
HIGH (BANK 1)
Detect open or short circuit of oil flow control solenoid valve.
Judge as NG when the current is large even though the duty signal is small.
2. ENABLE CONDITION
Normality Judgment
None
Judgment Value
duty
< 0.39 %
current
> 0.306 A
Judgment Value
< 0.08 A
GD(H4DOTC)-250
GENERAL DESCRIPTION
7. FAIL SAFE
AVCS control:
perienced.
DU:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
LOW (BANK 2)
NOTE:
SHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) De-
tecting Criteria.>
DV:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
HIGH (BANK 2)
NOTE:
SHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) De-
tecting Criteria.>
GD(H4DOTC)-251
GENERAL DESCRIPTION
DW:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1
3. ENABLE CONDITION
MPH) or more.
back learning
Completed
established.
> 1 sec
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H4DOTC)-252
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Sub feedback learning value < 0.02 (AT model)
< 0.02 (MT model)
Judgment Value
Sub feedback learning value > 0.02 + 0.005
(AT model)
> 0.02 + 0
(MT model)
GD(H4DOTC)-253
GENERAL DESCRIPTION
DX:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1
3. ENABLE CONDITION
MPH) or more.
back learning
Completed
established.
> 1 sec
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H4DOTC)-254
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Sub feedback learning value > 0.04 (AT model)
> 0.04 (MT model)
Judgment Value
Sub feedback learning value < 0.04 + 0.005
(AT model)
< 0.04 + 0
(MT model)
GD(H4DOTC)-255
GENERAL DESCRIPTION
DY:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/
PERFORMANCE
3. ENABLE CONDITION
Under control of electronic throttle con-
trol
ON
CPU communication line sub
main normal judgment
Normal
EN-01867
(3) (2)
(5) (2)
(4)
(1)
(6)
(7)
12V 12V
GD(H4DOTC)-256
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Motor current > 8 A
or
Drive circuit inner temperature > 175C (347F)
Judgment Value
Motor current s 8 A
Drive circuit inner temperature s 175C (347F)
GD(H4DOTC)-257
GENERAL DESCRIPTION
DZ:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW
3. ENABLE CONDITION
EN-01868
(2)
(3)
(1)
(4)
(5)
12V 12V
GD(H4DOTC)-258
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Motor power voltage s 5 V
Judgment Value
Motor power voltage > 5 V
GD(H4DOTC)-259
GENERAL DESCRIPTION
EA:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
3. ENABLE CONDITION
EN-01868
(2)
(3)
(1)
(4)
(5)
12V 12V
GD(H4DOTC)-260
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
Motor power voltage < 5 V
GD(H4DOTC)-261
GENERAL DESCRIPTION
EB:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP
PERFORMANCE
3. ENABLE CONDITION
(2) Drive circuit
EN-01869
(1)
(2)
(3)
(4)
GD(H4DOTC)-262
GENERAL DESCRIPTION
Time Needed for Diagnosis: 8 msec 80 msec
Normality Judgment
8. FAIL SAFE
Judgment Value
< 10.127 deg
or
> 19.872 deg
or
position
< 1.683 deg
Judgment Value
> 10.127 deg
and
s 19.872 deg
position
> 1.683 deg
GD(H4DOTC)-263
GENERAL DESCRIPTION
EC:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT
LOW INPUT
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
EN-01861
(2)
(3)
(4)
(1)
GD(H4DOTC)-264
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-265
GENERAL DESCRIPTION
ED:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT
HIGH INPUT
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
EN-01861
(2)
(3)
(4)
(1)
GD(H4DOTC)-266
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-267
GENERAL DESCRIPTION
EE:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT
LOW INPUT
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
EN-01861
(2)
(3)
(4)
(1)
GD(H4DOTC)-268
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-269
GENERAL DESCRIPTION
EF:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT
HIGH INPUT
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
EN-01861
(2)
(3)
(4)
(1)
GD(H4DOTC)-270
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H4DOTC)-271
GENERAL DESCRIPTION
EG:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B
VOLTAGE CORRELATION
3. ENABLE CONDITION
Ignition switch ON
EN-01859
(1)
(2)
(3)
(4)
GD(H4DOTC)-272
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Map
0 s d < 2.125 deg
2.125 deg s d <
4.25 deg
4.25 deg s d <
9 deg
9 deg s d <
31.625 deg
31.625 deg s d
Sensor output difference
()
4.5 deg 5.5 deg 7.625 deg 9.75 deg 11.75 deg
Judgment Value
Signal difference between two sensors s Value from Map
GD(H4DOTC)-273
GENERAL DESCRIPTION
EH:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E
VOLTAGE CORRELATION
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
EN-01861
(2)
(3)
(4)
(1)
GD(H4DOTC)-274
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Map
0 s d < 0.6 deg
0.6 deg s d <
1.2 deg
1.2 deg s d <
2 deg
2 deg s d < 4 deg 4 deg s d
Sensor output difference
()
1.465 deg 1.597 deg 1.663 deg 2.455 deg 3.116 deg
Judgment Value
Signal difference between two sensors s Map
GD(H4DOTC)-275
GENERAL DESCRIPTION
EI: DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL
CIRCUIT LOW
Detect open or short circuit of the purge control solenoid valve 2.
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
puts OFF signal
Low
Judgment Value
puts OFF signal
High
GD(H4DOTC)-276
GENERAL DESCRIPTION
EJ: DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL
CIRCUIT HIGH
Detect open or short circuit of the purge control solenoid valve 2.
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
puts ON signal
High
Judgment Value
puts ON signal
Low
GD(H4DOTC)-277
GENERAL DESCRIPTION
EK:DTC P2431 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE
SENSOR CIRCUIT RANGE/PERFORMANCE
Detect the malfunction of secondary air pressure sensor output property.
Judge as NG when the secondary air pressure sensor output is largely different from the intake manifold
pressure at engine start.
Perform the diagnosis with ignition switch ON.
cles.
Normality Judgment
7. FAIL SAFE
None
After secondary air system stops > 2976 ms
Judgment Value
|Secondary air pipe pressure Intake
manifold pressure|
> 26.66 kPa (200 mmHg,
7.874 inHg)
< 1.33 kPa (9.99 mmHg,
0.393 inHg)
Judgment Value
|Secondary air pipe pressure Intake
manifold pressure|
< 26.66 kPa (200 mmHg,
7.874 inHg)
GD(H4DOTC)-278
GENERAL DESCRIPTION
EL:DTC P2432 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE
SENSOR CIRCUIT LOW
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Ignition switch ON
Judgment Value
Ignition switch ON
GD(H4DOTC)-279
GENERAL DESCRIPTION
EM:DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE
SENSOR CIRCUIT HIGH
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Ignition switch ON
Judgment Value
Ignition switch ON
GD(H4DOTC)-280
GENERAL DESCRIPTION
EN:DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
STUCK OPEN (BANK 1)
NOTE:
EO:DTC P2441 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
STUCK CLOSED (BANK 1)
NOTE:
EP:DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
STUCK OPEN (BANK2)
NOTE:
EQ:DTC P2443 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
STUCK CLOSED (BANK2)
NOTE:
GD(H4DOTC)-281
GENERAL DESCRIPTION
ER:DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON
Detect the secondary air pump malfunction (always ON).
After the secondary air pump turns to OFF, judge as NG if the secondary air pipe pressure is higher than that
before the secondary air pump operation.
Normality Judgment
7. FAIL SAFE
None
Engine In operation
Judgment Value
Time since secondary air control com-
pletion
> 3000 ms
and
s 8000 ms
Secondary air pipe pressure > 6.67 kPa (50 mmHg, 1.969 inHg)
Judgment Value
Time since secondary air control com-
pletion
> 3000 ms
and
s 8000 ms
Secondary air pipe pressure s 6.67 kPa (50 mmHg, 1.969 inHg)
GD(H4DOTC)-282
GENERAL DESCRIPTION
FU(H6DO)-2
General Description
A: SPECIFICATION
Fuel tank
Location Under rear seat
Fuel pump
Type Impeller
2
, 79.8 123.3 psi)
Discharge rate
155 2 (41 US gal, 34.1 Imp gal)/h or more.
[12 V at 300 kPa (3.06 kg/cm
2
, 43.5 psi)]
Fuel filter In-tank type
FU(H6DO)-3
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T2
T2
T4
T5
T4
T4
T4
T4
T5
(5)
(6)
(2)
(16)
(17)
(15)
(17)
(12)
(2)
T2
T2
T2
T3
(9)
T3
(10)
(11)
(18)
T1
T2
T2
(14)
(13)
(14)
(14)
(13)
(14)
T1
(4)
(3)
T2
T4
(7)
(8)
(1)
FU-03215
FU(H6DO)-4
General Description
2. FUEL INJECTOR
(1) Intake manifold (10) Nipple (18) EGR pipe
(2) O-ring (11) Fuel pipe protector LH
(3) Manifold absolute pressure sensor (12) Fuel pipe ASSY Tightening torque:Nm (kgf-m, ft-lb)
(4) Filter (13) Hose T1: 1.5 (0.15, 1.1)
(5) Fuel pipe protector RH (14) Clamp T2: 6.4 (0.65, 4.7)
(6) Purge control solenoid valve (15) EGR valve T3: 17 (1.7, 12.5)
(7) Hose (16) Gasket T4: 19 (1.9, 14.0)
(8) Hose (17) Gasket T5: 25 (2.5, 18.4)
(9) Plug
(1) Fuel injector pipe LH (4) Injection rubber Tightening torque:Nm (kgf-m, ft-lb)
(2) Insulator (5) O-ring T: 19 (1.9, 14.0)
(3) Fuel injector (6) Fuel injector pipe RH
FU-02561
(6)
T
T
(5)
(4)
(3)
(2)
(2)
(3)
(4)
(5)
(1)
FU(H6DO)-5
General Description
(1) O-ring (2) Throttle body Tightening torque:Nm (kgf-m, ft-lb)
T: 8 (0.8, 5.9)
FU-02109
(1)
(2)
T
FU(H6DO)-6
General Description
(1) Crankshaft position sensor (6) Variable valve lift diagnosis oil
pressure switch RH
(2) Knock sensor RH T1: 6.4 (0.65, 4.7)
(3) Knock sensor LH (7) Variable valve lift diagnosis oil
pressure switch LH
T2: 17 (1.7, 12.5)
(4) Camshaft position sensor RH T3: 22 (2.2, 16.2)
(5) Camshaft position sensor LH (8) Oil temperature sensor T4: 25 (2.5, 18.4)
FU-02110
(6)
(4)
T2
T1
(3)
T4
(1)
(8)
T1
T3
(5)
T1
(2)
T4
(7)
T2
FU(H6DO)-7
General Description
5. FUEL TANK
T4
T1
T4
T3
T3
T3
T2
T3
T3
T4
T1
(15)
(13)
(14)
(14)
(16)
(18)
(16)
(5)
(20)
(4)
(3)
(21)
(22)
(23)
(2)
(18)
(19)
(10)
(11)
(12)
(7)
(6)
(9)
(16)
(16)
(29)
(8)
(1)
T2
T3
(20)
(16)
(24)
(25)
(26)
(16)
(28)
(27)
(31)
(30)
(16)
(32)
FU-03216
FU(H6DO)-8
General Description
(1) Fuel tank (14) Clamp (27) Evaporation hose D
(2) Fuel tank band RH (15) Evaporation hose A (28) Evaporation pipe
(3) Fuel tank band LH (16) Clip (29) Evaporation hose E
(4) Delivery tube (17) Fuel tank protector LH (Rear) (30) Evaporation hose F
(5) Jet pump tube (18) Stopper RH (31) Fuel sub level sensor filter
(6) Fuel pump ASSY (19) Stopper LH (32) Fuel sub level sensor protector
(7) Fuel pump upper plate (20) Retainer
(8) Fuel pump gasket (21) Heat shield cover Tightening torque:Nm (kgf-m, ft-lb)
(9) Fuel level sensor (22) Fuel tank protector RH (Front) T1: 4.4 (0.45, 3.2)
(10) Fuel sub level sensor (23) Fuel tank protector LH (Front) T2: 9 (0.9, 6.6)
(11) Fuel sub level sensor upper plate (24) Evaporation hose B T3: 17.5 (1.78, 12.9)
(12) Fuel sub level sensor gasket (25) Connector T4: 33 (3.4, 24.3)
(13) Fuel filler hose (26) Evaporation hose C
FU(H6DO)-9
General Description
6. FUEL LINE
B
A
C
(6)
(19)
(20)
(4)
(4)
(4)
(4)
(3)
(4)
(2)
(5)
(1)
(8)
(7)
(10)
(9) (11)
(15)
(17)
(18)
(4)
(4)
(4)
(24)
(25)
(4)
(21)
(26)
(23)
(16)
(22)
(4)
(4)
(27)
(29)
(28)
(4)
(12)
(13)
(14)
(4)
C
T4
T6
T5
T4
T4
T4
T4
T3
T3
T4
T1
T4
T1
T4
(34)
(30)
(31)
(32)
(33)
B
A
(40)
(41)
T2
T4 (42)
(39)
(39)
(36)
(38)
(35)
(37)
(4)
(43)
(4)
(39)
FU-03217
FU(H6DO)-10
General Description
C: CAUTION
forming any work.
points.
the battery.
ing area.
(1) Evaporation pipe protector (18) Canister (35) Fuel delivery hose A
(2) Evaporation hose D (19) Fuel filler pipe (36) Fuel delivery hose B
(3) Evaporation pipe B (20) Fuel tank pressure sensor (37) Clamp
(4) Clip (21) Canister hose B (38) Quick connector check cover
(5) Fuel filler cap (22) Connector B (39) Clip
(6) Filler ring (23) Pressure control solenoid valve (40) Fuel damper
(7) Shut valve (24) Canister hose A (41) Fuel damper holder
(8) Gasket (25) Connector B (42) Fuel damper bracket
(9) Evaporation hose C (26) Connector A (43) Evaporation hose A
(10) Evaporation hose C (27) Evaporation hose E
(11) Evaporation pipe A (28) Evaporation tube Tightening torque:Nm (kgf-m, ft-lb)
(12) Drain hose connector (29) Retainer T1: 1.0 (0.1, 0.7)
(13) Drain hose (30) Purge pipe T2: 1.25 (0.13, 0.94)
(14) Connector A (31) Purge hose C T3: 4.4 (0.45, 3.2)
(15) Canister protector (32) Fuel hose T4: 7.5 (0.76, 5.5)
(16) Drain filter (33) Connector T5: 8 (0.8, 5.9)
(17) Drain valve (34) Fuel pipe ASSY T6: 17.6 (1.8, 13)
FU(H6DO)-11
General Description
D: PREPARATION TOOL
REMOVER
engine compartment.
18471AA000
FUEL PIPE
ADAPTER
MONITOR III KIT
ST42099AE000
ST18471AA000
ST1B021XU0
FU(H6DO)-12
Throttle Body
2. Throttle Body
A: REMOVAL
IN(H6DO)-7, REMOVAL, Air Intake Chamber.>
4) Disconnect the connector from throttle body.
5) Disconnect the engine coolant hoses (A) from
the throttle body.
6) Remove the bolts (B) which secure throttle body
to intake manifold.
B: INSTALLATION
NOTE:
Use new O-rings.
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
IN-00203
FU-02111
FU-02112
(A)
(B)
(B)
(A)
FU(H6DO)-13
Intake Manifold
3. Intake Manifold
A: REMOVAL
2) Release the fuel pressure. <Ref. to FU(H6DO)-
DURE, Fuel.>
filler cap.
5) Remove the air cleaner case and air intake
chamber. <Ref. to IN(H6DO)-5, REMOVAL, Air
Cleaner Case.> <Ref. to IN(H6DO)-7, REMOVAL,
Air Intake Chamber.>
6) Disconnect the connector (A) from the throttle
body.
7) Disconnect the engine harness connector (B).
8) Disconnect the engine coolant hose from throttle
body.
9) Disconnect the PCV hose.
10) Disconnect the brake booster hose.
11) Disconnect the fuel hoses from the fuel pipe.
(1) Disconnect the connector of fuel pipe by
pushing the ST in the direction of arrow.
CAUTION:
or cloth.
IN-00203
FU-02845
(A)
(B)
FU-02114
EC-02202
FU-03219
FU-02866
ST
FU(H6DO)-14
Intake Manifold
12) Remove the EGR pipe from the EGR valve.
NOTE:
Be careful not to drop the gasket.
14) Remove the engine harness from the fuel injec-
tor pipe LH.
15) Remove the bolts which hold fuel injector pipe
LH to cylinder head.
tor pipe RH.
18) Remove the bolts which hold the fuel injector
pipe RH to the cylinder head.
19) Remove the bolts which hold the intake mani-
fold to the cylinder head.
LH side
RH side
FU-00547
FU-02117
FU-02118
FU-02119
FU-02120
FU-02121
FU-02122
FU(H6DO)-15
Intake Manifold
B: INSTALLATION
NOTE:
Use new O-rings.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
RH side
LH side
2) Install the bolts which hold fuel injector pipe RH
to cylinder head.
NOTE:
Use new O-rings.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
3) Install the engine harness to fuel injector pipe
RH.
4) Install the fuel pipe protector RH.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
5) Install the bolts which hold fuel injector pipe LH
to cylinder head.
NOTE:
Use new O-rings.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
6) Install the engine harness to fuel injector pipe
LH.
7) Install the fuel pipe protector LH.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02122
FU-02121
FU-02120
FU-02119
FU-02118
FU-02117
FU(H6DO)-16
Intake Manifold
8) Install the EGR pipe to the EGR valve.
NOTE:
Use a new gasket.
Tightening torque
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
9) Connect the fuel hoses to fuel pipe.
10) Connect the brake booster hose.
12) Connect the engine coolant hoses to throttle
body.
13) Connect the connector (A) to throttle body.
14) Connect the engine harness connector (B).
15) Install the air cleaner case and air intake cham-
ber. <Ref. to IN(H6DO)-6, INSTALLATION, Air
Cleaner Case.> <Ref. to IN(H6DO)-7, INSTALLA-
TION, Air Intake Chamber.>
box.
FU-00547
FU-03218
FU-03219
EC-02202
FU-02114
FU-02845
(A)
(B)
IN-00203
FU(H6DO)-17
Intake Manifold
C: DISASSEMBLY
1) Remove the engine harness from intake mani-
fold.
2) Remove the throttle body. <Ref. to FU(H6DO)-
3) Remove the EGR valve. <Ref. to FU(H6DO)-26,
REMOVAL, EGR Valve.>
4) Remove the manifold absolute pressure sensor.
<Ref. to FU(H6DO)-24, REMOVAL, Manifold Ab-
solute Pressure Sensor.>
5) Remove the purge control solenoid valve. <Ref.
to EC(H6DO)-7, REMOVAL, Purge Control Sole-
noid Valve.>
6) Loosen the clamp which holds fuel injector pipe
to the fuel hose, and then disconnect the pipe from
fuel hose.
7) Remove the bolts which install fuel pipes on in-
take manifold.
D: ASSEMBLY
NOTE:
When assembling the nipple, apply liquid gasket.
Liquid gasket:
equivalent
1) Tighten the bolts which install fuel pipes on in-
take manifold.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
2) Connect the fuel injector pipe to fuel hose, and
tighten the clamp screw.
Tightening torque:
1.5 Nm (0.15 kgf-m, 1.1 ft-lb)
3) Install the purge control solenoid valve. <Ref. to
EC(H6DO)-7, INSTALLATION, Purge Control So-
lenoid Valve.>
4) Install the manifold absolute pressure sensor.
<Ref. to FU(H6DO)-24, INSTALLATION, Manifold
Absolute Pressure Sensor.>
5) Install the EGR valve. <Ref. to FU(H6DO)-26,
INSTALLATION, EGR Valve.>
FU-02124
FU-02125
FU-02126
FU-02125
FU-02126
FU-02124
FU(H6DO)-18
Intake Manifold
6) Install the throttle body to intake manifold. <Ref.
to FU(H6DO)-12, INSTALLATION, Throttle Body.>
7) Install the engine harness to the intake manifold.
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
damaged and the connections are tightened firmly.
FU(H6DO)-19
Sensor
A: REMOVAL
B: INSTALLATION
Tightening torque:
22 Nm (2.2 kgf-m, 16.2 ft-lb)
IN-00203
FU-00572
FU-00572
FU(H6DO)-20
A: REMOVAL
6) Disconnect the connector from crankshaft posi-
tion sensor.
B: INSTALLATION
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203
FU-02127
FU-02128
FU-02128
FU(H6DO)-21
A: REMOVAL
3) Remove the generator harness from the fuel
pipe protector LH.
5) Disconnect the connector from camshaft posi-
tion sensor LH.
6) Remove the camshaft position sensor LH.
7) Remove the camshaft position sensor RH in the
same procedure as LH.
B: INSTALLATION
Tightening torque:
Camshaft position sensor
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Fuel pipe protector
19 Nm (1.9 kgf-m, 14.0 ft-lb)
IN-00203
FU-02117
FU-02129
FU-02130
FU(H6DO)-22
Knock Sensor
7. Knock Sensor
A: REMOVAL
3) Remove the intake manifold. <Ref. toFU(H6DO)-
13, REMOVAL, Intake Manifold.>
block.
B: INSTALLATION
1) Install the knock sensor to cylinder block.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
NOTE:
For the knock sensor installation angle, refer to the
figure below.
3) Install the intake manifold. <Ref. to FU(H6DO)-
15, INSTALLATION, Intake Manifold.>
(A) Front side
IN-00203
FU-00577
45
30
10
(A) FU-00578
IN-00203
FU(H6DO)-23
A: SPECIFICATION
body. Refer to Throttle Body for removal and in-
stallation procedure. <Ref. to FU(H6DO)-12, RE-
MOVAL, Throttle Body.> <Ref. to FU(H6DO)-12,
INSTALLATION, Throttle Body.>
FU(H6DO)-24
9. Manifold Absolute Pressure
Sensor
A: REMOVAL
3) Disconnect the connector from the manifold ab-
solute pressure sensor (A), and remove the filter
assembly (B) from the intake manifold.
from intake manifold.
B: INSTALLATION
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203
FU-02131
(B)
(A)
FU(H6DO)-25
10.Mass Air Flow and Intake Air
Temperature Sensor
A: REMOVAL
ature sensor.
B: INSTALLATION
Tightening torque:
1 Nm (0.1 kgf-m, 0.7 ft-lb)
IN-00203
IN-02009
FU-03236
FU(H6DO)-26
EGR Valve
11.EGR Valve
A: REMOVAL
1) Remove the collector cover and the engine side
cover.
4) Remove the starter. <Ref. to SC(H4SO)-6, RE-
MOVAL, Starter.>
5) Remove the EGR pipe from the EGR valve and
the cylinder head.
6) Remove the EGR valve from intake manifold.
7) Disconnect the connector from the EGR valve.
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
EGR valve
19 Nm (1.9 kgf-m, 14.0 ft-lb)
EGR pipe
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203
FU-02133
FU-02133
FU(H6DO)-27
Fuel Injector
12.Fuel Injector
A: REMOVAL
1. RH SIDE
DURE, Fuel.>
filler cap.
IN(H6DO)-5, REMOVAL, Air Cleaner Case.>
tor pipe RH.
9) Remove the bolts which hold fuel injector pipe to
the cylinder head.
injector pipe.
2. LH SIDE
DURE, Fuel.>
filler cap.
5) Remove the generator harness from the fuel
pipe protector LH.
tor pipe LH.
IN-00203
FU-02119
FU-02134
FU-02120
FU-02117
FU-02135
FU(H6DO)-28
Fuel Injector
9) Remove the bolts which hold fuel injector pipe to
the cylinder head.
injector pipe.
B: INSTALLATION
1. RH SIDE
NOTE:
Use new O-rings.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
2. LH SIDE
NOTE:
Use new O-rings.
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-02118
FU-02120
FU-02119
FU-02118
FU-02117
FU(H6DO)-29
Variable Valve Lift Diagnosis Oil Pressure Switch
13.Variable Valve Lift Diagnosis
Oil Pressure Switch
A: REMOVAL
4) Disconnect the connector from the variable
valve lift diagnosis oil pressure switch.
sure switch.
LH side
RH side
B: INSTALLATION
NOTE:
Apply liquid gasket to the variable valve lift diagno-
sis oil pressure switch threads.
Liquid gasket:
equivalent
Tightening torque:
17 Nm (1.7 kgf-m, 12.5 ft-lb)
IN-00203
FU-02136
FU-02137
FU(H6DO)-30
Oil Temperature Sensor
14.Oil Temperature Sensor
A: REMOVAL
4) Disconnect the connector from the oil tempera-
ture sensor.
B: INSTALLATION
Tightening torque:
22 Nm (2.2 kgf-m, 16.2 ft-lb)
IN-00203
FU-02138
FU(H6DO)-31
A: REMOVAL
4) Disconnect the connector of front oxygen (A/F)
sensor.
LH side
RH side
tion of front oxygen (A/F) sensor, and leave it for
one minute or more.
CAUTION:
When removing the front oxygen (A/F) sensor,
wait until exhaust pipe cools, otherwise it will
LH side
RH side
B: INSTALLATION
ply anti-seize compound only to the threaded por-
tion of front oxygen (A/F) sensor to make the next
removal easier.
equivalent
CAUTION:
IN-00203
FU-02139
FU-02140
FU-02141
FU-02142
FU(H6DO)-32
Tightening torque:
21 Nm (2.1 kgf-m, 15.5 ft-lb)
LH side
RH side
sensor.
LH side
RH side
FU-02141
FU-02142
FU-02139
FU-02140
IN-00203
FU(H6DO)-33
Rear Oxygen Sensor
A: REMOVAL
4) Disconnect the connector from rear oxygen sen-
sor.
LH side
RH side
5) Remove the clip holding the harness.
tion of rear oxygen sensor, and leave it for one
minute or more.
CAUTION:
When removing the rear oxygen sensor, wait
LH side
RH side
IN-00203
FU-02143
FU-02144
FU-02145
FU-02146
FU(H6DO)-34
Rear Oxygen Sensor
B: INSTALLATION
1) Before installing rear oxygen sensor, apply the
anti-seize compound only to the threaded portion of
rear oxygen sensor to make the next removal eas-
ier.
equivalent
CAUTION:
Tightening torque:
21 Nm (2.1 kgf-m, 15.5 ft-lb)
LH side
RH side
3) Hold the harness with clip.
LH side
RH side
FU-02145
FU-02146
FU-02143
FU-02144
IN-00203
FU(H6DO)-35
SI-DRIVE (SUBARU Intelligent Drive) Selector
17.SI-DRIVE (SUBARU Intelligent
Drive) Selector
A: REMOVAL
MOVAL, Glove Box.>
3) Disconnect the connectors from the SI-DRIVE
selector.
4) Remove the screws securing the upper side of
the SI-DRIVE selector to the console box.
5) Remove the screws which secure the cup holder
to the console box, then remove the SI-DRIVE se-
lector.
B: INSTALLATION
C: INSPECTION
Measure the resistance between SI-DRIVE selec-
tor terminals.
IN-00203
AT-03718
AT-03719
Sport (when turning the SI-
DRIVE selector to the left)
2 and 3
Less than 10
Intelligent (when pushing
the SI-DRIVE selector)
0.8 1.2 k
Sport Sharp (when turning
the SI-DRIVE selector to the
right)
2.14 3.2 k
FU-03123
2 3 4 1 5
FU(H6DO)-36
SI-DRIVE (SUBARU Intelligent Drive) S# Switch
18.SI-DRIVE (SUBARU Intelligent
Drive) S# Switch
A: REMOVAL
WARNING:
forming service on the airbag modules. <Ref. to
AB-4, CAUTION, General Description.>
3) Remove the screw which holds SI-DRIVE S#
switch to the steering wheel, and disconnect the
connector from the SI-DRIVE S# switch.
B: INSTALLATION
C: INSPECTION
Measure the resistance between SI-DRIVE S#
switch terminals.
IN-00203
FU-03122
ON (When the SI-DRIVE
S# switch is pressed)
3 and 4
Less than 10
OFF 1 M or more
2 3 4 1
FU-03121
FU(H6DO)-37
A: REMOVAL
side. <Ref. to EI-61, REMOVAL, Lower Inner
Trim.>
to the bracket.
the ECM.
B: INSTALLATION
NOTE:
the wrong spec. ECM to avoid any damage on the
fuel injection system.
When replacing the ECM, immobilizer system
must be registered. To do so, all ignition keys and
ID cards need to be prepared. Refer to the IMMO-
BILIZER TEACHING OPERATION MANUAL.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
IN-00203
FU-02090
(A)
FU-02488
FU(H6DO)-38
Main Relay
20.Main Relay
A: REMOVAL
AL, Glove Box.>
B: INSTALLATION
IN-00203
FU-02092
(A)
FU-02406
FU(H6DO)-39
Fuel Pump Relay
21.Fuel Pump Relay
A: REMOVAL
AL, Glove Box.>
B: INSTALLATION
IN-00203
FU-02092
(A)
FU-02407
FU(H6DO)-40
Relay
A: REMOVAL
AL, Glove Box.>
control relay.
B: INSTALLATION
IN-00203
FU-02092
(A)
FU-02408
FU(H6DO)-41
Fuel Pump Control Unit
23.Fuel Pump Control Unit
A: REMOVAL
2) Remove the rear quarter trim of the left side.
(Wagon model) <Ref. to EI-63, REMOVAL, Rear
Quarter Trim.>
3) Peel the trunk side trim of the left side. (Sedan
model)
4) Remove the fuel pump control unit.
Wagon model
Sedan model
5) Disconnect the connector from fuel pump control
unit.
B: INSTALLATION
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
IN-00203
FU-03220
FU-03231
FU(H6DO)-42
Fuel
24.Fuel
A: PROCEDURE
WARNING:
working area.
CAUTION:
box.
onds.
LECT MONITOR)
WARNING:
working area.
CAUTION:
NOTE:
If the fuel pump cannot be actuated, refer to
DRAINING FUEL (THROUGH THE FUEL FILLER
HOSE) <Ref. to FU(H6DO)-43, DRAINING FUEL
(THROUGH THE FUEL FILLER HOSE), PROCE-
DURE, Fuel.>.
Be careful not to allow the battery to go flat.
DURE, Fuel.>
delivery hose.
CAUTION:
or cloth.
4) Connect the gasoline proof hose to ST, and put
the hose end into the container.
5) Actuate the fuel pump and drain the fuel using
Subaru Select Monitor. <Ref. to EN(H6DO)(diag)-
59, FUEL PUMP CONTROL (ON/OFF OPERA-
TION), OPERATION, System Operation Check
Mode.>
CAUTION:
FU-01122
FU-02866
ST
FU(H6DO)-43
Fuel
FILLER HOSE)
WARNING:
working area.
CAUTION:
Fuel may remain in the fuel filler pipe. Per-
form the work after draining the fuel from the
fuel filler pipe through the fill opening using the
gasoline proof pump and the gasoline proof
hose (10 or less).
<Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust
Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.>
filler cap.
filler pipe.
CAUTION:
or cloth.
7) Set a container under the vehicle and insert the
gasoline proof hose (10 or less) into the fuel filler
hose to drain the fuel.
CAUTION:
(A)
FU-02394
(B)
FU(H6DO)-44
Fuel Tank
25.Fuel Tank
A: REMOVAL
WARNING:
working area.
CAUTION:
DURE, Fuel.>
3) Drain fuel from fuel tank. <Ref. to FU(H6DO)-42,
DRAINING FUEL (WITH SUBARU SELECT MON-
ITOR), PROCEDURE, Fuel.>
sensor.
service hole cover.
sensor.
10) Disconnect the quick connector on the fuel de-
livery hose (B). <Ref. to FU(H6DO)-60, REMOVAL,
Fuel Delivery and Evaporation Lines.>
Quarter Trim.>
FU-02387
FU-03221
FU-03222
(B)
(A)
FU-03223
(B)
(A)
(A)
FU-02853
(A)
(B)
FU-02390
FU(H6DO)-45
Fuel Tank
FU(H6DO)-60, REMOVAL, Fuel Delivery and
Evaporation Lines.>
20) Remove the rear exhaust pipe. <Ref. to
EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.>
wheel speed sensor.
cable clamp.
FU-02391
FU-01128
FU-00462
FU-02894
FU-02895
FU-02896
FU(H6DO)-46
Fuel Tank
CAUTION:
mission jack.
tion hose (B).
WARNING:
Fuel may remain in the fuel tank. Be careful
not to let the fuel tank fall off when removing as
it is bad balance on either side.
FU-01132
FU-01133
FU-02891
FU-02392
FU-02393
(A)
FU-02394
(B)
FU-03293
FU(H6DO)-47
Fuel Tank
B: INSTALLATION
WARNING:
en the clamp.
Tightening torque:
2.5 Nm (0.25 kgf-m, 1.8 ft-lb)
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
(1) Hose
(2) Clip or clamp
(3) Pipe
FU-03293
(A)
FU-02394
(B)
( 1 )
( 2 ) ( 3 )
FU-00104
L
L/2
FU-02393
FU-02392
FU(H6DO)-48
Fuel Tank
CAUTION:
mission jack.
Tightening torque:
T1: 125 Nm (12.7 kgf-m, 92.2 ft-lb)
T2: 175 Nm (17.8 kgf-m, 129 ft-lb)
Tightening torque:
62 Nm (6.3 kgf-m, 46 ft-lb)
clamp.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
speed sensor.
11) Install the rear exhaust pipe. <Ref. to
EX(H6DO)-8, INSTALLATION, Rear Exhaust
Pipe.>
FU-01150
T1
T1
T1
T1
FU-02892
T2
T2
FU-01132
FU-02895
FU-02896
FU-02894
FU(H6DO)-49
Fuel Tank
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
pipe. <Ref. to FU(H6DO)-61, INSTALLATION, Fuel
Delivery and Evaporation Lines.>
Trim.>
Trim.>
sor.
22) Connect the quick connector (B) of the fuel de-
livery hose. <Ref. to FU(H6DO)-61, INSTALLA-
TION, Fuel Delivery and Evaporation Lines.>
sensor.
FU-01128
FU-02391
FU-02390
(A) Bolt
(B) Grommet
FU-02853
(A)
(B)
FU-03223
(B)
(A)
(A)
FU-03222
(B)
(A)
FU-03221
FU(H6DO)-50
Fuel Tank
box.
30) Inspect the wheel alignment and adjust if nec-
essary.
C: INSPECTION
FU-02387
IN-00203
FU(H6DO)-51
Fuel Filler Pipe
26.Fuel Filler Pipe
A: REMOVAL
WARNING:
working area.
CAUTION:
1) Drain fuel from fuel tank. <Ref. to FU(H6DO)-42,
DRAINING FUEL (WITH SUBARU SELECT MON-
ITOR), PROCEDURE, Fuel.>
MOVAL, Mud Guard.>
the vehicle.
B: INSTALLATION
of apron.
NOTE:
FU-00095
FU-02395
(A)
FU-02396
(B)
FU-02397
(B)
FU-00103
(A)
(C)
(B)
FU(H6DO)-52
Fuel Filler Pipe
en the clamp.
Tightening torque:
(A) 2.5 Nm (0.3 kgf-m, 1.8 ft-lb)
et on the body.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
LATION, Mud Guard.>
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
C: INSPECTION
(1) Hose
(2) Clip or clamp
(3) Pipe
(A)
FU-02396
(B)
FU-02397
(B)
( 1 )
( 2 ) ( 3 )
FU-00104
L
L/2
FU-02395
IN-00203
FU(H6DO)-53
Fuel Filler Pipe
D: DISASSEMBLY
<Ref. to EC(H4SO)-14, REMOVAL, Shut Valve.>
E: ASSEMBLY
1) Install the shut valve to the fuel filler pipe. <Ref.
to EC(H4SO)-14, INSTALLATION, Shut Valve.>
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
FU-02398
FU-02399
FU-02400
FU-02399
FU-02400
FU-02398
FU(H6DO)-54
Fuel Pump
27.Fuel Pump
A: REMOVAL
WARNING:
working area.
CAUTION:
NOTE:
DURE, Fuel.>
2) Drain fuel. <Ref. to FU(H6DO)-42, DRAINING
PROCEDURE, Fuel.>
<Ref. to FU(H6DO)-60, REMOVAL, Fuel Delivery
bly onto fuel tank.
tank.
B: INSTALLATION
Install in the reverse order of removal while being
careful of the following.
Install so that the protrusion (A) of gasket is
pointed towards the front of the vehicle.
Insert the protrusion (B) of the gasket into the up-
per plate. (3 places)
Align the protrusion (C) of fuel pump assembly
with the cutout on the upper plate.
NOTE:
Use a new gasket and a retainer.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.2 ft-lb)
FU-02387
FU-03221
(A) Delivery hose
(B) Jet pump hose
FU-02670
(A)
(B)
FU-02835
1
2
3
4
5 6
7
8
(C)
(B)
(B)
(B)
(A)
FU(H6DO)-55
Fuel Pump
C: INSPECTION
CAUTION:
as possible.
Be sure to perform the ON/OFF operation on
the battery side.
FU-01330
2
4
6
1
3
5
FU(H6DO)-56
Fuel Level Sensor
A: REMOVAL
WARNING:
working area.
CAUTION:
two thirds of the total, perform the work after
NOTE:
FU(H6DO)-54, REMOVAL, Fuel Pump.>
et.
3) Remove the fuel temperature sensor.
4) Remove the fuel level sensor.
B: INSTALLATION
(A) Connector
FU-02401
(A)
(B)
(C)
FU(H6DO)-57
A: REMOVAL
WARNING:
working area.
CAUTION:
1) Drain fuel. <Ref. to FU(H6DO)-42, DRAINING
PROCEDURE, Fuel.>
service hole cover.
sensor.
<Ref. to FU(H6DO)-60, REMOVAL, Fuel Delivery
B: INSTALLATION
Install in the reverse order of removal while being
careful of the following.
Align the protrusion (A) of gasket with the posi-
tion shown in the figure.
Align the protrusion (B) of fuel sub level sensor
with the cutout on the upper plate of fuel sub level
sensor.
NOTE:
Use a new gasket and retainer.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.2 ft-lb)
FU-03223
(B)
(A)
(A)
FU-03010
(A) Jet pump hose
(B) Delivery hose
FU-02673
(B)
(A)
FU-02836
1
6
5
2
4
3
(B)
(A)
FU-02674
FU(H6DO)-58
Fuel Filter
30.Fuel Filter
A: SPECIFICATION
Fuel filter forms a single unit with fuel pump. Refer
to Fuel Pump for removal and installation. <Ref.
to FU(H6DO)-54, REMOVAL, Fuel Pump.> <Ref.
to FU(H6DO)-54, INSTALLATION, Fuel Pump.>
FU(H6DO)-59
Fuel Damper Valve
A: REMOVAL
CAUTION:
or cloth.
DURE, Fuel.>
livery line.
B: INSTALLATION
CAUTION:
If fuel hoses or clamps are damaged, replace
them with new parts.
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
FU-03008
FU(H6DO)-60
32.Fuel Delivery and Evaporation Lines
A: REMOVAL
WARNING:
CAUTION:
Catch the fuel from hoses using a container or cloth.
2) Release the fuel pressure. <Ref. to FU(H6DO)-42, RELEASING OF FUEL PRESSURE, PROCEDURE,
Fuel.>
5) Disconnect the fuel delivery pipes and hoses, and then disconnect the evaporation pipes and hoses.
FU-03224
FU(H6DO)-61
6) In the engine compartment, disconnect the fuel
delivery hoses and evaporation hose.
(1) Disconnect the quick connector of the fuel
of the arrow.
CAUTION:
or cloth.
8) Remove the fuel tank. <Ref. to FU(H6DO)-44,
REMOVAL, Fuel Tank.>
covered with dust.
plastic bag etc.
(B) down.
(B).
B: INSTALLATION
CAUTION:
Make sure there is no damage or dust on the
connections. If necessary, clean seal surface of
pipe.
NOTE:
Use a new retainer.
FU-02866
ST
FU-01333
(A) Connector
(B) Retainer
(C) Pipe
(A) Seal surface
(B) Pipe
FU-00124
( A )
( B )
( C )
FU-00125
( A )
( B )
FU(H6DO)-62
CAUTION:
securely.
Make sure the two retainer pawls are en-
gaged in their mating positions in the connec-
tor.
2) Connect the fuel delivery hose to the pipe with
fied.
specified.
L1: 2.51.5 mm (0.0980.059 in)
L2: 22.52.5 mm (0.8860.098 in)
CAUTION:
L = 17.52.5 mm (0.6890.098 in)
C: INSPECTION
(A) Connector
(B) Retainer
(C) Pipe
(A) Connector
(B) Retainer
(C) Pipe
FU-00126
( A )
( B )
( C )
FU-00127
( A )
( B )
( C )
(1) Type A
(2) Type B
(3) Pipe
(4) Clamp
(5) Hose
(1) Hose
(2) Clip
(3) Pipe
FU-03390
(3) (4) (5)
L2
(1)
(2)
L1
L1
FU-00129
(1)
(2)
L/2
L
(3)
FU(H6DO)-63
A: INSPECTION
NOTE:
Fill fuel fully to prevent the problem.
securely.
3) Clogged fuel filter Replace the fuel pump and clean or replace the fuel tank.
6) Clogged or bent air breather tube or pipe Clean, correct or replace the air breather tube or pipe.
4) Clogged or bent air breather tube or air vent tube
tube.
1)
pipe
Retighten.
2) Problem in tightness of the fuel saucer gasket air Correct or replace the gasket.
5. Noise
FU(H6DO)-64
EC(H6DO)-2
General Description
A: CAUTION
forming any work.
points.
battery.
EC(H6DO)-3
A: REMOVAL
The front and rear catalytic converters are integrat-
ed into the front exhaust pipe; therefore, refer to
Front Exhaust Pipe for the removal procedure.
<Ref. to EX(H6DO)-4, REMOVAL, Front Exhaust
Pipe.>
B: INSTALLATION
The front and rear catalytic converters are integrated
into front exhaust pipe as one unit; therefore, refer to
Front Exhaust Pipe for installation procedure. <Ref.
to EX(H6DO)-5, INSTALLATION, Front Exhaust
Pipe.>
C: INSPECTION
leaks.
(A) Front catalytic converter
(B) Rear catalytic converter
(A)
(B)
EC-02018
(A)
(B)
EC-02018
EC(H6DO)-4
A: REMOVAL
The front and rear catalytic converters are integrat-
ed into the front exhaust pipe; therefore, refer to
Front Exhaust Pipe for the removal procedure.
Pipe.>
B: INSTALLATION
The front and rear catalytic converters are integrated
into front exhaust pipe as one unit; therefore, refer to
Front Exhaust Pipe for installation procedure.
<Ref. to EX(H6DO)-5, INSTALLATION, Front Ex-
haust Pipe.>
C: INSPECTION
leaks.
(A)
(B)
EC-02018
(A)
(B)
EC-02018
EC(H6DO)-5
EGR Valve
4. EGR Valve
A: SPECIFICATION
Refer to EGR valve for the removal and installation
procedure. <Ref. to FU(H6DO)-26, EGR Valve.>
EC(H6DO)-6
Canister
5. Canister
A: REMOVAL
8) Remove clip (C).
B: INSTALLATION
NOTE:
the pipe.
Tightening torque:
8.0 Nm (0.82 kgf-m, 5.9 ft-lb)
C: INSPECTION
cracked or loose.
IN-00203
EC-02079
(A)
(A)
(C)
(B)
EC-02080
EC-02080
EC(H6DO)-7
A: REMOVAL
4) Disconnect the connector and hoses of purge
control solenoid valve, and then remove the purge
control solenoid valve.
B: INSTALLATION
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
NOTE:
ure.
C: INSPECTION
IN-00203
EC-02019
(A) To fuel pipe (evaporation line)
(B) To intake manifold
EC-02019
EC-02020
(B)
(A)
EC(H6DO)-8
Fuel Level Sensor
A: REMOVAL
For removal procedure, refer to FU(H6DO) sec-
tion. <Ref. to FU(H6DO)-56, REMOVAL, Fuel Lev-
el Sensor.>
B: INSTALLATION
For installation procedure, refer to FU(H6DO) sec-
tion. <Ref. to FU(H6DO)-56, INSTALLATION, Fuel
Level Sensor.>
EC(H6DO)-9
A: REMOVAL
The fuel temperature sensor is integrated into fuel
level sensor as one unit; therefore, refer to Fuel
FU(H6DO)-56, REMOVAL, Fuel Level Sensor.>
B: INSTALLATION
FU(H6DO)-56, INSTALLATION, Fuel Level Sen-
sor.>
EC-02083
(A)
EC-02083
(A)
EC(H6DO)-10
A: REMOVAL
For removal procedure, refer to FU(H6DO) sec-
tion. <Ref. to FU(H6DO)-57, REMOVAL, Fuel Sub
Level Sensor.>
B: INSTALLATION
For installation procedure, refer to FU(H6DO)
section. <Ref. to FU(H6DO)-57, INSTALLATION,
Fuel Sub Level Sensor.>
EC(H6DO)-11
10.Fuel Tank Pressure Sensor
A: REMOVAL
filler cap.
pressure sensor.
pressure sensor.
with the bracket.
B: INSTALLATION
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
C: INSPECTION
IN-00203
EC-02084
EC-02084
EC(H6DO)-12
Valve
A: REMOVAL
to the fuel tank.
from the bracket.
B: INSTALLATION
Tightening torque:
7.35 Nm (0.75 kgf-m, 5.4 ft-lb)
C: INSPECTION
IN-00203
(C)
(B)
EC-02086
(B)
(A)
EC-02087
EC(H6DO)-13
Drain Filter
12.Drain Filter
A: SPECIFICATION
move the drain filter from canister. Refer to Canis-
ter for removal and installation procedure. <Ref. to
EC(H6DO)-6, INSTALLATION, Canister.>
EC(H6DO)-14
Shut Valve
13.Shut Valve
A: REMOVAL
1) Remove the fuel filler pipe. <Ref. to FU(H6DO)-
51, REMOVAL, Fuel Filler Pipe.>
valve.
B: INSTALLATION
Tightening torque:
4.5 Nm (0.46 kgf-m, 3.3 ft-lb)
C: INSPECTION
EC-02088
EC-02089
EC-02089
EC(H6DO)-15
Drain Valve
14.Drain Valve
A: SPECIFICATION
move the drain valve from canister. Refer to Can-
ister for removal and installation procedure. <Ref.
to EC(H6DO)-6, REMOVAL, Canister.> <Ref. to
EC(H6DO)-6, INSTALLATION, Canister.>
EC(H6DO)-16
PCV Valve
15.PCV Valve
A: REMOVAL
1) Disconnect the PCV hose.
2) Remove the PCV valve from rocker cover.
B: INSTALLATION
NOTE:
Apply liquid gasket to the bolt threads of PCV
valve.
Liquid gasket:
equivalent
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
EC-02202
EC-02203
IN(H6DO)-2
General Description
INTAKE (INDUCTION)
A: COMPONENT
(12)
(16)
(15)
(11)
T1
(6)
(5)
(9)
(9)
(8)
(18)
(7)
(4)
(17)
(3)
(2)
(1)
T3
T3
(13)
T2
T2
(14)
(13)
(14)
T4
T5
(10)
T3
IN-02212
IN(H6DO)-3
General Description
INTAKE (INDUCTION)
B: CAUTION
forming any work.
points.
the battery.
(1) Air intake duct (11) Intake boot Tightening torque:Nm (kgf-m, ft-lb)
(2) Clip (12) Clamp T1: 6.0 (0.6, 4.4)
(3) Resonator chamber (13) Cushion T2: 6.5 (0.66, 4.8)
(4) Air cleaner case (front) (14) Spacer T3: 3.0 (0.3, 2.2)
(5) Spacer (15) Air intake chamber T4: 7.5 (0.76, 5.5)
(6) Cushion (16) Clamp T5: 1.0 (0.10, 0.7)
(7) Air cleaner element (17) Cushion
(8) Air cleaner case (rear) (18) Mass air flow and intake air tem-
perature sensor
(9) Clip
(10) Clamp
IN(H6DO)-4
Air Cleaner Element
INTAKE (INDUCTION)
A: REMOVAL
3) Remove the clip (A) securing upper side of air
cleaner case.
4) Pull the air cleaner case (rear) backward of the
vehicle, and remove the air cleaner element.
NOTE:
Be careful of the power steering hose fixed to the
bottom of the air cleaner case (rear).
B: INSTALLATION
CAUTION:
NOTE:
case.
C: INSPECTION
Replace if excessively damaged or dirty.
IN-00203
IN-02009
(A)
IN-02010
IN-00207
IN(H6DO)-5
Air Cleaner Case
INTAKE (INDUCTION)
3. Air Cleaner Case
A: REMOVAL
2) Remove the air intake duct. <Ref. to IN(H6DO)-
cleaner case and the intake boot.
5) Remove the clip (B) securing the upper side of
air cleaner case.
6) Remove the air cleaner case (rear) and air
cleaner element.
7) Remove the bolts (A) and nut (B) which secure
the air cleaner case to body.
IN-00203
IN-02009
(B)
IN-02011
(A)
IN-00206
(B)
(A)
IN-02213
IN(H6DO)-6
Air Cleaner Case
INTAKE (INDUCTION)
B: INSTALLATION
Tightening torque:
Bolt (A): 6.0 Nm (0.6 kgf-m, 4.4 ft-lb)
Nut (B): 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
NOTE:
case.
C: INSPECTION
(B)
(A)
IN-02213
IN-00207
IN(H6DO)-7
Air Intake Chamber
INTAKE (INDUCTION)
4. Air Intake Chamber
A: REMOVAL
2) Loosen the clamp (A) which connects air intake
chamber to throttle body.
3) Loosen the clamp (B) which connects intake
boot to air intake chamber.
4) Remove the bolt (C) which secures air intake
chamber to the stay.
5) Disconnect the blow-by hoses, then remove the
air intake chamber.
B: INSTALLATION
Tightening torque:
Clamp (A), (B)
3.0 Nm (0.3 kgf-m, 2.2 ft-lb)
Bolt (C)
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
C: INSPECTION
take chamber.
(A)
IN-02095
(C)
(C)
(B)
(A)
IN-02095
(C)
(C)
(B)
IN(H6DO)-8
Air Intake Duct
INTAKE (INDUCTION)
5. Air Intake Duct
A: REMOVAL
B: INSTALLATION
C: INSPECTION
take duct.
IN-02013
IN(H6DO)-9
Resonator Chamber
INTAKE (INDUCTION)
A: REMOVAL
er Case for removal procedure. <Ref. to IN(H6DO)-
5, REMOVAL, Air Cleaner Case.>
B: INSTALLATION
er Case for installation procedure. <Ref. to
IN(H6DO)-6, INSTALLATION, Air Cleaner Case.>
C: INSPECTION
IN(H6DO)-10
Resonator Chamber
INTAKE (INDUCTION)
ME(H6DO)-2
General Description
MECHANICAL
A: SPECIFICATION
NOTE:
OS: Oversize US: Undersize
Engine
Horizontally opposed, liquid cooled,
6-cylinder, 4-stroke gasoline engine
Chain driven, double overhead camshaft,
4-valve/cylinder
Bore Stroke mm (in) 89.2 80 (3.512 3.150)
Displacement cm
3
(cu in) 3,000 (183)
(350 rpm and fully open throttle):
kPa (kgf/cm
2
, psi) 1,275 1,471 (13.0 15.0, 185 213)
Intake valve timing
Min. advance
Open BTDC 47
Close ABDC 23
Max. retard
Open ATDC 3
Close ABDC 73
Open BBDC 46
Close ATDC 6
Intake 0.20
+0.04
-0.06
(0.0079
+0.0016
-0.0024
)
Exhaust 0.350.05 (0.01380.0020)
Idle rpm [P or N range] rpm
No load 65050
A/C ON 77050
Ignition order 1 6 3 2 5 4
Ignition timing BTDC/rpm 158/650
ME(H6DO)-3
General Description
MECHANICAL
Camshaft
Side clearance mm (in)
Intake Standard 0.075 0.135 (0.0030 0.0053)
Cam lobe height mm (in)
Intake
HIGH Standard 42.09 42.19 (1.6571 1.6610)
LOW1 Standard 38.14 38.24 (1.5016 1.5055)
LOW2 Standard 38.14 38.24 (1.5016 1.5055)
Cam base circle diameter mm (in)
Intake
HIGH Standard 32.00 (1.2598)
LOW1 Standard 31.84 (1.2535)
LOW2 Standard 31.84 (1.2535)
Exhaust Standard 32.00 (1.2598)
Journal O.D. mm (in)
Front Standard 37.946 37.963 (1.4939 1.4946)
Except for front Standard 25.946 25.963 (1.0215 1.0222)
Cylinder
head
Warping limit
(Mating with cylinder block)
mm (in) Standard 0.02 (0.0008)
Inner diameter of valve lifter hole mm (in) 32.994 33.016 (1.2990 1.2998)
Standard height mm (in) 1240.05 (4.880.0020)
Valve seat
Seating angle 90
Intake Standard 1.0 (0.039)
Valve guide
Inside diameter mm (in) 5.500 5.512 (0.2165 0.2170)
Protrusion above head mm (in) 11.4 11.8 (0.449 0.465)
Valve
Intake Standard 1.0 (0.039)
Intake 5.455 5.470 (0.2148 0.2154)
Exhaust 5.445 5.460 (0.2144 0.2150)
Stem oil clearance mm (in)
Intake Standard 0.030 0.057 (0.0012 0.0022)
Intake 99.7 (3.925)
Exhaust 105.2 (4.142)
Outer diameter of valve lifter mm (in) 32.959 32.975 (1.2976 1.2982)
Valve spring
Free length mm (in)
Intake
Inner 39.55 (1.5571)
Outer 41.18 (1.6213)
Exhaust 46.32 (1.8236)
Squareness
Intake
Inner 2.5, 1.7 mm (0.067 in) or less
Outer 2.5, 1.8 mm (0.071 in) or less
Exhaust 2.5, 2.0 mm (0.079 in) or less
Cylinder
block
Standard height mm (in) 202 (7.95)
Warping limit
(Mating with cylinder head)
mm (in) Standard 0.02 (0.0008)
Cylinder inner diameter mm (in) Standard
A 89.205 89.215 (3.5120 3.5124)
B 89.195 89.205 (3.5116 3.5120)
Cylindricality mm (in) Standard 0.030 (0.0012)
Piston
Outer diameter mm (in)
Standard
A 89.205 89.215 (3.5120 3.5124)
B 89.195 89.205 (3.5116 3.5120)
0.25 (0.0098) OS 89.445 89.465 (3.5215 3.5222)
0.50 (0.0197) OS 89.695 89.715 (3.5313 3.5321)
Inner diameter of piston pin hole mm (in) Standard 22.000 22.006 (0.8661 0.8664)
ME(H6DO)-4
General Description
MECHANICAL
Piston pin
Outer diameter mm (in) Standard 21.994 22.000 (0.8659 0.8661)
Standard clearance between piston and piston pin mm (in) Standard 0.004 0.008 (0.0002 0.0003)
Piston ring
Connecting
rod
Bearing of
large end
Bearing size (Thickness at center) mm (in)
Standard 1.490 1.506 (0.0587 0.0593)
0.03 (0.0012) US 1.509 1.513 (0.0594 0.0596)
0.05 (0.0020) US 1.519 1.523 (0.0598 0.0600)
0.25 (0.0098) US 1.619 1.623 (0.0637 0.0639)
Bushing of
small end
Clearance between piston pin and bushing mm (in) Standard 0 0.022 (0 0.0009)
Crankshaft
Crank pin and crank journal
Crank pin outer diameter mm (in)
Standard 51.984 52.000 (2.0466 2.0472)
0.03 (0.0012) US 51.954 51.970 (2.0454 2.0461)
0.05 (0.0020) US 51.934 51.950 (2.0446 2.0453)
0.25 (0.0098) US 51.734 51.750 (2.0368 2.0374)
Crank journal outer diameter mm (in)
#1, #3, #5,
#7
Standard 63.992 64.008 (2.5194 2.5200)
0.03 (0.0012) US 63.962 63.978 (2.5182 2.5188)
0.05 (0.0020) US 63.942 63.958 (2.5174 2.5180)
0.25 (0.0098) US 63.742 63.758 (2.5095 2.5102)
#2, #4, #6
Standard 63.992 64.008 (2.5194 2.5200)
0.03 (0.0012) US 63.962 63.978 (2.5182 2.5188)
0.05 (0.0020) US 63.942 63.958 (2.5174 2.5180)
0.25 (0.0098) US 63.742 63.758 (2.5095 2.5102)
Main bearing
Bearing size (Thickness at
center)
mm (in)
#1, #3, #5,
#7
Standard 1.992 2.005 (0.0784 0.0789)
0.03 (0.0012) US 2.011 2.014 (0.0792 0.0793)
0.05 (0.0020) US 2.021 2.024 (0.0796 0.0797)
0.25 (0.0098) US 2.121 2.124 (0.0835 0.0836)
#2, #4, #6
Standard 1.996 2.009 (0.0786 0.0791)
0.03 (0.0012) US 2.015 2.018 (0.0793 0.0794)
0.05 (0.0020) US 2.025 2.028 (0.0797 0.0798)
0.25 (0.0098) US 2.125 2.128 (0.0837 0.0838)
ME(H6DO)-5
General Description
MECHANICAL
B: COMPONENT
1. V-BELT
(1) V-belt (6) Generator plate Tightening torque:Nm (kgf-m, ft-lb)
(2) Collector cover bracket (7) A/C compressor stay T1: 6.4 (0.65, 4.7)
(3) Belt tension adjuster ASSY (8) Idler pulley T2: 20 (2.0, 14.8)
(4) Power steering pump bracket (9) Idler pulley cover T3: 25 (2.5, 18.4)
(5) Generator (10) Cushion T4: 33 (3.4, 25)
ME-03100
T1
T3
T3
T2
T4
(1)
(9)
(2)
(10)
(10)
(3)
(4)
(5)
(6)
(8)
(7)
ME(H6DO)-6
General Description
MECHANICAL
2. TIMING CHAIN COVER
(1) Crank pulley cover (5) Oil seal Tightening torque:Nm (kgf-m, ft-lb)
(2) O-ring (6) Front chain cover T1: <Ref. to ME(H6DO)-41, Crank
Pulley.>
(3) Crank pulley (7) Rear chain cover
(4) Sealing washer (8) Water pump gasket T2: <Ref. to ME(H6DO)-42, Front
Chain Cover.>
T3: <Ref. to ME(H6DO)-52, Rear
Chain Cover.>
T4: 6.4 (0.65, 4.7)
T2
T2
T2
T2
T3
T3
T3
T3
T3
(4)
(6)
(7)
(8)
(5)
T1
T4
(1)
(3)
(2)
ME-03328
ME(H6DO)-7
General Description
MECHANICAL
3. TIMING CHAIN
(1) Crank sprocket (12) Chain tensioner (RH) (23) Idler sprocket collar
(2) Oil relief case (13) Chain tensioner lever (LH) (24) Idler sprocket (upper)
(3) Inner rotor (14) Chain tensioner (LH)
(4) Outer rotor (15) Water pump Tightening torque:Nm (kgf-m, ft-lb)
(5) Chain guide (center) (16) O-ring T1: 6.4 (0.65, 4.7)
(6) Intake cam sprocket (RH) (17) Chain guide (LH) T2: 7.8 (0.8, 5.8)
(7) Exhaust cam sprocket (RH) (18) Chain guide (LH: between cams) T3: <Ref. to ME(H6DO)-50, Cam
Sprocket.>
(8) Chain guide (RH: between cams) (19) Timing chain (LH)
(9) Timing chain (RH) (20) Intake cam sprocket (LH) T4: 16 (1.6, 11.8)
(10) Chain guide (RH) (21) Exhaust cam sprocket (LH) T5: 69 (7.0, 50.9)
(11) Chain tensioner lever (RH) (22) Idler sprocket (lower) T6: <Ref. to LU(H6DO)-8, Oil
Pump.>
ME-02380
T6
(2)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(5)
T3
T3
T5
T2
T1
T1
T1
T4
T4
T4
T4
T4
(7)
(21)
(20)
(22)
(23)
(23)
(24)
(6)
(1)
(3)
(4)
ME(H6DO)-8
General Description
MECHANICAL
ME-03326
(1)
(9)
(10)
(22)
(23)
(24)
(26)
(27)
(28)
(25)
(32)
(37)
(8)
(18)
(16)
(13)
(12)
(6)
(36) (5)
(14)
(15)
(19)
(20)
(21)
(7)
(11)
(31)
(34)
(36)
(35)
(30)
(29)
(33)
T5
T1
T6
T4
T2
T2
T1
T6
T4
T4
T7
T2
T2
T5
T8
T4
T8
T8
T8
(17)
(37)
(17)
(2)
(3)
T4
T3
(4)
T3
T4
(38)
(38)
(38)
(38)
ME(H6DO)-9
General Description
MECHANICAL
(1) Rocker cover (RH) (17) Gasket (34) Oil pipe (LH)
(2) Oil switching solenoid valve (RH) (18) Cylinder head gasket (RH) (35) Rocker cover (LH)
(3) Oil switching solenoid valve holder
(RH)
(19) Oil switching solenoid valve (LH) (36) Union screw with filter
(with protrusion)
(20) Oil switching solenoid valve holder
(LH) (4) Oil switching solenoid valve gas-
ket (RH)
(37) Union screw without filter
(without protrusion)
(21) Oil switching solenoid valve gas-
ket (LH) (5) Front chain cover (38) Rocker cover gasket
(6) Oil pipe (RH) (22) Cylinder head gasket (LH)
(7) Oil flow control solenoid valve
(RH)
(23) Cylinder head (LH) Tightening torque:Nm (kgf-m, ft-lb)
(24) Intake camshaft (LH) T1: <Ref. to ME(H6DO)-58, Cylinder
Head.>
(8) Intake camshaft cap (Center RH) (25) Exhaust camshaft (LH)
(9) Intake camshaft cap (Rear RH) (26) Oil flow control solenoid valve (LH) T2: <Ref. to ME(H6DO)-54, Cam-
shaft.>
(10) Exhaust camshaft cap (Rear RH) (27) Intake camshaft cap (Rear LH)
(11) Exhaust camshaft cap
(Center RH)
(28) Intake camshaft cap (Center LH) T3: <Ref. to ME(H6DO)-81, Oil
Switching Solenoid Valve.>
(29) Exhaust camshaft cap (Rear LH)
(12) Exhaust camshaft cap (Front RH) (30) Exhaust camshaft cap
(Center LH)
T4: 6.4 (0.65, 4.7)
(13) Front camshaft cap (RH) T5: 9.75 (1.0, 7.2)
(14) Intake camshaft (RH) (31) Exhaust camshaft cap (Front LH) T6: 16 (1.6, 11.8)
(15) Exhaust camshaft (RH) (32) Front camshaft cap (LH) T7: 60 (6.1, 44)
(16) Cylinder head (RH) (33) Plug T8: 29 (3.0, 21.4)
ME(H6DO)-10
General Description
MECHANICAL
(1) Exhaust valve (7) Valve spring (Outer) (13) Exhaust valve stem seal
(2) Intake valve (8) Retainer (14) Valve spring
(3) Intake valve guide (9) Retainer key (15) Valve lifter (Exhaust)
(4) Valve spring seat (10) Shim (16) Cylinder head
(5) Intake valve stem seal (11) Valve lifter (Intake)
(6) Valve spring (Inner) (12) Exhaust valve guide
ME-03102
(16)
(3)
(12)
(13)
(4)
(14)
(8)
(9)
(15)
(4) (5) (6) (7) (8) (9) (11) (10)
(1)
(2)
ME(H6DO)-11
General Description
MECHANICAL
6. CYLINDER BLOCK
(5)
(6)
(7)
(9)
(5)
(8)
(19)
(19)
(10)
(19)
(19)
(21)
(22)
(23)
T1
T2
T2
T2
T1
T2
T2
T5
T2
T9
ME-03327
T4
T6
T10
(5)
(1)
(3)
(4)
(5)
(2)
(19)
(19)
(20)
(19)
(19)
T1
T1
T8
T3
T5
T8
T8
(5)
(18)
(17)
(13)
(14)
(13)
(16)
(13)
(14)
(13)
(15)
(13)
(13)
(11)
(12)
(14)
T6
T1
T7
T3
T1
(14)
(13)
(24)
T4
T4
ME(H6DO)-12
General Description
MECHANICAL
(1) Cylinder block (RH) (13) Clamp Tightening torque:Nm (kgf-m, ft-lb)
(2) Cylinder block (LH) (14) Hose T1: 6.4 (0.65, 4.7)
(3) Rear oil seal (15) Oil cooler pipe T2: 18 (1.8, 13.3)
(4) Service hole cover (16) Oil cooler T3: 25 (2.5, 18.4)
(5) O-ring (17) Connector T4: 16 (1.6, 11.8)
(6) Oil pan upper (18) Oil filter T5: 37 (3.8, 27)
(7) Oil pressure switch (19) Plug T6: 44 (4.5, 32.5)
(8) Oil strainer (20) Crankshaft position sensor holder T7: 54 (5.5, 40)
(9) Magnet (21) Relief valve T8: 70 (7.1, 51.6)
(10) Oil pan lower (22) Relief valve spring T9: 23 (2.3, 17)
(11) Metal gasket (23) Plug T10: 90 (9.2, 67)
(12) Drain plug (24) Water pipe
ME(H6DO)-13
General Description
MECHANICAL
(1) Reinforcement (9) Piston pin (17) Crankshaft bearing #2, #4, #6
(2) Drive plate (10) Connecting rod (18) Crankshaft bearing #7
(3) Crankshaft sensor plate (11) Connecting rod bearing
(4) Top ring (12) Connecting rod bolt Tightening torque:Nm (kgf-m, ft-lb)
(5) Second ring (13) Connecting rod cap T1: 53 (5.4, 39)
(6) Oil ring (14) Crankshaft T2: 81 (8.3, 60)
(7) Snap ring (15) Woodruff key
(8) Piston (16) Crankshaft bearing #1, #3, #5
(9)
(1)
(3)
(2)
(4)
(5)
(6)
(7)
(8)
(9)
(7)
(8)
(7)
(6)
(5)
(4)
(7)
(15)
(11)
(13)
(12)
(12)
(14)
(10)
(11)
(11)
(13)
(18)
(16)
(17)
(17)
(16)
(17)
(16)
(10)
T1
T2
T1
ME-02454
ME(H6DO)-14
General Description
MECHANICAL
8. ENGINE MOUNTING
C: CAUTION
forming any work.
points.
the battery.
and bearings.
assembly.
making rechecks.
ready use.
jacks, etc.
T1: 35 (3.6, 25.8)
T2: 85 (8.7, 62.7)
(1)
T2
T1
T1
T2
ME-00445
ME(H6DO)-15
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
18250AA010 CYLINDER HEAD
TABLE
18232AA000 ENGINE STAND Used for disassembling and assembling engine.
STOPPER
Used for removing and installing the drive plate.
18254AA000 PISTON GUIDE Used for installing piston in cylinder.
ST18250AA010
ST18232AA000
ST-498497100
ST18254AA000
ME(H6DO)-16
General Description
MECHANICAL
GUIDE
Used for press-fitting of intake and exhaust
valve guide oil seals.
18253AA000 PISTON PIN GUIDE Used for installing piston pin, piston and con-
necting rod.
18350AA000 CONNECTING ROD
BUSHING
REMOVER AND
INSTALLER
bushing.
REMOVER ASSY
WRENCH
sprocket.
ST-499585500
ST18253AA000
ST18350AA000
ST-499097700
ST-499977500
ME(H6DO)-17
General Description
MECHANICAL
WRENCH
sprocket.
SEAL INSTALLER
SEAL GUIDE (499597100).
SEAL GUIDE
REMOVER
18251AA040 VALVE GUIDE
ADJUSTER
Used for installing valve guides.
ST18231AA020
ST-499587200
ST-499597100
ST-499718000
ST18251AA040
ME(H6DO)-18
General Description
MECHANICAL
REMOVER
REAMER
WRENCH
Used for stopping rotation of crank pulley when
loosening/tightening crank pulley bolt.
18252AA000 CRANKSHAFT
SOCKET
MONITOR III KIT
ST-499765700
ST-499765900
ST-499977100
ST18252AA000
ST1B021XU0
ME(H6DO)-19
General Description
MECHANICAL
18233AA000 PISTON PIN SNAP
RING PLIERS
Used for removing and installing snap ring of
piston pin.
assembly to engine.
REMOVER
engine compartment.
18471AA000 FUEL PIPE
ADAPTER
Used for fuel pressure.
42075AG690 FUEL HOSE Used for fuel pressure.
This is the SUBARU genuine part.
ST18233AA000
ST-498277200
ST42099AE000
ST18471AA000
ST42075AG690
ME(H6DO)-20
General Description
MECHANICAL
2. GENERAL TOOL
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 chain
Camshaft
Cylinder head
TOOL NAME REMARKS
Vacuum gauge Used for measuring intake manifold vacuum.
ME(H6DO)-21
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
ment.
switch to OFF.
DURE, Fuel.>
4) Remove all the spark plugs. <Ref. to IG(H6DO)-
4, REMOVAL, Spark Plug.>
spark plug hole.
NOTE:
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
9) Perform at least two measurements per cylinder,
and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard:
1,275 1,471 kPa (13.0 15.0 kgf/cm
2
,
185 213 psi)
Service limit:
1,128 kPa (11.5 kgf/cm
2
, 164 psi)
ME-00446
ME(H6DO)-22
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
lowing item:
properly.
not illuminate.
Monitor. <Ref. to EN(H6DO)(diag)-36, READ CUR-
and etc. are OFF)
Idle speed [No load and gears in P or N range]:
65050 rpm
Idle speed [A/C ON and gears in P or N range]:
77050 rpm
NOTE:
General On-board Diagnosis Table under Engine
Control System. <Ref. to EN(H6DO)(diag)-2, Ba-
sic Diagnostic Procedure.>
ME(H6DO)-23
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot.
Be careful not to burn yourself at measurement.
1. METHOD WITH SUBARU SELECT MON-
ITOR
following item:
not illuminate.
3) Read the ignition timing using Subaru Select
Monitor. <Ref. to EN(H6DO)(diag)-36, READ CUR-
158/650
EN(H6DO)(diag)-2, Basic Diagnostic Procedure.>
2. METHOD WITH TIMING LIGHT
following item:
not illuminate.
OFF.
IN(H6DO)-5, REMOVAL, Air Cleaner Case.>
5) Connect the timing light to the power wire of #1
ignition coil.
6) Install the air cleaner case. <Ref. to IN(H6DO)-6,
INSTALLATION, Air Cleaner Case.>
7) Start the engine, turn the timing light to the crank
pulley, and check the ignition timing by means of
crank pulley indicator.
158/650
EN(H6DO)(diag)-2, Basic Diagnostic Procedure.>
ME(H6DO)-24
MECHANICAL
A: INSPECTION
2) Disconnect the brake vacuum hose from the in-
take manifold, and install the vacuum gauge.
uum gauge indication. By observing the vacuum
gauge needle movement, internal condition of the
engine can be diagnosed as described below.
ME-02383
Air leakage around intake manifold gasket, disconnection or
damage of vacuum hose
position.
tion.
Sticky valve
range.
Defective ignition system or throttle chamber idle adjustment
ME(H6DO)-25
Engine Oil Pressure
MECHANICAL
A: INSPECTION
1) Remove the oil pressure switch from the cylinder
block. <Ref. to LU(H6DO)-14, REMOVAL, Oil
Pressure Switch.>
2) Connect the oil pressure gauge hose to the cyl-
inder block.
OIL PRESSURE (at oil temperature of 80C
(176F)):
Standard:
135 kPa (1.4 kgf/cm
2
, 20 psi) or more
(at 600 rpm)
500 kPa (5.1 kgf/cm
2
, 73 psi) or more
(at 5,000 rpm)
If the oil pressure is out of specification, check oil
pump, oil filter and lubrication line. <Ref. to
LU(H6DO)-18, INSPECTION, Engine Lubrication
System Trouble in General.>
sure switch. <Ref. to LU(H6DO)-18, INSPECTION,
Engine Lubrication System Trouble in General.>
pressure switch. <Ref. to LU(H6DO)-14, INSTAL-
LATION, Oil Pressure Switch.>
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
ME(H6DO)-26
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
WARNING:
CAUTION:
or cloth.
NOTE:
Check or replace the fuel pump and fuel delivery
line if the fuel pressure is out of the standard value.
DURE, Fuel.>
2) Disconnect the fuel delivery hose and connect
(1) Disconnect the fuel delivery hose using the
ST1.
ST1 42099AE000 CONNECTOR REMOVER
(2) Connect the fuel pressure gauge with ST2
and ST3.
NOTE:
ST2 is the SUBARU genuine part.
ST2 42075AG690 FUEL HOSE
ST3 18471AA000 FUEL PIPE ADAPTER
3) Install the fuse of fuel pump to the main fuse box.
5) Measure the fuel pressure after warming up the
engine.
Fuel pressure:
Standard: 338 348 kPa (3.4 3.5 kgf/cm
2
,
49 50.5 psi)
NOTE:
to 0.2 kgf/cm
2
(A) ST2
(B) ST3
FU-02676
ST
(A)
(B)
ME-02666
FU-01122
ME(H6DO)-27
Valve Clearance
MECHANICAL
8. Valve Clearance
A: INSPECTION
NOTE:
Inspection and adjustment of valve clearance should
be performed while engine is cold.
7) When inspecting RH side cylinders:
(1) Remove the air intake duct and air cleaner
case. <Ref. to IN(H6DO)-8, REMOVAL, Air In-
take Duct.> <Ref. to IN(H6DO)-5, REMOVAL,
Air Cleaner Case.>
(2) Remove the fuel pipe protector (RH).
(3) Disconnect the connector of oil pressure
switch.
<Ref. to IG(H6DO)-7, REMOVAL, Ignition Coil.>
(5) Remove the rocker cover (RH).
8) When inspecting LH side cylinders:
(1) Disconnect the battery cable, and then re-
move the battery and battery carrier.
(2) Disconnect the PCV hose and blow-by hose
from the rocker cover (LH).
(3) Remove the fuel pipe protector (LH).
(4) Remove the ignition coil. <Ref. to IG(H6DO)
-7, REMOVAL, Ignition Coil.>
(5) Remove the rocker cover (LH).
IN-00203
FU-02119
ME-00460
FU-02117
ME(H6DO)-28
Valve Clearance
MECHANICAL
9) Turn the crankshaft clockwise until the cam is
set to position shown in the figure.
10) Measure the clearance of intake valve and ex-
haust valve using thickness gauge (A).
NOTE:
Measure it within the range of 30 from speci-
fied position shown in the figure.
Measure it in low lift cam for intake side.
zontal as possible with respect to the valve lifter.
Valve clearance
Intake:
0.20
+0.04
0.06
mm (0.0079
+0.0016
0.0024
in)
Exhaust:
0.350.05 mm (0.01380.0020 in)
If the measured value is not within specification,
take notes of the value in order to adjust the valve
clearance later on.
to ME(H6DO)-28, ADJUSTMENT, Valve Clear-
ance.>
12) Further turn the crank pulley clockwise and
then measure the valve clearances again.
B: ADJUSTMENT
1. INTAKE SIDE
NOTE:
Do not wear gloves during removal and installa-
tion of valve lifter.
Do not use valve lifters that were dropped or oth-
erwise exposed to strong impacts.
When installing the valve lifter, align the anti-ro-
tation of valve lifter with groove on cylinder head,
and insert the valve lifter.
ME(H6DO)-27, INSPECTION, Valve Clearance.>
NOTE:
2) Remove the camshaft. <Ref. to ME(H6DO)-54,
REMOVAL, Camshaft.>
4) Remove the shim from valve lifter.
5) Check the thickness of the shim from the mark-
ings on the side of the shim that was removed.
(1) Valve clearance (Intake side)
(2) Valve clearance (Exhaust side)
(3) High lift cam
(4) Low lift cam
ME-02565
(4) (3) (3) (4)
(1)
(2)
(1)
(2)
(23 ) (23 )
(A)
ME-00464
ME(H6DO)-29
Valve Clearance
MECHANICAL
6) Select a shim of suitable thickness from the fol-
lowing table using the measured valve clearance
and shim thickness.
Unit: mm (in)
S = (V + T) 0.20 (0.0079)
S: Required shim thickness
T: Shim thickness to be used
13218AK890 1.92 (0.0756)
13218AK900 1.94 (0.0764)
13218AK910 1.96 (0.0772)
13218AK920 1.98 (0.0780)
13218AK930 2.00 (0.0787)
13218AK940 2.02 (0.0795)
13218AK950 2.04 (0.0803)
13218AK960 2.06 (0.0811)
13218AK970 2.07 (0.0815)
13218AK980 2.08 (0.0819)
13218AK990 2.09 (0.0823)
13218AL000 2.10 (0.0827)
13218AL010 2.11 (0.0831)
13218AL020 2.12 (0.0835)
13218AL030 2.13 (0.0839)
13218AL040 2.14 (0.0843)
13218AL050 2.15 (0.0846)
13218AL060 2.16 (0.0850)
13218AL070 2.17 (0.0854)
13218AL080 2.18 (0.0858)
13218AL090 2.19 (0.0862)
13218AL100 2.20 (0.0866)
13218AL110 2.21 (0.0870)
13218AL120 2.22 (0.0874)
13218AL130 2.23 (0.0878)
13218AL140 2.24 (0.0882)
13218AL150 2.25 (0.0886)
13218AL160 2.26 (0.0890)
13218AL170 2.27 (0.0894)
13218AL180 2.28 (0.0898)
13218AL190 2.29 (0.0902)
13218AL200 2.30 (0.0906)
13218AL210 2.31 (0.0909)
13218AL220 2.32 (0.0913)
13218AL230 2.33 (0.0917)
13218AL240 2.34 (0.0921)
13218AL250 2.35 (0.0925)
13218AL260 2.36 (0.0929)
13218AL270 2.37 (0.0933)
13218AL280 2.38 (0.0937)
13218AL290 2.39 (0.0941)
13218AL300 2.40 (0.0945)
13218AL310 2.41 (0.0949)
13218AL320 2.42 (0.0953)
13218AL330 2.43 (0.0957)
13218AL340 2.44 (0.0961)
13218AL350 2.45 (0.0965)
13218AL360 2.46 (0.0969)
13218AL370 2.47 (0.0972)
13218AL380 2.48 (0.0976)
13218AL390 2.49 (0.0980)
13218AL400 2.50 (0.0984)
13218AL410 2.51 (0.0988)
13218AL420 2.52 (0.0992)
13218AL430 2.53 (0.0996)
13218AL440 2.54 (0.1000)
13218AL450 2.55 (0.1004)
13218AL460 2.56 (0.1008)
13218AL470 2.57 (0.1012)
13218AL480 2.58 (0.1016)
13218AL490 2.59 (0.1020)
13218AL500 2.60 (0.1024)
13218AL510 2.61 (0.1028)
13218AL520 2.62 (0.1032)
13218AL530 2.64 (0.1039)
13218AL540 2.66 (0.1047)
13218AL550 2.68 (0.1055)
13218AL560 2.70 (0.1063)
13218AL570 2.72 (0.1071)
13218AL580 2.74 (0.1079)
13218AL590 2.76 (0.1087)
ME(H6DO)-30
Valve Clearance
MECHANICAL
2. EXHAUST SIDE
NOTE:
Do not wear gloves during removal and installa-
tion of valve lifter.
Do not use valve lifters that were dropped or oth-
erwise exposed to strong impacts.
ME(H6DO)-27, INSPECTION, Valve Clearance.>
NOTE:
REMOVAL, Camshaft.>
4) Measure the thickness of valve lifter using mi-
crometer.
5) Select a valve lifter of suitable thickness from the
following table using the measured valve clearance
and valve lifter thickness.
Unit: mm (in)
S = (V + T) 0.35 (0.0138)
S: Valve lifter thickness required
T: Valve lifter thickness to be used
13228AD181 4.32 (0.1701)
13228AD191 4.34 (0.1709)
13228AD201 4.36 (0.1717)
13228AD211 4.38 (0.1724)
13228AD221 4.40 (0.1732)
13228AD231 4.42 (0.1740)
13228AD241 4.44 (0.1748)
13228AD251 4.46 (0.1756)
13228AD261 4.48 (0.1764)
13228AD271 4.50 (0.1772)
13228AD281 4.52 (0.1780)
13228AD291 4.54 (0.1787)
13228AD301 4.56 (0.1795)
13228AD311 4.58 (0.1803)
13228AD321 4.60 (0.1811)
ME-00025
13228AC581 4.62 (0.1819)
13228AC591 4.63 (0.1823)
13228AC601 4.64 (0.1827)
13228AC611 4.65 (0.1831)
13228AC621 4.66 (0.1835)
13228AC631 4.67 (0.1839)
13228AC641 4.68 (0.1843)
13228AC651 4.69 (0.1846)
13228AC661 4.70 (0.1850)
13228AC671 4.71 (0.1854)
13228AC681 4.72 (0.1858)
13228AC691 4.73 (0.1862)
13228AC701 4.74 (0.1866)
13228AC711 4.75 (0.1870)
13228AC721 4.76 (0.1874)
13228AC731 4.77 (0.1878)
13228AC741 4.78 (0.1882)
13228AC751 4.79 (0.1886)
13228AC761 4.80 (0.1890)
13228AC771 4.81 (0.1894)
13228AC781 4.82 (0.1898)
13228AC791 4.83 (0.1902)
13228AC801 4.84 (0.1906)
13228AC811 4.85 (0.1909)
13228AC821 4.86 (0.1913)
13228AC831 4.87 (0.1917)
13228AC841 4.88 (0.1921)
13228AC851 4.89 (0.1925)
13228AC861 4.90 (0.1929)
13228AC871 4.91 (0.1933)
13228AC881 4.92 (0.1937)
13228AC891 4.93 (0.1941)
13228AC901 4.94 (0.1945)
13228AC911 4.95 (0.1949)
13228AC921 4.96 (0.1953)
13228AC931 4.97 (0.1957)
13228AC941 4.98 (0.1961)
13228AC951 4.99 (0.1965)
13228AC961 5.00 (0.1969)
13228AC971 5.01 (0.1972)
13228AC981 5.02 (0.1976)
13228AC991 5.03 (0.1980)
13228AD001 5.04 (0.1984)
13228AD011 5.05 (0.1988)
13228AD021 5.06 (0.1992)
13228AD031 5.07 (0.1996)
13228AD041 5.08 (0.2000)
13228AD051 5.09 (0.2004)
13228AD061 5.10 (0.2008)
13228AD071 5.11 (0.2012)
ME(H6DO)-31
Valve Clearance
MECHANICAL
13228AD081 5.12 (0.2016)
13228AD091 5.13 (0.2020)
13228AD101 5.14 (0.2024)
13228AD111 5.15 (0.2028)
13228AD121 5.16 (0.2032)
13228AD131 5.17 (0.2035)
13228AD141 5.18 (0.2039)
13228AD151 5.19 (0.2043)
13228AD161 5.20 (0.2047)
13228AD171 5.21 (0.2051)
13228AD331 5.23 (0.2059)
13228AD341 5.25 (0.2067)
13228AD351 5.27 (0.2075)
13228AD361 5.29 (0.2083)
13228AD371 5.31 (0.2091)
13228AD381 5.33 (0.2098)
13228AD391 5.35 (0.2106)
13228AD401 5.37 (0.2114)
13228AD411 5.39 (0.2122)
13228AD421 5.41 (0.2130)
13228AD431 5.43 (0.2138)
13228AD441 5.45 (0.2146)
13228AD451 5.47 (0.2154)
13228AD461 5.49 (0.2161)
13228AD471 5.51 (0.2169)
13228AD481 5.53 (0.2177)
13228AD491 5.55 (0.2185)
13228AD501 5.57 (0.2193)
13228AD511 5.59 (0.2201)
ME(H6DO)-32
Engine Assembly
MECHANICAL
9. Engine Assembly
A: REMOVAL
front hood stay.
4) Collect the refrigerant from the A/C system.
<Ref. to AC-21, PROCEDURE, Refrigerant Recov-
ery Procedure.>
DURE, Fuel.>
6) Remove the fuel filler cap.
7) Remove the battery from vehicle.
air intake chamber. <Ref. to IN(H6DO)-8, REMOV-
AL, Air Intake Duct.> <Ref. to IN(H6DO)-5, RE-
MOVAL, Air Cleaner Case.> <Ref. to IN(H6DO)-7,
REMOVAL, Air Intake Chamber.>
9) Remove the radiator from vehicle. <Ref. to
CO(H6DO)-16, REMOVAL, Radiator.>
10) Remove the V-belts. <Ref. to ME(H6DO)-40,
REMOVAL, V-belt.>
11) Disconnect the A/C pressure hoses from the A/
C compressor. <Ref. to AC-39, REMOVAL, Hose
and Tube.>
12) Remove the engine ground terminal.
13) Disconnect the following connector.
(3) Pressure regulator vacuum hose
15) Remove the power steering pump together with
the bracket.
NOTE:
Do not disconnect the hose and pipe from the
pump body.
16) Place the power steering pump on the right
side wheel apron.
ME-00476
ME-02382
(A) Cloth
ME-02383
ME-02992
ME-02990
(A)
ME-00483
ME(H6DO)-33
Engine Assembly
MECHANICAL
19) Remove the front exhaust pipe. <Ref. to
EX(H6DO)-4, REMOVAL, Front Exhaust Pipe.>
NOTE:
Be careful not to let the front exhaust pipe interfere
with water pipes on engine side.
20) Remove the ground cable.
plate.
(2) Remove the service hole plug (A).
(4) Remove other bolts while rotating the crank-
ME-02027
AT-03238
ME-00485
(A)
ME-02445
ME-03286
ME(H6DO)-34
Engine Assembly
MECHANICAL
25) Disconnect the fuel delivery hose and evapora-
tion hose.
CAUTION:
or cloth.
(1) Disconnect the connector of fuel pipe by
pushing the ST in the direction of arrow.
(2) Remove the clip, and disconnect the evapo-
wire ropes.
CAUTION:
weight.
CAUTION:
overlooked.
28) Separation of engine and transmission:
REMOVAL, Starter.>
(2) Remove the bolts which hold upper side of
29) Attach the ST to the converter case.
compartment.
NOTE:
(A) Transmission
(B) Garage jack
FU-02866
ST
(A)
(B)
ME-00490
AT-03237
ST
ME-00492
ME(H6DO)-35
Engine Assembly
MECHANICAL
B: INSTALLATION
1) Install the front cushion rubbers.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
NOTE:
mission to 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, 42.8 ft-lb)
7) Remove the ST from converter case.
NOTE:
Be careful not to drop the ST into the converter
case when removing the ST.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
(3) Install the service hole plug (A) to prevent
getting foreign matter inside.
AT-03237
ME-03287
T2
T1
(A)
ME-02445
ME(H6DO)-36
Engine Assembly
MECHANICAL
Tightening torque:
(A) 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(B): 33 Nm (3.4 kgf-m, 24.3 ft-lb)
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
Tightening torque:
85 Nm (8.7 kgf-m, 62.7 ft-lb)
NOTE:
14) Install the front exhaust pipe. <Ref. to
EX(H6DO)-5, INSTALLATION, Front Exhaust
Pipe.>
NOTE:
Be care not to let the front exhaust pipe interfere
with water pipes and crossmember on engine side.
Be care not to scratch the flange surface of front
exhaust pipe with stud bolt on engine.
15) Connect the ground cable.
(1) Fuel delivery hose and evaporation hose
(4) Pressure regulator vacuum hose
(A)
(B)
ME-02993
(B) (B)
ME-02991
AT-03238
(A) (B) (B) (A)
ME-00494
ME-02027
ME(H6DO)-37
Engine Assembly
MECHANICAL
20) Install the engine ground terminals.
Tightening torque:
14 Nm (1.4 kgf-m, 10.1 ft-lb)
21) Install the A/C pressure hoses. <Ref. to AC-39,
INSTALLATION, Hose and Tube.>
22) Install the V-belts. <Ref. to ME(H6DO)-40, IN-
23) Install the radiator to vehicle. <Ref. to
CO(H6DO)-17, INSTALLATION, Radiator.>
24) Install the air intake duct, air cleaner case and air
intake chamber. <Ref. to IN(H6DO)-8, INSTALLA-
TION, Air Intake Duct.> <Ref. to IN(H6DO)-6, IN-
STALLATION, Air Cleaner Case.> <Ref. to
IN(H6DO)-7, INSTALLATION, Air Intake Chamber.>
cables.
26) Fill engine coolant. <Ref. to CO(H6DO)-11,
sary. <Ref. to 5AT-28, INSPECTION, Automatic
Transmission Fluid.>
Procedure.>
hood.
C: INSPECTION
1) Check the pipes and hoses are installed firmly.
2) Check the engine coolant and ATF are at speci-
fied levels.
3) Start the engine and check for leaks of fuel, ex-
haust gas, engine coolant, etc. Also check for noise
and vibrations.
ME-02382
ME-00476
ME(H6DO)-38
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine unit. <Ref. to ME(H6DO)-
32, REMOVAL, Engine Assembly.>
sembly.
B: INSTALLATION
Tightening torque:
Engine mounting:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
exist.
ME(H6DO)-39
MECHANICAL
A: REMOVAL
1) Remove the engine assembly from the body.
<Ref. to ME(H6DO)-32, REMOVAL, Engine As-
sembly.>
2) Set the engine on ST.
ST 18232AA000 ENGINE STAND
3) Before servicing overhaul, remove the sensor,
pipe and hose that installed to engine.
(1) Remove the intake manifold. <Ref. to
FU(H6DO)-13, REMOVAL, Intake Manifold.>
(2) Remove the generator. <Ref. to SC(H4SO)-
15, REMOVAL, Generator.>
(3) Remove the A/C compressor. <Ref. to AC-
35, REMOVAL, Compressor.>
(4) Disconnect the water pipe and hose.
(5) Disconnect the engine harness.
(6) Remove the spark plug. <Ref. to IG(H6DO)-
(7) Remove the camshaft position sensor.
<Ref. to FU(H6DO)-21, REMOVAL, Camshaft
Position Sensor.>
(8) Remove the crankshaft position sensor.
<Ref. to FU(H6DO)-20, REMOVAL, Crankshaft
Position Sensor.>
(9) Remove the knock sensor. <Ref. to
FU(H6DO)-22, REMOVAL, Knock Sensor.>
(10) Remove the engine coolant temperature
sensor. <Ref. to FU(H6DO)-19, REMOVAL,
Engine Coolant Temperature Sensor.>
(11) Remove the oil pressure switch. <Ref. to
LU(H6DO)-14, REMOVAL, Oil Pressure Switch.>
(12) Remove the oil filter. <Ref. to LU(H6DO)-
15, REMOVAL, Engine Oil Filter.>
(13) Remove the oil cooler. <Ref. to LU(H6DO)-
16, REMOVAL, Oil Cooler.>
ST
ME-02448
ME(H6DO)-40
V-belt
MECHANICAL
12.V-belt
A: REMOVAL
NOTE:
2) Install the tool to belt tension adjuster assembly
installation bolt.
3) Rotate the tool clockwise and loosen the V-belt
to remove.
B: INSTALLATION
C: INSPECTION
1) Replace the V-belt, if cracks, fraying or wear is
found.
2) Make sure that the V-belt automatic belt tension
indicator (A) is within the range (D).
(1) Power steering oil pump pulley
(2) Belt tension adjuster ASSY
(3) Crank pulley
(4) A/C compressor
(5) Belt idler
(6) Generator
ME-00473
(1)
(6)
(4)
(5)
(2)
(3)
ME-00474
(A) Indicator
(B) Generator
(C) Power steering oil pump pulley
(D) Service limit
(B)
(A)
(D)
(C)
ME-00475
ME(H6DO)-41
Crank Pulley
MECHANICAL
13.Crank Pulley
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
2) Remove the crank pulley cover.
shaft, use ST.
B: INSTALLATION
2) Install the crank pulley bolt. To lock the crank-
shaft, use ST.
pressed air.
and thread.
Tightening torque:
178 Nm (18.1 kgf-m, 131 ft-lb)
3) Install the crank pulley cover.
NOTE:
Use new O-rings.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
C: INSPECTION
1) Check the crank pulley cover for oil and air leak-
age.
2) Check the crank pulley for looseness.
ME-02028
ME-02598
ST
ME-00497
ME-02028
ME(H6DO)-42
Front Chain Cover
MECHANICAL
14.Front Chain Cover
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H6DO)-
3) Remove the bolts which install oil pipe (RH) onto
the front chain cover.
4) Remove the front chain cover.
NOTE:
Chain cover installation bolt has three different siz-
es. To prevent the confusion in installation, keep
these bolts on container individually.
B: INSTALLATION
1) Remove the used liquid gasket from mating sur-
face, and degrease it.
2) Apply liquid gasket to the mating surface of front
chain cover.
NOTE:
Liquid gasket
or equivalent
Applying liquid gasket diameter
2.50.5 mm (0.0980.020 in)
3) Install the front chain cover. Temporarily tighten
the bolts.
CAUTION:
Do not install the bolts in wrong place.
(A) M6 16
(B) M6 30
(C) M6 45
*: Sealing washer
(C)
(C)
(A)
(B)
(B)
ME-02029
(A)
(A) M6 16
(B) M6 30
(C) M6 45
*: Sealing washer
ME-02385
(C)
(C)
(A)
(B)
(B)
ME-02029
(A)
ME(H6DO)-43
Front Chain Cover
MECHANICAL
4) Tighten the bolts in the numerical order as shown in the figure.
Tightening torque:
6.6 Nm (0.67 kgf-m, 4.8 ft-lb)
5) Tighten the bolts which install oil pipe (RH) onto
the front chain cover.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6) Install the crank pulley. <Ref. to ME(H6DO)-41,
C: INSPECTION
Check the cover surface for scratch and damage.
Check for oil leakage on cover mating surface and
installation part of crank pulley.
ME-02031
(21)
(22)
(40)
(39)
(38)
(37)
(36)
(35)
(34)
(33)
(32)
(13)
(12)
(11)
(9)
(10)
(23)
(24)
(8)
(6)
(25)
(26)
(27)
(28)
(29) (30) (31)
(19)
(18)
(17)
(16) (15) (14)
(20)
(3)
(2)
(4)
(5)
(1)
(7)
ME(H6DO)-44
Timing Chain Assembly
MECHANICAL
15.Timing Chain Assembly
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
3) Remove the front chain cover. <Ref. to
ME(H6DO)-42, REMOVAL, Front Chain Cover.>
4) Remove the chain tensioner (RH).
NOTE:
Be careful not to come out the plunger (A).
5) Remove the chain guide (RH: between cams).
6) Remove the chain guide (RH).
7) Remove the chain tensioner lever (RH).
8) Remove the timing chain (RH).
9) Remove the chain tensioner (LH).
NOTE:
Be careful not to come out the plunger.
10) Remove the chain tensioner lever (LH).
11) Remove the chain guide (LH: between cams).
12) Remove the chain guide (LH).
(A) Chain guide (RH)
(B) Chain tensioner lever (RH)
(A)
ME-00501
ME-02032
ME-02033
(A)
(B)
ME-02034
ME-02035
ME-02036
ME-02037
ME(H6DO)-45
MECHANICAL
13) Remove the chain guide (center).
14) Remove the idler sprocket (upper).
15) Remove the timing chain (LH).
16) Remove the idler sprocket (lower).
B: INSTALLATION
NOTE:
Be careful that the foreign matter is not into or
onto assembled component during installation.
Apply engine oil to the chain guide, chain ten-
sioner lever and idler sprocket when installing.
1) Preparation for chain tensioner installation
(1) Insert the screw, spring pin and tension rod
into tensioner body.
(2) While depressing the tensioner onto rubber
mat, twist it to shorten tension rod. Then insert
the thin pin into the hole between tension rod
and tension body to keep it.
NOTE:
Work on the rubber mat or other anti-skid materials.
2) Using the ST, align the Top mark on crank
sprocket to 9 oclock position as shown in the figure
ST 18252AA000 CRANKSHAFT SOCKET
3) Align the key groove on exhaust cam sprocket to
12 oclock position as shown in the figure.
ME-02038
ME-02039
ME-00510
ME-00511
ME-02040
ME-02041
ME(H6DO)-46
MECHANICAL
4) Align the intake cam sprocket as shown in the
figure.
5) Turn the crank sprocket clockwise, align the
Top mark to 12 oclock position. (Piston #1 is in
TDC position)
NOTE:
Do not rotate the crank shaft and cam sprocket be-
fore completing timing chain installation.
6) Install the idler sprocket (lower).
Tightening torque:
69 Nm (7.0 kgf-m, 50.9 ft-lb)
7) Install the timing chain (LH).
(1) Align the timing mark (B) on the crank
sprocket with mark (A) on the timing chain (LH).
(2) Install the timing chain (LH) to the idler
sprocket (lower), water pump, exhaust cam
sprocket (LH) and intake cam sprocket (LH) in
this order.
NOTE:
Check that the mark on timing chain (A) and cam
sprocket (B) is aligned as same as aligned on crank
sprocket.
(3) Install the idler sprocket (upper).
Tightening torque:
69 Nm (7.0 kgf-m, 50.9 ft-lb)
(A) Top mark
(B) 40
(C) 15
(A) Gold
(B) Mark
(B)
(A)
LH RH
(C)
ME-02456
ME-00510
(A)
(B)
ME-00515
(A) Blue
(B) Mark
(A)
(B)
(A)
(B)
ME-02043
ME-02039
ME(H6DO)-47
MECHANICAL
(4) Install the chain guide (LH: between cams).
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Use a new installing bolt.
(5) Install the chain guide (LH).
Tightening torque:
16 Nm (1.6 kgf-m, 12 ft-lb)
(6) Install the chain tensioner lever (LH).
Tightening torque:
16 Nm (1.6 kgf-m, 12 ft-lb)
(7) Install the chain tensioner (LH).
Tightening torque:
16 Nm (1.6 kgf-m, 12 ft-lb)
8) Install the timing chain (RH).
(1) Align the marks of timing chain LH and RH
on the idler sprocket (lower).
ME-02036
ME-02037
ME-02035
(A) Idler sprocket (lower)
(B) Timing chain (RH)
(C) Timing chain (LH)
(D) Blue
ME-02034
(A)
(B)
(C)
(D)
ME-00518
ME(H6DO)-48
MECHANICAL
(2) Install the timing chain (RH) to the intake
cam sprocket (RH) and exhaust cam sprocket
(RH) in this order.
NOTE:
Check that the mark on timing chain (A) and cam
sprocket (B) is aligned as same as aligned on crank
sprocket.
(3) Install the chain guide (RH).
(4) Install the chain tensioner lever (RH).
Tightening torque:
16 Nm (1.6 kgf-m, 12 ft-lb)
(5) Install the chain guide (RH: between cams).
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
NOTE:
(6) Install the chain tensioner (RH).
Tightening torque:
16 Nm (1.6 kgf-m, 12 ft-lb)
(7) Adjust the clearance between chain guide
(RH) and chain guide (center) within 8.4 8.6 mm
(0.331 0.339 in). Install the chain guide (center).
Tightening torque:
7.8 Nm (0.8 kgf-m, 5.9 ft-lb)
NOTE:
(8) Check that each mark on the sprocket and
timing chain is matched, and then draw out the
stopper pin from chain tensioner.
(A) Gold
(B) Mark
(A) Chain guide (RH)
(B) Chain tensioner lever (RH)
(A)
(A)
(B)
(B)
ME-02044
ME-02033
(A)
(B)
ME-02032
ME-00520
ME-00521
ME(H6DO)-49
MECHANICAL
9) Install the front chain cover. <Ref. to ME(H6DO)-
42, INSTALLATION, Front Chain Cover.>
ME(H6DO)-50
Cam Sprocket
MECHANICAL
16.Cam Sprocket
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
4) Remove the timing chain assembly. <Ref. to
ME(H6DO)-44, REMOVAL, Timing Chain Assem-
bly.>
5) Remove the cam sprocket. To lock the cam-
shaft, use the ST.
B: INSTALLATION
1) Install the cam sprocket. To lock the camshaft,
use the ST.
Tightening torque:
29.5 Nm (3.0 kgf-m, 21.8 ft-lb)
2) Further tighten the bolt.
Tightening angle:
Intake side
455
Exhaust side
255
3) Install the timing chain assembly. <Ref. to
ME(H6DO)-45, INSTALLATION, Timing Chain As-
sembly.>
C: INSPECTION
and scratches.
sprocket and key.
ME-02045
ME-02046
ME-02045
ME-02046
ME(H6DO)-51
Crank Sprocket
MECHANICAL
17.Crank Sprocket
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
bly.>
5) Remove the crank sprocket (A).
B: INSTALLATION
1) Install the crank sprocket (A).
sembly.>
C: INSPECTION
wear and scratches.
sprocket and key.
ME-02047
(A)
ME-02047
(A)
ME(H6DO)-52
Rear Chain Cover
MECHANICAL
18.Rear Chain Cover
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
4) Remove the timing chain. <Ref. to ME(H6DO)-
44, REMOVAL, Timing Chain Assembly.>
5) Remove the cam sprocket. <Ref. to ME(H6DO)-
ME(H6DO)-51, REMOVAL, Crank Sprocket.>
7) Remove the oil pump. <Ref. to LU(H6DO)-8,
REMOVAL, Oil Pump.>
8) Remove the water pump. <Ref. to CO(H6DO)-
9) Remove the rear chain cover.
NOTE:
Installation bolt has seven different sizes. To pre-
vent the confusion in installation, keep these bolts
on container individually.
B: INSTALLATION
NOTE:
When replacing the rear chain cover, suitable size
cover must be selected. <Ref. to LU(H6DO)-9, IN-
SPECTION, Oil Pump.>
1) Remove the used liquid gasket from mating sur-
face, and degrease it.
2) Apply liquid gasket to the mating surface of rear
chain cover.
NOTE:
Liquid gasket
or equivalent
Applying liquid gasket diameter
(A) 1.00.5 mm (0.0390.020 in)
(B) 3.01.0 mm (0.1180.039 in)
3) Install the O-ring.
NOTE:
Use new O-rings.
Do not install the O-ring in wrong place.
4) Install the water pump gasket.
NOTE:
Use a new gasket.
(A) M6 14
(B) M6 18 (Light green coating)
(C) M6 30
(D) M6 18
(E) M8 40
(F) M8 30
(G) M6 22
ME-02048
(F)
(C)
(D)
(E)
(G)
(A) (B)
(A) 14.2 1.9
(B) 19.2 2.4
(C) 25 2
(D) 31.2 1.9
(A)
(B)
ME-02049
(B)
(D)
(C)
(A) (A)
ME-02457
ME(H6DO)-53
Rear Chain Cover
MECHANICAL
5) Temporarily tighten the rear chain cover.
NOTE:
6) Tighten the bolts in the numerical order as
Tightening torque:
7) Install the water pump. <Ref. to CO(H6DO)-13,
INSTALLATION, Water Pump.>
8) Install the oil pump. <Ref. to LU(H6DO)-8, IN-
STALLATION, Oil Pump.>
9) Install the crank sprocket. <Ref. to ME(H6DO)-
51, INSTALLATION, Crank Sprocket.>
10) Install the cam sprocket. <Ref. to ME(H6DO)-
11) Install the timing chain. <Ref. to ME(H6DO)-45,
INSTALLATION, Timing Chain Assembly.>
(A) M6 14
(B) M6 18 (Light green coating)
(C) M6 30
(D) M6 18
(E) M8 40
(F) M8 30
(G) M6 22
(1) (11) 9 Nm (0.9 kgf-m, 6.5 ft-lb)
(12) (19) 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(20) (30) 9 Nm (0.9 kgf-m, 6.5 ft-lb)
(31) (38) 12 Nm (1.2 kgf-m, 8.7 ft-lb)
(39) (45) 9 Nm (0.9 kgf-m, 6.5 ft-lb)
ME-02048
(F)
(C)
(D)
(E)
(G)
(A) (B)
ME-02051
(15)
(14)
(26)
(27)
(13)
(25)
(24)
(23)
(22)
(21)
(20)
(16) (17)
(12)
(19)
(30)
(18)
(4)
(3) (2)
(1)
(33)
(8)
(9) (10)
(11)
(32)
(31)
(45)
(44)
(43)
(42)
(41)
(40)
(39)
(38)
(37)
(36)
(5)
(6)
(7)
(29)
(28)
(35)
(34)
ME(H6DO)-54
Camshaft
MECHANICAL
19.Camshaft
A: REMOVAL
NOTE:
ance for preparation. <Ref. to ME(H6DO)-27,
Valve Clearance.>
REMOVAL, V-belt.>
bly.>
ME(H6DO)-51, REMOVAL, Crank Sprocket.>
7) Remove the rear chain cover. <Ref. to
ME(H6DO)-52, REMOVAL, Rear Chain Cover.>
8) Disconnect the oil pipe.
9) Remove the rocker cover (LH).
10) Remove the plugs (LH).
11) Loosen the camshaft cap bolts equally, a little
at a time in alphabetical sequence shown in the fig-
ure.
12) Remove the camshaft caps and camshaft (LH).
NOTE:
Arrange camshaft caps in order so that they can be
installed in their original positions.
lated parts.
(A) Bolt without filter (without protrusion)
(B) Bolt with filter (with protrusion)
ME-02513
(A)
(B)
ME-00529
ME-02055
ME-02054
(1)
(2)
(8)
(7) (9)
(3)
(4)
(5)
(6) (10)
(11) (13)
(14) (12)
(15)
(16)
ME(H6DO)-55
Camshaft
MECHANICAL
B: INSTALLATION
1) Apply engine oil to camshaft journals, and install
the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket sparingly to back side of
front camshaft cap as shown in the figure.
CAUTION:
Do not apply liquid gasket excessively. Apply-
ing excessively may cause excess gasket to
flow toward cam journal, resulting in engine
seizure.
NOTE:
Liquid gasket:
or equivalent
Applying liquid gasket diameter:
2.00.5 mm (0.0790.020 in)
(2) Apply engine oil to cap bearing surface, and
install the cap to camshaft.
(3) Tighten the rocker cover bolts in the numer-
ical order as shown in the figure.
Tightening torque:
(1) (12): 16 Nm (1.6 kgf-m, 12 ft-lb)
(13) (16): 9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
3) Install the plugs.
Tightening torque:
60 Nm (6.1 kgf-m, 44 ft-lb)
cover.
NOTE:
(2) Apply liquid gasket sparingly to the mating
surface of cylinder head and rocker cover as
CAUTION:
Do not apply liquid gasket excessively. Applying
excessively may cause excess gasket to flow to-
ward cam journal, resulting in engine seizure.
NOTE:
Liquid gasket:
or equivalent
LH side
RH side
ME-02057
ME-02058
(1)
(2)
(8)
(7) (9)
(3)
(4)
(5)
(6)
(10)
(11)
(13)
(14)
(15)
(16)
(12)
ME-02055
ME-03103
ME-03104
ME(H6DO)-56
Camshaft
MECHANICAL
(3) Tighten the rocker cover bolts in the numer-
ical order as shown in the figure.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
LH side
RH side
5) Connect the oil pipe.
NOTE:
Be careful not to mistake the location of (A) and
(B).
Use a new gasket.
Tightening torque:
(A), (B)
29 Nm (3.0 kgf-m, 21.4 ft-lb)
(C)
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6) Install the rear chain cover. <Ref. to ME(H6DO)-
52, INSTALLATION, Rear Chain Cover.>
8) Install the cam sprocket. <Ref. to ME(H6DO)-50,
sembly.>
10) Install the front chain cover. <Ref. to
ME(H6DO)-42, INSTALLATION, Front Chain Cov-
er.>
C: INSPECTION
1) Measure the bend of camshaft. Repair or re-
place if bended.
place if faulty.
3) Check the cutout portion used for camshaft sen-
sor for damage. Replace if faulty.
4) Measure the outside diameter of camshaft jour-
nal. If the journal diameter is not within specifica-
tion, check the oil clearance.
(A) Bolt without filter (without protrusion)
(B) Bolt with filter (with protrusion)
(C) Oil pipe bolt
ME-02061
(2)
(7) (3) (1) (10)
(6)
(8) (4)
(5)
(9)
ME-03105
(8) (1) (3)
(5)
(7)
(9)
(2) (4)
(6)
(10)
ME-02567
(A)
(C)
(B)
Camshaft journal
Front Except for front
Standard
mm (in)
37.946 37.963
(1.4939 1.4946)
25.946 25.963
(1.0215 1.0222)
ME-00539
ME(H6DO)-57
Camshaft
MECHANICAL
5) Measurement of the camshaft journal oil clear-
ance:
(1) Clean the bearing caps and camshaft jour-
nals.
(2) Place the camshafts on cylinder head.
(Without installing the valve rocker.)
(3) Place a plastigauge across each camshaft
journals.
(4) Install the bearing cap.
NOTE:
Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the widest point of the plastigauge
on each journal. If oil clearance exceeds the
standard, 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)
(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. If it exceeds the standard or offset wear
occurs, replace it.
Cam height H:
Standard
Intake
HIGH 42.09 42.19 mm
(1.6571 1.6610 in)
LOW1 38.14 38.24 mm
(1.5016 1.5055 in)
LOW2 38.14 38.24 mm
(1.5016 1.5055 in)
Exhaust
40.45 40.55 mm (1.5925 1.5965 in)
Intake
HIGH 32.0 mm (1.2598 in)
LOW1 31.84 mm (1.2535 in)
LOW2 31.84 mm (1.2535 in)
Exhaust
32.0 mm (1.2598 in)
7) Measure the side clearance of the camshaft with
a dial gauge. If the side clearance exceeds the
standard or there is offset wear, replace the caps
and cylinder head as a set. If necessary replace the
camshaft.
Standard
Intake
0.075 0.135 mm (0.0030 0.0053 in)
Exhaust
0.030 0.090 mm (0.0012 0.0035 in)
ME-00119
ME-00120
H
A
ME(H6DO)-58
Cylinder Head
MECHANICAL
20.Cylinder Head
A: REMOVAL
NOTE:
ance for preparation. <Ref. to ME(H6DO)-27, Valve
Clearance.>
REMOVAL, V-belt.>
bly.>
6) Remove the crank sprocket. <Ref. to ME(H6DO)-
51, REMOVAL, Crank Sprocket.>
7) Remove the rear chain cover. <Ref. to ME(H6DO)-
52, REMOVAL, Rear Chain Cover.>
REMOVAL, Camshaft.>
9) Remove the cylinder head bolts in the numerical
order as shown in the figure.
Leave bolts (2) and (4) engaged by three or four
threads to prevent the cylinder head from falling.
hammer, separate it from cylinder block.
11) Remove the bolts (2) and (4) to remove cylin-
der head.
CAUTION:
B: INSTALLATION
block.
CAUTION:
NOTE:
(1) Apply a coat of engine oil to washers and
cylinder head bolt threads.
(2) Install the cylinder head to cylinder block,
and then tighten the bolts with torque of 20 Nm
(2.0 kgf-m, 14.8 ft-lb) in numerical sequence as
(3) Tighten the bolts with torque of 50 Nm
(4) Loosen all the bolts by 180 in reverse order
of installation, and loosen again by 180.
(5) Tighten the bolts with torque of 20 Nm
(6) Tighten the bolts (1) (4) with torque of
48 Nm (4.9 kgf-m, 35.4 ft-lb) in numerical se-
quence.
(7) Tighten the bolts (5) (8) with torque of
44 Nm (4.5 kgf-m, 32.5 ft-lb) in numerical se-
quence.
(8) Tighten all bolts 90 in the numerical order
(9) Tighten the bolt (1) (4) by 45 in the nu-
merical order.
3) Install the camshaft. <Ref. to ME(H6DO)-55, IN-
STALLATION, Camshaft.>
(2)
(8) (6)
(5) (7)
(4)
(1)
(3)
ME-02063
(2)
(8) (6)
(5) (7)
(4)
(1)
(3)
ME-02063
(7)
(1) (3)
(4) (2)
(5)
(8)
(6)
ME-02064
ME(H6DO)-59
Cylinder Head
MECHANICAL
6) Install the cam sprocket. <Ref. to ME(H6DO)-50,
sembly.>
C: DISASSEMBLY
1) Set the cylinder head on ST.
ST 18250AA010 CYLINDER HEAD TABLE
3) Set the ST on valve spring retainer. Compress
the valve spring and remove the valve spring re-
tainer key. Remove each valve and valve spring.
NOTE:
Pay careful attention not to damage the lips of in-
take valve oil seals and exhaust valve oil seals.
Keep all the removed parts in order for re-install-
ing in their original positions.
D: ASSEMBLY
1) Installation of valve spring and valve:
(1) Set the cylinder head on ST.
NOTE:
NOTE:
For the valve spring on intake side, install two of
them (inner and outer).
Install the valve spring with the painted side fac-
ing to retainer.
(4) Set the ST on valve spring.
2) Apply oil to the surface of valve lifter and valve
shim.
3) Install the valve lifter and valve shim.
ME-03106
ST
(1) Valve spring seat
(2) Valve spring
(3) Retainer
(4) Painted face
ME-03107
(1)
(2)
(3)
(4)
ME-03106
ST
ME(H6DO)-60
Cylinder Head
MECHANICAL
E: INSPECTION
1. CYLINDER HEAD
2) Set the cylinder head on ST.
3) Inspect the cylinder head surface that mates
with cylinder block for warping by using a straight
edge (A) and thickness gauge (B). If the warping
exceeds the limit, replace the cylinder head.
Warping limit:
0.02 mm (0.0008 in)
1240.05 mm (4.880.0020 in)
NOTE:
cause warping. When reinstalling, pay special at-
tention to the torque so as to tighten evenly.
2. VALVE SEAT
Inspect the intake and exhaust valve seats. Correct
the contact surfaces with a valve seat cutter if they
are defective or when valve guides are replaced.
Valve seat width W:
Standard
Intake
1.0 mm (0.039 in)
Exhaust
1.5 mm (0.059 in)
3. VALVE GUIDE
stem. The clearance can be checked by measuring
the valve stem outer diameter with a micrometer
and valve guide inner diameter with a caliper gauge
respectively.
stem:
Standard
Intake
0.030 0.057 mm (0.0012 0.0022 in)
Exhaust
0.040 0.067 mm (0.0016 0.0026 in)
2) If the clearance between valve guide and stem
exceeds the standard, replace the valve guide or
valve itself whichever shows greater amount of
wear or damaged and etc. See the following proce-
dure for valve guide replacement.
5.500 5.512 mm (0.2165 0.2170 in)
Intake
5.455 5.470 mm (0.2148 0.2154 in)
Exhaust
5.445 5.460 mm (0.2144 0.2150 in)
ST1 18250AA010 CYLINDER HEAD TABLE
(A)
(B)
ME-00551
ME-00127
W
ME-00553
ME(H6DO)-61
Cylinder Head
MECHANICAL
ST 18251AA040 VALVE GUIDE ADJUSTER
inder head.
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 18251AA040 VALVE GUIDE ADJUSTER
11.4 11.8 mm (0.449 0.465 in)
NOTE:
stone.
remedy the ST.
move chips.
guide.
1) Inspect the flange and stem of the valve, and re-
place if damaged, worn, or deformed, or if H is
outside of the standard.
Standard
Intake (A)
1.0 mm (0.039 in)
Exhaust (B)
1.2 mm (0.047 in)
seat surface, and lap the valve and valve seat. In-
stall a new valve oil seal after lapping.
NOTE:
Intake
99.7 mm (3.925 in)
Exhaust
105.2 mm (4.142 in)
ME-00757
ST
L
ME-00130
ST1
ST2
ME-02096
H
H
(B)
(A)
90 0
+1
90 0
+1
ME(H6DO)-62
Cylinder Head
MECHANICAL
5. VALVE SPRING
SEAL
part.
When the lip is damaged
When the spring is out of the specified position
valve seat
When replacing the valve guide
2) Set the cylinder head on ST1.
ST1 18250AA010 CYLINDER HEAD TABLE
NOTE:
mer to strike in.
Free
length
mm (in)
Intake
Inner 39.55 (1.5571)
Outer 41.18 (1.6213)
Exhaust 46.32 (1.8236)
Squareness
Intake
Inner
2.5, 1.7 mm
(0.067 in) or less
Outer
2.5, 1.8 mm
(0.071 in) or less
Exhaust
2.5, 2.0 mm
(0.079 in) or less
ME-00132
ME-03108
ME(H6DO)-63
Cylinder Head
MECHANICAL
7. VALVE LIFTER
1) Check the valve lifter visually.
2) Measure the outer diameter of valve lifter.
Outer diameter:
32.959 32.975 mm (1.2976 1.2982 in)
3) Measure the inner diameter of valve lifter hole of
cylinder head.
Inner diameter:
32.994 33.016 mm (1.2990 1.2998 in)
NOTE:
If difference between outer diameter of valve lifter
and inner diameter of valve lifter hole is out of the
standard or offset wearing is emitted, replace the
cylinder head.
Standard:
0.019 0.057 mm (0.0007 0.0022 in)
ME-00134
ME-03109
ME(H6DO)-64
Cylinder Block
MECHANICAL
21.Cylinder Block
A: REMOVAL
NOTE:
oil completely.
1) Remove the V-belts. <Ref. to ME(H6DO)-40, RE-
MOVAL, V-belt.>
bly.>
6) Remove the crank sprocket. <Ref. to ME(H6DO)-
51, REMOVAL, Crank Sprocket.>
7) Remove the rear chain cover. <Ref. to ME(H6DO)-
52, REMOVAL, Rear Chain Cover.>
REMOVAL, Camshaft.>
9) Remove the cylinder head. <Ref. to ME(H6DO)-
58, REMOVAL, Cylinder Head.>
10) Remove the drive plate using the ST.
11) Remove the crankshaft position sensor plate.
12) Remove the crankshaft position sensor bracket.
13) Rotate the engine to set oil pan upper.
14) Remove the bolts which secure oil pan lower to
oil pan upper.
CAUTION:
ST
ME-00557
ME-00558
ME-00559
ME-00560
LU-02108
ME(H6DO)-65
Cylinder Block
MECHANICAL
17) Remove the bolts which install oil pan upper
onto cylinder block.
NOTE:
Installation bolt has five different sizes. To prevent
the confusion in installation, keep these bolts on
container individually.
18) Remove the service hole cover and service
hole plugs using a hexagon wrench.
tons to bottom dead center position, then, using the
ST, remove the piston snap ring through service
hole of #1 and #2 cylinders.
ST 18233AA000 PISTON PIN SNAP RING PLI-
ERS
using ST.
NOTE:
21) Similarly remove the piston pins from #3, #4,
#5, and #6 pistons.
22) Remove the cylinder block connecting bolts.
23) Separate the cylinder block (LH) and (RH).
NOTE:
When separating the cylinder block, do not allow
the connecting rod to fall and damage the cylinder
block.
ing rod.
NOTE:
combination.
Press the bearing at the end opposite to locking
lip.
27) Draw out each piston from cylinder block using
NOTE:
(A) M8 40
(B) M8 65
(C) M8 85
(D) M8 130.5
(E) M8 24
ME-02065
(D)
(E)
(A)
(A)
(A)
(A)
(A)
(A)
(A)
(E)
(A) (A) (A)
(C) (B)
(A)
(D)
(A)
(A)
(A)
(A)
(A)
(B)
ME-00563
ST4
ME-00564
ME-00565
ME-00566
ME(H6DO)-66
Cylinder Block
MECHANICAL
B: INSTALLATION
1) After setting the cylinder block to ST, install the
crankshaft bearing.
ST 18232AA000 ENGINE STAND
NOTE:
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 on the cylinder block
(RH).
(LH).
NOTE:
Liquid gasket:
or equivalent
NOTE:
Do not allow liquid gasket to run over to oil passag-
es, bearing grooves, etc.
1.00.2 mm (0.0390.008 in)
thread.
5) Tighten all bolts in the numerical order as shown
in the figure.
Tightening torque:
(1) (11), (13): 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(12), (14): 20 Nm (2.0 kgf-m, 14.8 ft-lb)
6) Retighten all bolts in the numerical order as
Tightening torque:
(1) (11), (13): 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(12), (14): 20 Nm (2.0 kgf-m, 14.8 ft-lb)
7) Tighten all bolts 90 110 in the numerical or-
8) Install the upper bolt to cylinder block.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
NOTE:
After tightening the cylinder block connecting bolts,
remove the liquid gasket which is running over to
the sealing surface for rear chain cover and oil pan
upper.
ME-00567
(1) (6) (8) (3) (9)
(2) (4) (5) (7) (10)
(11)
(12)
(13)
(14)
ME-00568
(1) (6) (8) (3) (9)
(2) (4) (5) (7) (10)
(11)
(12)
(13)
(14)
ME-00568
(1) (6) (8) (3) (9)
(2) (4) (5) (7) (10)
(11)
(12)
(13)
(14)
ME-00568
ME-00569
ME(H6DO)-67
Cylinder Block
MECHANICAL
NOTE:
Use a new rear oil seal.
GUIDE
STALLER
10) Position the top ring gap at (A) in the figure.
11) Position the second ring gap at (B).
13) Position the expander gap at (D) in the figure.
14) Position the lower rail gap at (E) in the figure.
CAUTION:
Make sure ring gaps do not face the same di-
rection.
skirt area.
Assemble it so that R mark faces to top side
of piston.
Install the snap rings in the piston holes located op-
posite to the service holes in cylinder block when
positioning all pistons in corresponding cylinders.
NOTE:
Use new snap rings.
16) Installing piston:
#3 and #4 connecting rod small ends are set on
the service hole (A).
ST1 18252AA000 CRANKSHAFT SOCKET
(2) Apply a thin coat of engine oil to piston and
cylinder.
(A) Rear oil seal
(B) Drive plate installation bolt
ST2 ST1
(A)
(B)
ME-00570
180
(A) (B)
ME-02066
25
35
(C)
(D)
(E)
ME-02067
(A) Front side of vehicle
(A)
#1
#2
#3
#4
#5
#6
ME-00573
ST1 (A)
(A)
ME-00574
ME(H6DO)-68
Cylinder Block
MECHANICAL
(3) Using the ST2, press-fit the piston into cylin-
der.
ST2 18254AA000 PISTON GUIDE
NOTE:
Let the piston front mark (A) face towards the front
of engine.
17) Installing piston pin:
(1) Apply a coat of engine oil to ST3 before in-
sertion, and then insert it into the service hole to
align piston pin hole with connecting rod small
end.
ST3 18253AA000 PISTON PIN GUIDE
(3) Using the ST4, install the snap ring.
ST4 18233AA000 PISTON PIN SNAP RING PLI-
ERS
NOTE:
Use new snap rings.
(4) Similarly install the #1, #2, #5 and #6 pis-
tons.
18) Install the service hole plug and O-ring.
NOTE:
Use new O-rings.
19) Apply liquid gasket to the mating surface of oil
pan upper.
NOTE:
Liquid gasket:
or equivalent
Full line part
3.01.0 mm (0.120.04 in)
Broken line part
1.0 mm (0.04 in)
NOTE:
Use new O-rings.
ST2
ME-00576
(A)
ME-02076
ST3
ME-00577
(A) O-ring
ST4
ME-00564
ME-02068
(A)
(A)
(A)
(A)
ME(H6DO)-69
Cylinder Block
MECHANICAL
20) Temporarily tighten the oil pan upper.
NOTE:
21) Tighten the oil pan upper installing bolts in the
numerical order as shown in the figure.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Use new O-rings.
23) Apply liquid gasket to the matching surface of
oil pan lower.
NOTE:
Liquid gasket:
or equivalent
5.01.0 mm (0.200.04 in)
(A) M8 40
(B) M8 65
(C) M8 85
(D) M8 130.5
(E) M8 24
*: Coating
ME-02069
(D)
(E)
(A)
(A)
(A)
(A)
(A)
(A)
(A)
(E)
(A) (A) (A)
(C) (B)
(A)
(D)
(A)
(A)
(A)
(A)
(A)
(B)
ME-02070
(19)
(14)
(12)
(16)
(24)
(22)
(27)
(25)
(21)
(17)
(13)
(11)
(15)
(23)
(26)
(20)
(18)
(7) (6) (9)
(8) (10)
(5)
(3)
(4)
(1)
(2)
LU-02108
ME-00581
ME(H6DO)-70
Cylinder Block
MECHANICAL
24) Tighten the oil pan lower installing bolts in the
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
25) Install the crankshaft position sensor holder.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
26) Install the crankshaft sensor plate.
27) Using the ST, install the drive plate.
Tightening torque:
81 Nm (8.3 kgf-m, 60 ft-lb)
28) Install the cylinder head. <Ref. to ME(H6DO)-
58, INSTALLATION, Cylinder Head.>
29) Install the camshaft. <Ref. to ME(H6DO)-55,
32) Install the cam sprocket. <Ref. to ME(H6DO)-
sembly.>
(1) (2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
ME-00582
ME-00559
ME-00558
ST
ME-00557
ME(H6DO)-71
Cylinder Block
MECHANICAL
C: DISASSEMBLY
NOTE:
Arrange the removed connecting rod, connecting
rod cap and bearing in order, to prevent confusion.
pander.
NOTE:
(1)
(1)
(2)
(2)
(2)
(3)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
ME-02097
ME(H6DO)-72
Cylinder Block
MECHANICAL
D: ASSEMBLY
2) Position each connecting rod with the marking
side facing forward.
3) Install the connecting rod cap. Make sure the ar-
row mark on connecting rod cap facing front during
installation.
CAUTION:
When tightening the connecting rod bolts,
apply oil on the threads and flange end.
Tightening torque:
53 Nm (5.4 kgf-m, 39 ft-lb)
4) Install the oil ring spacer, upper rail and lower rail
by hand.
ring expander.
(1) Connecting rod cap (5) Oil ring Tightening torque:Nm (kgf-m, ft-lb)
(2) Connecting rod bearing (6) Snap ring T: 53 (5.4, 39)
(3) Top ring (7) Connecting rod
(4) Second ring
(1)
(1)
(2)
(2)
(2)
(7)
(3)
(4)
(5)
(7)
(3)
(4)
(5)
(6)
(6)
T
T
ME-02459
ME(H6DO)-73
Cylinder Block
MECHANICAL
E: INSPECTION
1. CYLINDER BLOCK
edge. If the warping exceeds the limit, replace the
cylinder block.
Warping limit:
0.02 mm (0.0008 in)
202 mm (7.95 in)
NOTE:
ature of 20C (68F).
Standard diameter:
A: 89.205 89.215 mm (3.5120 3.5124 in)
B: 89.195 89.205 mm (3.5116 3.5120 in)
2) How to measure the inner diameter of each cyl-
inder:
NOTE:
ture of 20C (68F).
Cylindricality:
Standard
0.030 mm (0.0012 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.
(B) Cylinder bore size mark
(C) Cylinder block (RH) (LH) combination mark
#7 #6
#5
#2
#1
#4
#3
#6
#5
#4
#3
#2
#1
B
B
B
2
4
2
B
A
B
4
(A)
(B)
(C)
ME-00585
H1: 10 mm (0.39 in)
H2: 45 mm (1.77 in)
H3: 80 mm (3.15 in)
ME-00586
H1
H2
H3
Unit: mm (in)
(B)
(A)
ME(H6DO)-74
Cylinder Block
MECHANICAL
4) How to measure the outer diameter of each pis-
ton:
NOTE:
ture of 20C (68F).
37.3 mm (1.4685 in)
Piston outer diameter:
Standard
A: 89.205 89.215 mm (3.5120 3.5124
in)
B: 89.195 89.205 mm (3.5116 3.5120
in)
89.445 89.465 mm (3.5215 3.5222 in)
89.695 89.715 mm (3.5313 3.5321 in)
piston.
NOTE:
ture of 20C (68F).
Standard
0.010 0.010 mm (0.0004 0.0004 in)
6) Boring and honing:
(1) If the value of cylindrically, out-of-round-
ness, or cylinder-to-piston clearance measured
is out of standard 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,
other cylinders must be bored at the same time,
Do not perform boring on one cylinder only.
Do not replace only a single cylinder for an
oversize piston.
der block.
To 89.715 mm (3.5321 in)
NOTE:
rise. Thus, pay attention to this when measuring
the cylinder diameter.
ME-00172
H
ME(H6DO)-75
Cylinder Block
MECHANICAL
2) Check the piston ring groove for wear or dam-
Replace if faulty.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 0.008 mm (0.0002 0.0003 in)
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 re-
placed, replace the piston ring with a new part of
the same size as piston.
NOTE:
stalling the ring to piston, face this mark to the top
side.
lower rail. When installing on the piston, be careful
of the direction of each rail.
inder, and measure the piston ring gap with a thick-
ness gauge.
ME-00173
ME-00174
ME-00175
(A)
(A) Top ring
(B) Second ring
(C) Oil ring
(a) Upper rail
(b) Expander
(c) Lower rail
Standard
mm (in)
Piston ring gap
Top ring
0.20 0.35
(0.0079 0.0138)
Second ring
0.35 0.50
(0.0138 0.0197)
Oil ring
0.20 0.60
(0.0079 0.0236)
(a)
(c)
(b)
(A)
(B)
(C)
ME-00591
ME-00592
ME(H6DO)-76
Cylinder Block
MECHANICAL
gauge.
NOTE:
5. CONNECTING ROD
aligner. Replace the connecting rod if it has the
bend or twist.
crankshaft and measure the thrust clearance. If the
thrust clearance exceeds the standard or uneven
wear is found, replace the connecting rod.
Standard
0.070 0.330 mm (0.0028 0.0130 in)
Standard
mm (in)
Clearance
between piston
ring and piston
ring groove
Top ring
0.040 0.080
(0.0016 0.0031)
Second ring
0.030 0.070
(0.0012 0.0028)
Clearance between oil ring and oil
ring groove
0.045 0.125
(0.0018 0.0049)
ME-00178
(A) Thickness gauge
(B) Connecting rod
( A)
( A)
( B)
( B)
ME-00179
ME-00180
ME(H6DO)-77
Cylinder Block
MECHANICAL
size as necessary. (See the table below.)
Standard
0.016 0.043 mm (0.0006 0.0017 in)
and replace if worn or damaged.
Standard
0 0.022 mm (0 0.0009 in)
with ST and press.
(2) Press the bushing with ST after applying oil
on the periphery of bushing.
ST 18350AA000 CONNECTING ROD BUSH-
ING REMOVER AND IN-
STALLER
Unit: mm (in)
Bearing
Bearing size
(Thickness at cen-
ter)
Outer diameter of
crank pin
Standard
1.490 1.506
(0.0587 0.0593)
51.984 52.000
(2.0466 2.0472)
0.03 (0.0012)
undersize
1.509 1.513
(0.0594 0.0596)
51.954 51.970
(2.0454 2.0461)
0.05 (0.0020)
undersize
1.519 1.523
(0.0598 0.0600)
51.934 51.950
(2.0446 2.0453)
0.25 (0.0098)
undersize
1.619 1.623
(0.0637 0.0639)
51.734 51.750
(2.0368 2.0374)
ME-00181
ME-00174
ST
ME-00597
ME(H6DO)-78
Cylinder Block
MECHANICAL
BEARING
cracks using liquid penetrant tester. Replace if de-
fective.
2) Check the crankshaft for bend, and repair or re-
place if needed. Repair or replace if bended.
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 check
the crankshaft bend using a dial gauge.
place or readjust crankshaft as necessary. When
grinding the crank journal or crank pin, finish them
to the specified dimensions according to the under-
size bearing to be used.
Crank pin and crank journal:
Out-of-roundness
0.005 mm (0.0002 in)
Cylindricality
0.006 mm (0.0002 in)
ME-00598
ME-00184
Unit: mm (in)
Crank journal diameter
#1, #3, #5, #7 #2, #4, #6
Standard
Journal O.D.
63.992 64.008
(2.5194 2.5200)
51.984 52.000
(2.0466 2.0472)
Bearing size
1.992 2.005
(0.0784 0.0789)
1.996 2.009
(0.0786 0.0791)
1.490 1.506
(0.0587 0.0593)
0.03 (0.0012)
undersize
Journal O.D.
63.962 63.978
(2.5182 2.5188)
51.954 51.970
(2.0454 2.0461)
Bearing size
2.011 2.014
(0.0792 0.0793)
2.015 2.018
(0.0793 0.0794)
1.509 1.513
(0.0594 0.0596)
0.05 (0.0020)
undersize
Journal O.D.
63.942 63.958
(2.5174 2.5180)
51.934 51.950
(2.0446 2.0453)
Bearing size
2.021 2.024
(0.0796 0.0797)
2.025 2.028
(0.0797 0.0798)
1.519 1.523
(0.0598 0.0600)
0.25 (0.0098)
undersize
Journal O.D.
63.742 63.758
(2.5095 2.5102)
51.734 51.750
(2.0368 2.0374)
Bearing size
2.121 2.124
(0.0835 0.0836)
2.125 2.128
(0.0837 0.0838)
1.619 1.623
(0.0637 0.0639)
ME(H6DO)-79
Cylinder Block
MECHANICAL
center bearing by using thickness gauge. If the
thrust clearance is not within the standard, replace
the bearing.
Standard
0.030 0.115 mm (0.0012 0.0045 in)
an undersize one, and replace or recondition the
crankshaft as necessary.
Standard
0.010 0.030 mm (0.0004 0.0012 in)
ME-00600
ME(H6DO)-80
Oil Flow Control Solenoid Valve
MECHANICAL
22.Oil Flow Control Solenoid
Valve
A: REMOVAL
Oil flow control solenoid valve is a unit with camshaft
cap. Refer to Camshaft for removal procedure.
<Ref. to ME(H6DO)-54, REMOVAL, Camshaft.>
B: INSTALLATION
ME(H6DO)-81
MECHANICAL
23.Oil Switching Solenoid Valve
A: REMOVAL
solenoid valve.
sure switch. <Ref. to FU(H6DO)-29, REMOVAL,
Variable Valve Lift Diagnosis Oil Pressure Switch.>
6) Remove the oil temperature sensor. <Ref. to
FU(H6DO)-30, REMOVAL, Oil Temperature Sen-
sor.>
B: INSTALLATION
1) Install the oil switching solenoid valve holder.
NOTE:
Use a new gasket.
(1) Temporarily tighten the bolts by tightening
torque of 5 10 Nm (0.5 1.0 kgf-m, 3.7
7.4 ft-lb) in order shown in the figure.
(2) Tighten the bolts by tightening torque of
100.5 Nm (1.00.05 kgf-m, 7.40.37 ft-lb) in
order shown in the figure.
2) Install the oil temperature sensor. <Ref. to
FU(H6DO)-30, INSTALLATION, Oil Temperature
Sensor.>
3) Install the variable valve lift diagnosis oil pres-
sure switch. <Ref. to FU(H6DO)-29, INSTALLA-
TION, Variable Valve Lift Diagnosis Oil Pressure
Switch.>
4) Install the oil switching solenoid valve.
5) Connect the connector to oil switching solenoid
valve.
6) Install the air intake chamber. <Ref. to IN(H6DO)-
7, INSTALLATION, Air Intake Chamber.>
IN-00203
ME-02071
ME-02072
ME-02073
(2)
(1)
(5)
(4)
(3)
ME-02071
IN-00203
ME(H6DO)-82
MECHANICAL
A: SPECIFICATION
Refer to Cylinder Head for removal and installa-
tion procedures of intake and exhaust valves. <Ref.
to ME(H6DO)-58, REMOVAL, Cylinder Head.>
<Ref. to ME(H6DO)-58, INSTALLATION, Cylinder
Head.>
ME(H6DO)-83
Piston
MECHANICAL
25.Piston
A: SPECIFICATION
tion procedures of pistons. <Ref. to ME(H6DO)-64,
REMOVAL, Cylinder Block.> <Ref. to ME(H6DO)-
ME(H6DO)-84
Connecting Rod
MECHANICAL
26.Connecting Rod
A: SPECIFICATION
procedures of connecting rod. <Ref. to ME(H6DO)-
64, REMOVAL, Cylinder Block.> <Ref. to ME(H6DO)-
ME(H6DO)-85
Crankshaft
MECHANICAL
27.Crankshaft
A: SPECIFICATION
procedures of crankshaft. <Ref. to ME(H6DO)-64,
REMOVAL, Cylinder Block.> <Ref. to ME(H6DO)-
ME(H6DO)-86
MECHANICAL
A: INSPECTION
NOTE:
The RANK shown in the chart shows the possibilities of the cause of trouble in order from Most likely to
Rarely.
A Very often
B Sometimes
C Rarely
Defective inhibitor switch or neutral switch C
Defective starter B
Battery Improper connection of terminal A
Run-down battery A
Seized camshaft C
not occur.
Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line C
Timing chain Trouble B
Defective timing B
Trouble of valve lifter C
Trouble of valve lifter. In case noise occurs with valve
moving. Or when the harness involved to oil switching
solenoid valve, variable valve lift diagnosis oil pressure
switch and variable valve lift has trouble in a past.
B
ME(H6DO)-87
MECHANICAL
3) Initial combustion occurs. Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line C
Defective timing B
moving. Or the harness involved to oil switching sole-
noid valve, variable valve lift diagnosis oil pressure
B
combustion.
Defective timing B
B
ME(H6DO)-88
MECHANICAL
stall
Clogged fuel line C
Timing chain Defective timing C
B
Cooling system Overheat C
ME(H6DO)-89
MECHANICAL
poor acceleration
Clogged fuel line B
Timing chain Defective timing B
B
Cooling system Overheat C
Over-cooling C
ME(H6DO)-90
MECHANICAL
4. Surging Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Clogged fuel line B
B
Cooling system Overheat B
idle.
6. Dieseling (Run-on) Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
Cooling system Overheat B
ME(H6DO)-91
MECHANICAL
system
B
8. Knocking Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> A
B
Cooling system Overheat A
sumption
ket
B
Defective oil filter O-ring B
ME(H6DO)-92
MECHANICAL
tion
B
ME(H6DO)-93
Engine Noise
MECHANICAL
29.Engine Noise
A: INSPECTION
NOTE*)
Therefore, perform the Clear Memory Mode <Ref. to EN(H6DO)(diag)-57, OPERATION, Clear Memory Mode.> and Inspection
Mode <Ref. to EN(H6DO)(diag)-45, PROCEDURE, Inspection Mode.> after connecting the fuel injector connector.
speed increases.
Worn camshaft
Broken valve spring
Trouble of valve lifter
Oil pressure is normal. Damaged engine mounting
High-pitched clank
condition.
Wrong spark plug
Improper gasoline
between 1,000 and 2,000 rpm.
(NOTE*)
and engine is warm
(NOTE*)
Unusually worn valve lifter
Worn cam gear
engine

a dry cloth

Loose drive belt
Hissing sound
Timing chain noise
Loose timing chain
Chain contacting with case/adjacent part
Valve noise
Trouble of valve lifter
ME(H6DO)-94
Engine Noise
MECHANICAL
EX(H6DO)-2
General Description
EXHAUST
A: COMPONENT
EX-02208
T3
T5
T6
T2
T2
T4
T4
T1
T1
(18)
(12)
(11)
(10)
(8)
T7
T7
(20)
(21)
(22)
(23)
(25)
(24)
(17) (24)
(24)
(24)
(26)
(24)
(25)
(16)
(26)
(13)
(15)
(19)
(14)
T4
(6)
(7)
(5)
T4
(4)
(3)
(1)
(2)
(9)
EX(H6DO)-3
General Description
EXHAUST
B: CAUTION
forming any work.
points.
the battery.
cover (RH)
cover (LH)
(23) Rear exhaust pipe
(24) Cushion rubber
cover (RH)
(12) Front exhaust pipe (LH) (25) Self-locking nut
(13) Front catalytic converter (LH) (26) Gasket
(3) Gasket (14) Front oxygen (A/F) sensor (LH)
(4) Front exhaust pipe (RH) (15) Rear oxygen sensor (LH) Tightening torque:Nm (kgf-m, ft-lb)
(5) Front catalytic converter (RH) (16) Muffler (RH) T1: 70 (7.1, 51.6)
(6) Front oxygen (A/F) sensor (RH) (17) Muffler (LH) T2: 13 (1.3, 9.4)
(7) Rear oxygen sensor (RH) (18) Rear catalytic converter T3: 18 (1.8, 13.3)
(8) Gasket (19) Bracket T4: 21 (2.1, 15.5)
(9) Gasket (20) Gasket T5: 30 (3.1, 22.1)
cover (LH)
(21) Spring T6: 35 (3.6, 26.0)
(22) Chamber T7: 48 (4.9, 35.4)
EX(H6DO)-4
Front Exhaust Pipe
EXHAUST
A: REMOVAL
CAUTION:
ning.
5) Remove the front oxygen (A/F) sensor connec-
tor (A) and rear oxygen sensor connector (B).
6) Separate the front exhaust pipe assembly from
the rear exhaust pipe.
7) Remove the nuts which hold front exhaust pipe
assembly onto cylinder heads.
CAUTION:
Be careful not to pull down the front exhaust
pipe assembly.
8) Remove the bolts which hold front exhaust pipe
assembly to hanger bracket.
9) Remove the front exhaust pipe assembly from
vehicle.
CAUTION:
Be careful not to let the front exhaust pipe as-
sembly fall off when removing, since it is very
heavy.
After removing the front exhaust pipe assem-
bly, do not apply excessive pulling force on the
rear exhaust pipe.
10) Separate the front exhaust pipe (RH) from front
exhaust pipe assembly.
oxygen sensor. <Ref. to FU(H6DO)-31, REMOV-
FU(H6DO)-33, REMOVAL, Rear Oxygen Sensor.>
IN-00203
EX-02014
(A)
(B)
EX-02015
EX-02016
EX-00061
EX-02017
EX(H6DO)-5
Front Exhaust Pipe
EXHAUST
B: INSTALLATION
ygen sensor. <Ref. to FU(H6DO)-31, INSTALLA-
TION, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H6DO)-34, INSTALLATION, Rear Oxygen
Sensor.>
2) Install the front exhaust pipe (RH) to front ex-
haust pipe (LH).
NOTE:
Use a new gasket.
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
3) Install the front exhaust pipe assembly to vehi-
cle.
4) Temporarily tighten the nuts which hold front ex-
haust pipe assembly onto cylinder heads.
NOTE:
Use a new gasket.
5) Temporarily tighten the bolts which hold front ex-
haust pipe assembly to hanger bracket.
6) Tighten the bolts which install front exhaust pipe
to rear exhaust pipe.
NOTE:
Use a new gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
7) Tighten the bolts which hold front exhaust pipe
assembly to hanger bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
8) Tighten the nuts which hold front exhaust pipe to
cylinder heads.
Tightening torque:
70 Nm (7.1 kgf-m, 51.6 ft-lb)
EX-02017
EX-02016
EX-00061
EX-02015
EX-00061
EX-02016
EX(H6DO)-6
Front Exhaust Pipe
EXHAUST
10) Connect the front oxygen (A/F) sensor connec-
tor (A) and rear oxygen sensor connector (B).
C: INSPECTION
leaks.
EX-02014
(A)
(B)
IN-00203
EX(H6DO)-7
Rear Exhaust Pipe
EXHAUST
A: REMOVAL
CAUTION:
ning.
3) Separate the rear exhaust pipe from front ex-
haust pipe assembly.
4) Separate the rear exhaust pipe from muffler.
CAUTION:
pipe.
LH side
RH side
cushion rubber.
EX-02015
EX-00222
EX-00218
EX-00219
EX(H6DO)-8
Rear Exhaust Pipe
EXHAUST
B: INSTALLATION
rubber.
NOTE:
installing.
3) Install the rear exhaust pipe to muffler.
NOTE:
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
LH side
RH side
4) Install the rear exhaust pipe assembly to center
exhaust pipe.
NOTE:
Use a new gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
C: INSPECTION
leaks.
EX-00219
EX-00222
EX-00218
EX-02015
EX(H6DO)-9
Muffler
EXHAUST
4. Muffler
A: REMOVAL
CAUTION:
ning.
3) Separate the muffler from rear exhaust pipe.
LH side
RH side
LH side
RH side
5) Remove the front and rear cushion rubber, and
then remove the muffler.
EX-00222
EX-00218
EX-00220
EX-00221
EX(H6DO)-10
Muffler
EXHAUST
B: INSTALLATION
NOTE:
installing.
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
LH side
RH side
C: INSPECTION
leaks.
EX-00222
EX-00218
CO(H6DO)-2
General Description
COOLING
A: SPECIFICATION
Cooling system Electric fan + Forced engine coolant circulation system
Total engine coolant capacity 2 (US qt, Imp qt) Approx. 7.2 (7.6, 6.3)
Water pump
Discharge
performance I
Discharge rate
2 (US gal, Imp gal)/min.
320 (84.5, 70.4)
Pump speed Discharge
pressure
5,500 rpm 176.5 kPa (18 mAq)
Impeller diameter mm (in) 73.2 (2.88)
Number of pump sprocket teeth 22
Thermostat
Radiator fan
Motor input
Main fan W 160
Sub fan W 160
Fan diameter / Blade
Main fan 320 mm (12.6 in)/5
Sub fan 320 mm (12.6 in)/7
Radiator
Type Down flow, pressure type
Core dimensions
Width Height
Thickness
mm (in) 690 349 16 (27.17 13.74 0.63)
Pressure range in
which cap valve is open
kPa (kgf/cm
2
, psi)
Above: 10814.7
(1.10.15, 162)
Below: The atmospheric pressure or less
Reservoir tank Capacity 2 (US qt, Imp qt) 0.45 (0.48, 0.40)
Coolant SUBARU coolant 000016218 Phosphoric acid (non-amine) type
A/C compressor
A/C middle pressure
switch
Increase: less than 95C
(203F)
Decrease: less than 93C
(199F)
Increase: 95 101C
(203 214F)
Decrease: 93 99C
(199 210F)
or more
or more
OFF 0% Refer to fig. (1) 100%
ON
OFF Refer to fig. (2) 100%
ON Refer to fig. (3) 100%
CO(H6DO)-3
General Description
COOLING
(A) Fan speed (%) (B) Water temperature

(1) A/C OFF control (2) A/C ON control (A/C middle pres-
sure switch OFF)
(3) A/C ON control (A/C middle pres-
sure switch ON)
CO-02115
100
(1)
70
(A)
(B)
(2)
70
(A)
(B)
(3)
70
(A)
(B)
CO(H6DO)-4
General Description
COOLING
B: COMPONENT
1. WATER PUMP
(2) O-ring (5) Thermostat cover T: 6.4 (0.65, 4.7)
(3) Thermostat
(1)
(2)
(4)
(5)
T
T
(3)
CO-02291
CO(H6DO)-5
General Description
COOLING
2. RADIATOR AND RADIATOR FAN
(1) Radiator lower bracket (13) Radiator sub fan motor (25) ATF hose C
(2) Radiator lower cushion (14) Radiator sub fan shroud (26) ATF hose D
(3) Engine coolant drain plug (15) Radiator main fan (27) Radiator fan control unit
(4) Radiator (16) Radiator main fan motor
(5) Radiator upper bracket (17) Radiator main fan shroud Tightening torque:Nm (kgf-m, ft-lb)
(6) Radiator upper cushion (18) Engine coolant reservoir tank cap T1: 3.8 (0.39, 2.8)
(7) Clamp (19) Over flow hose T2: 5.4 (0.55, 4.0)
(8) Radiator hose A (20) Engine coolant reservoir tank T3: 6.2 (0.63, 4.6)
(9) Clamp (21) ATF hose clamp T4: 7.5 (0.76, 5.5)
(10) Radiator hose B (22) ATF hose A T5: 12 (1.2, 8.9)
(11) Radiator hose C (23) ATF hose B
(12) Radiator sub fan (24) ATF pipe
T1
T3
T4
T3
(12)
(14)
(27)
(16)
(13)
(15)
(17)
T1
T4
T2
CO-02362
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(7)
(7)
(7)
T4
T4
T5
(8)
(9)
(9)
(10)
(11)
(21)
(21)
(26)
(21)
(21)
(24)
(21)
(21)
(21)
(18)
(19)
(20)
(23)
(22)
(25)
T4
CO(H6DO)-6
General Description
COOLING
C: CAUTION
forming any work.
points.
the battery.
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
WRENCH
Used for stopping rotation of crank pulley
when loosening and tightening crank pulley
bolts.
TOOL NAME REMARKS
Radiator cap tester Used for measuring pressure.
ST-499977100
CO(H6DO)-7
Radiator Fan System
COOLING
A: WIRING DIAGRAM
CO-02254
312
B136
ECM
16
F108
F106
7
B361
1
7
F108
2 3 8
10
1
9
4
11 12 13 14 15 16
5 6 7
17 18
B361
1
7
2 3 4 5 6
8 9 10 11 12 13 14
2
9
1
8
F106
1 2 3
B
7
E
SBF-6 MAIN SBF
No.2
No.26
B143 B:
F36 E:
E
6
3 1 2
7 4 5 6
F36 E: B143
1 2 3 4 5 6 7
12 13 14 15 16 17 18
B:
8
19 11
9
20 10
E
M M
MAIN FAN RELAY 1
MAIN FUSE BOX (M/B)
F17
12
F17
1 2
B136
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
MAIN FAN MOTOR SUB FAN MOTOR
RADIATOR FAN
CONTROL UNIT
IGNITION SWITCH
CO(H6DO)-8
Radiator Fan System
COOLING
B: RADIATOR FAN CONTROL OUTPUT WAVEFORM
(A) 5 V
CO-02117
(V)
0
(A)
CO(H6DO)-9
Radiator Fan System
COOLING
C: INSPECTION
A/C switch is turned OFF.
Vehicle speed is 19 km/h (12 MPH) or less.
TROUBLE SYMPTOMS:
Radiator main and sub fans do not rotate under the above conditions.
Step Check Yes No
box.
fan relay 1 switch.
more?
fan relay 1.
1) Connect the battery to the main fan relay
1 coil side terminal.
fan relay 1.
3 CHECK POWER SUPPLY FOR ECM.
supply line.
4 CHECK POWER SUPPLY FOR RADIATOR
FAN CONTROL UNIT.
3) Disconnect the connector from radiator fan
control unit.
5) Measure the voltage between radiator fan
control unit connector and chassis ground.
supply line.
5 CHECK HARNESS BETWEEN ECM AND RA-
DIATOR FAN CONTROL UNIT.
radiator fan control unit and ECM connector.
(B136) No. 18 (F106) No. 2:
circuit of harness
between ECM and
radiator fan control
unit.
6 CHECK RADIATOR FAN CONTROL UNIT
AND GROUND CIRCUIT.
1) Connect the connector to ECM and radiator
fan control unit.
2) Measure the resistance between radiator
fan control unit connector and chassis ground.
circuit of harness
between radiator
fan control unit
connector and
chassis ground.
control unit.
2) Connect the battery positive (+) terminal to
terminal No. 1 of the radiator fan control unit,
and the ground () terminal to terminal No. 3.
Does the fan motor rotate? Go to step 8. Replace the fan
motor which does
not rotate.
CO(H6DO)-10
Radiator Fan System
COOLING
8 CHECK OUTPUT SIGNAL FROM ECM.
3) Check the output waveform using oscillo-
scope. <Ref. to CO(H6DO)-8, RADIATOR FAN
CONTROL OUTPUT WAVEFORM, Radiator
Fan System.>
Is waveform being output? Replace the radia-
tor fan control unit.
<Ref. to
CO(H6DO)-27,
Radiator Fan Con-
trol Unit.>
Replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
Step Check Yes No
CO(H6DO)-11
Engine Coolant
COOLING
3. Engine Coolant
A: REPLACEMENT
into container.
NOTE:
Remove the radiator cap so that engine coolant will
drain faster.
er neck.
system protective agent. <Ref. to CO(H6DO)-
2) Pour engine coolant into the radiator up to the
filler neck position.
mended engine coolant. <Ref. to CO(H6DO)-
Coolant level:
Refer to SPECIFICATION for the coolant
level. <Ref. to CO(H6DO)-2, SPECIFICATION,
FULL level.
4) Close the radiator cap and start the engine.
Race 5 to 6 times at 3,000 rpm or less, then stop
the engine. (Complete this operation within 40 sec-
onds.)
5) Wait for one minute after the engine stops, open
the radiator cap. If the engine coolant level drops,
add engine coolant into radiator up to the filler neck
position.
properly.
LO.
9) Run the engine at 2,000 rpm or less until radiator
fan starts and stops.
NOTE:
11) Open the radiator cap. If the engine coolant lev-
el drops, add engine coolant into radiator up to the
filler neck position and reservoir tank to the FULL
level.
properly.
CO-02012
(1) FULL
(2) LOW
(1)
(2)
CO-00110
CO(H6DO)-12
Engine Coolant
COOLING
B: INSPECTION
1. RELATIONSHIP OF COOLANT
TEMPERATURE
of coolant is shown in the diagram 1. Measuring the
temperature and specific gravity of the coolant will
provide this information.
[Example]
(7F) (point B), and the freezing temperature is
20C (4F) (point C).
Diagram 1
2. PROCEDURE TO ADJUST
THE CONCENTRATION OF THE COOLANT
temperature, find the proper fluid concentration in
the diagram 1 and replace the necessary amount of
coolant with an undiluted solution of coolant (con-
centration 50%).
[Example]
tical axis of the graph at height A. The quantity of cool-
ant 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)
undiluted coolant solution.
only.
Diagram 2
CO-02172
60%
(1.054)
1.000
1.010
1.020
1.030
1.040
1.050
1.060
1.070
1.080
1.090
1.100
Freezing
temperature
Concentration
of coolant
S
p
e
c
i
f
i
c

g
r
a
v
i
t
y
o
f

c
o
o
l
a
n
t
Coolant temperature
B
A
C
-40
(-40) (-22) (-4) (14) (32) (50) (68) (86)
( F)
(104)
-30 -20 -10 0 10 20 30 40
(
7
7

F
)
50%
40%
30%
20%
2
5

C10%
C
CO-00012
10
0
1
2
3
(1.1,
0.9)
(2.1,
1.8)
(3.2,
2.6)
10%
15%
25%
20%
30%
35%
40%
45%
A
20 30 40 50
Q
u
a
n
t
i
t
y

o
f

c
o
o
l
a
n
t

t
o

b
e
d
r
a
i
n
e
d

(
U
S

q
t
,

I
m
p

q
t
)
of coolant
CO(H6DO)-13
Water Pump
COOLING
4. Water Pump
A: REMOVAL
1) Remove the radiator. <Ref. to CO(H6DO)-16, RE-
MOVAL, Radiator.>
2) Remove the V-belts. <Ref. to ME(H6DO)-40, RE-
MOVAL, V-belt.>
bly.>
NOTE:
When the water pump cannot be removed easily,
screw-in the bolt (A) to the threaded end to remove
water pump.
B: INSTALLATION
1) Install the water pump to rear chain cover.
NOTE:
Use new O-rings.
Apply engine coolant to O-ring.
Tightening torque
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
sembly.>
6) Install the radiator. <Ref. to CO(H6DO)-17, IN-
7) Fill engine coolant. <Ref. to CO(H6DO)-11, FILL-
gine Coolant.>
C: INSPECTION
tion.
2) Check the water pump sprocket for abnormali-
ties.
CO-02013
(A)
(A)
CO-02014
CO(H6DO)-14
Thermostat
COOLING
5. Thermostat
A: REMOVAL
CO(H6DO)-11, DRAINING OF ENGINE COOLANT,
REPLACEMENT, Engine Coolant.>
stat cover.
the thermostat.
B: INSTALLATION
NOTE:
Use a new gasket.
NOTE:
The jiggle pin must face upward when installing.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
cover.
gine Coolant.>
(B) Thermostat
CO-02015
CO-02164
(A)
(B)
(B) Thermostat
(C) Gasket
(D) Jiggle pin
CO-02165
(D)
(A)
T
(B)
(C)
CO(H6DO)-15
Thermostat
COOLING
C: INSPECTION
Inspection method
NOTE:
five minutes or more before measuring the valve
lift.
Starting temperature to open:
80 84C (176 183F)
Fully opens:
95C (203F)
Valve lift:
(A) Thermometer
(B) Thermostat
CO-00033
( A)
( B)
CO(H6DO)-16
Radiator
COOLING
6. Radiator
A: REMOVAL
CAUTION:
CO(H6DO)-11, DRAINING OF ENGINE COOL-
7) Disconnect the radiator outlet hose from the ra-
diator.
8) Disconnect the ATF cooler hose from the radia-
tor.
control unit.
13) Remove the reservoir tank. <Ref. to CO(H6DO)-
14) Disconnect the radiator inlet hose from radia-
tor.
IN-00203
CO-02015
CO-00253
(A) Radiator inlet hose
(B) Radiator upper bracket
CO-02017
CO-02018
CO-02019
(A)
(B)
CO(H6DO)-17
Radiator
COOLING
B: INSTALLATION
1) Attach the radiator lower cushions to holes on
the vehicle.
NOTE:
the bolts.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
4) Connect the radiator inlet hose.
5) Install the reservoir tank. <Ref. to CO(H6DO)-
26, INSTALLATION, Reservoir Tank.>
6) Connect the connector to the radiator fan control
unit.
7) Install the air intake duct. <Ref. to IN(H6DO)-8,
INSTALLATION, Air Intake Duct.>
10) Connect the ATF cooler hoses.
gine Coolant.>
(A) Radiator inlet hose
(B) Radiator upper bracket
CO-00126
CO-02019
(A)
(B)
CO-02018
CO-02017
CO-00253
CO-02015
IN-00203
CO(H6DO)-18
Radiator
COOLING
C: INSPECTION
1) Remove the radiator cap, fill the radiator with en-
gine coolant, and then install the tester to the instal-
lation position of cap.
2) Apply a pressure of 157 kPa (1.6 kgf/cm
2
, 23 psi)
CAUTION:
vance.
Be careful of the spurt of engine coolant
when removing the tester.
Be careful not to deform the filler neck of ra-
diator when installing and removing the tester.
CO-00127
CO(H6DO)-19
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
Replace the cap if it is opened under a pressure
less than the service limit value.
Specification:
93 123 kPa (0.95 1.25 kgf/cm
2
, 14 18 psi)
Service limit:
83 kPa (0.85 kgf/cm
2
, 12 psi)
CAUTION:
Be sure to remove foreign matter and rust from
the cap in advance. Otherwise, results of pres-
sure test will be incorrect.
CO-00044
CO(H6DO)-20
COOLING
Motor
A: REMOVAL
6) Disconnect the connector from radiator fan con-
trol unit.
CO(H6DO)-11, DRAINING OF ENGINE COOL-
10) Remove the ATF hose from the clip of the radi-
ator main fan shroud.
11) Remove the radiator main fan motor harness
from the clip.
13) Remove the reservoir tank. <Ref. to CO(H6DO)-
14) Disconnect the inlet hose from radiator.
15) Remove the radiator sub fan motor assembly.
16) Remove the radiator main fan motor assembly.
NOTE:
When removing the main fan assembly with lifting it
up, the main fan shroud contacts to inlet part of en-
gine coolant. To avoid contacting it, move the main
fan assembly to sub fan assembly side before re-
moval.
IN-00203
CO-02017
CO-02029
CO-02020
CO-00129
CO-00130
CO(H6DO)-21
COOLING
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: DISASSEMBLY
1) Remove the nut which holds fan to fan motor
and shroud assembly.
2) Remove the clip which holds the fan motor onto
the shroud.
D: ASSEMBLY
Tightening torque:
3.8 Nm (0.39 kgf-m, 2.8 ft-lb)
Tightening torque:
6.2 Nm (0.63 kgf-m, 4.6 ft-lb)
CO-00130
CO-00132
CO-00133
CO-00133
CO-00132
CO(H6DO)-22
COOLING
E: INSPECTION
trol unit.
NOTE:
Do not remove the main fan motor harness connec-
tor.
2) Connect the battery to radiator fan control unit as
3) Check the fan motor for operations. If it does not
operate, check the fan motor.
CO-02018
CO-02037
CO(H6DO)-23
COOLING
Motor
A: REMOVAL
trol unit.
7) Remove the bolts which hold the sub shroud to
the radiator.
10) Remove the radiator sub fan shroud through
the under side of vehicle.
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
IN-00203
CO-02017
CO-02029
CO-00129
CO-00129
CO(H6DO)-24
COOLING
C: DISASSEMBLY
1) Remove the nut which holds fan to fan motor
and shroud assembly.
2) Remove the clip which holds the fan motor onto
the shroud.
3) Remove the bolts which hold the radiator fan
control unit to the shroud.
D: ASSEMBLY
Radiator fan control unit bolt tightening torque:
5.4 Nm (0.55 kgf-m, 4.0 ft-lb)
Tightening torque:
3.8 Nm (0.39 kgf-m, 2.8 ft-lb)
Tightening torque:
6.2 Nm (0.63 kgf-m, 4.6 ft-lb)
CO-00136
CO-00133
CO-00133
CO-00136
CO(H6DO)-25
COOLING
E: INSPECTION
trol unit.
NOTE:
Do not remove the main fan motor harness connec-
tor.
2) Connect the battery to radiator fan control unit as
3) Check the fan motor for operations. If it does not
operate, check the fan motor.
CO-02018
CO-02037
CO(H6DO)-26
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
2) Remove the bolts which hold the reservoir tank
to the fan shroud, then remove the reservoir tank.
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
FULL and LOW.
CO-02241
CO(H6DO)-27
Radiator Fan Control Unit
COOLING
11.Radiator Fan Control Unit
A: SPECIFICATION
Radiator fan control unit forms a unit with radiator
sub fan motor. Refer to Radiator Sub Fan and Fan
Motor for removal and installation procedure.
<Ref. to CO(H6DO)-23, REMOVAL, Radiator Sub
Fan and Fan Motor.> <Ref. to CO(H6DO)-23, IN-
STALLATION, Radiator Sub Fan and Fan Motor.>
<Ref. to CO(H6DO)-24, DISASSEMBLY, Radiator
Sub Fan and Fan Motor.> <Ref. to CO(H6DO)-24,
ASSEMBLY, Radiator Sub Fan and Fan Motor.>
CO(H6DO)-28
COOLING
A: INSPECTION
Overheat
c. Malfunction of water pump Replace.
d. Clogged engine coolant passage Clean.
e. Improper ignition timing
Inspect and repair ignition control system. <Ref. to
EN(H6DO)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>
f. Clogged or leaking radiator Clean, repair or replace.
g. Improper engine oil in engine coolant
Replace the engine coolant. If still no improvement,
inspect, repair or replace the engine related parts.
h. Air/fuel mixture ratio too lean
EN(H6DO)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>
i. Excessive back pressure in exhaust system Clean or replace.
j. Insufficient clearance between piston and cylinder Adjust or replace.
k. Slipping clutch Correct or replace.
l. Dragging brake Adjust.
m. Faulty transmission gear oil Replace.
n. Malfunction of radiator fan
Over-cooling
Engine coolant
leaks
a. Loosened or damaged connecting units on hoses Correct or replace.
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and cylinder
block
Correct or replace.
Noise
a. Defective drive belt Replace.
LU(H6DO)-2
General Description
LUBRICATION
A: SPECIFICATION
Recommended oil:
CAUTION:
NOTE:
If the vehicle is used in regions of high temperatures
or in other severe environments, use oil with the vis-
cosities shown below. API standard: SM or SL
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-50
Oil pump
Number of teeth
Inner rotor 7
Outer rotor 8
Tip clearance between inner and outer rotors
mm (in)
0.04 0.14 (0.0016 0.0055)
Side clearance between inner rotor and pump case
mm (in)
0.020 0.046 (0.0008 0.0018)
Case clearance between outer rotor and pump case
mm (in)
0.110 0.175 (0.0043 0.0069)
Oil filter
Filtration area cm
2
(sq in) 1,300 (201.5)
2
, psi) 160 (1.63, 23.2)
Outer diameter width mm (in) 80 75 (3.15 2.95)
2
, psi) 708 (7.2, 102.7)
Oil pressure
switch
2
, psi) 15 (0.15, 2.2)
2
, psi) 980 (10.0, 142) or more
Engine oil
(2) Recommended
( C) -30 -20 -15 0 15 30 40
-22 -4 5 32 59 86 104
SAE (1)
( F)
10W-30, 10W-40 , 10W-50
5W-30 (2)
LU-02329
LU(H6DO)-3
General Description
LUBRICATION
B: COMPONENT
(4)
(3)
T8
(26)
(16)
(20)
(2)
(17)
(13)
(7)
(9)
(6) (7)
(14)
(18)
(1)
(21)
(19)
(25)
(24)
(23)
T1
T4
T4
T1
T4
T7
T6
T4
T5
T3
T8
T10
(26)
(8)
(11)
(10)
T9
(12)
T2
(15)
(26)
(22)
(5)
(6)
(7)
(7)
(7)
(7)
T1
(6)
LU-02368
LU(H6DO)-4
General Description
LUBRICATION
C: CAUTION
any work.
tery.
D: PREPARATION TOOL
1. SPECIAL TOOL
(1) Oil pan lower (14) Outer rotor Tightening torque:Nm (kgf-m, ft-lb)
(2) Magnet (15) Crank sprocket T1: 6.4 (0.65, 4.7)
(3) Drain plug (16) Oil pan upper T2: <Ref. to LU(H6DO)-8, INSTAL-
LATION, Oil Pump.>
(4) Gasket (17) Plug
(5) Oil cooler pipe (18) Plug T3: 16 (1.6, 11.8)
(6) Hose (19) Plug T4: 18 (1.8, 13.3)
(7) Clamp (20) Oil pressure switch T5: 23 (2.3, 17)
(8) Gasket (21) Plug T6: 25 (2.5, 18.4)
(9) Oil cooler (22) Oil strainer T7: 37 (3.8, 27)
(10) Oil cooler connector (23) Plug T8: 44 (4.5, 32.5)
(11) Oil filter (24) Relief valve spring T9: 54 (5.5, 40)
(12) Oil pump cover (25) Relief valve T10: 90 (9.2, 66)
(13) Inner rotor (26) O-ring
WRENCH
498547000 OIL FILTER
WRENCH
Used for removing and installing oil filter.
ST-499977100
ST-498547000
LU(H6DO)-5
Oil Pressure System
LUBRICATION
A: WIRING DIAGRAM
LU-02306
E
i3
B38
B21
E2
1
7
E11
No.5
SBF-6 MAIN SBF
B72
3 6
B72
1
5
i10
3
1
i10
3
1 3
4 5 6
2 2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B38
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
BATTERY
IGNITION
SWITCH
COMBINATION
METER
O
I
L

P
R
E
S
S
U
R
E
W
A
R
N
I
N
G

L
I
G
H
T
OIL PRESSURE
SWITCH
LU(H6DO)-6
Oil Pressure System
LUBRICATION
B: INSPECTION
Step Check Yes No
2) Check the warning light of combination
meter.
nate?
the combination
4, INSPECTION,
Combination Meter
System.>
COMBINATION METER AND OIL PRES-
SURE SWITCH.
switch.
4) Measure the voltage between the oil pres-
sure switch connector and the engine ground.
pressure switch.
<Ref. to
LU(H6DO)-14, Oil
Pressure Switch.>
Go to step 3.
meter.
Terminals
(i10) No. 3 (i10) No. 15:
and connector.
NOTE:
the following item:
Open circuit of
harness between
combination meter
and oil pressure
switch
Poor contact in
combination meter
connector
Poor contact in
oil pressure switch
connector
Poor contact of
coupling connector
Repair or replace
the combination
4, INSPECTION,
Combination Meter
System.>
LU(H6DO)-7
Engine Oil
LUBRICATION
3. Engine Oil
A: INSPECTION
oil.
4) Remove it again and check the reading. If the
engine oil level is below L line, add oil to bring the
level up to F line.
the oil level.
NOTE:
B: REPLACEMENT
engine oil.
plug.
NOTE:
engine oil.
NOTE:
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
fill engine oil through the oil filler duct to the F line
on level gauge. Make sure that the vehicle is
Recommended oil:
mended oil. <Ref. to LU(H6DO)-2, SPECIFI-
capacity. <Ref. to LU(H6DO)-2, SPECIFICA-
9) Start the engine and circulate the engine oil.
necessary, add engine oil up to the F line on level
gauge.
(A) Oil level gauge
(C) F line
(D) L line
L
F
(A)
(B)
(C)
(D)
(E)
LU-02330
(A) Oil level gauge
(C) F line
(D) L line
LU-02011
L
F
(A)
(B)
(C)
(D)
(E)
LU-02330
LU(H6DO)-8
Oil Pump
LUBRICATION
4. Oil Pump
A: REMOVAL
6) Drain engine coolant. <Ref. to CO(H6DO)-11,
DRAINING OF ENGINE COOLANT, REPLACE-
8) Remove the radiator. <Ref. to CO(H6DO)-16,
REMOVAL, Radiator.>
REMOVAL, V-belt.>
11) Remove the timing chain. <Ref. to ME(H6DO)-
44, REMOVAL, Timing Chain Assembly.>
13) Remove the oil pump cover.
14) Remove the inner rotor and outer rotor.
B: INSTALLATION
1) Apply a coat of engine oil to the whole area of in-
ner rotor and outer rotor.
2) Install the inner rotor to the crank shaft, then as-
semble the outer rotor.
4) Tighten the bolts in the numerical order as
CAUTION:
Make sure that the bolt is installed in correct
position.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6) Install the timing chain. <Ref. to ME(H6DO)-45,
INSTALLATION, Timing Chain Assembly.>
9) Install the radiator. <Ref. to CO(H6DO)-17, IN-
IN-00203
LU-02012
Bolt installing position Bolt dimension
(1) and (3) 6 14 14
(2) and (4) 6 35 18
(5), (6), (7), (8), (9), (10) and (11) 6 35 15
(12), (15), (16) and (17) 6 16 16
(13) and (14) 6 26 15
LU-02032
LU-02013
(3)
(7)
(2)
(4)
(9)
(5)
(8)
(1) (6)
(12)
(13)
(14)
(15)
(16)
(17)
(11)
(10)
LU(H6DO)-9
Oil Pump
LUBRICATION
gine Coolant.>
C: INSPECTION
1. TIP CLEARANCE
exceeds specification, replace the rotors as a
matched set.
Tip clearance:
Standard
0.04 0.14 mm (0.0016 0.0055 in)
2. CASE CLEARANCE
rear chain cover rotor housing. If the clearance ex-
ceeds the standard value, replace the outer rotor.
Case clearance:
Standard
0.110 0.175 mm (0.0043 0.0069 in)
3. SIDE CLEARANCE
Measure the clearance between oil pump inner ro-
tor and rear chain cover. If the clearance exceeds
specification, replace the rotors as a matched set.
Side clearance:
Standard
0.020 0.046 mm (0.0008 0.0018 in)
Perform the replacement parts selection as follows.
When replacing all inner rotor, outer rotor and
rear chain cover with new parts
On the inner rotor, outer rotor and the rear chain
cover, there are identification marks in locations
shown on the figure. When replacing, use those
with matching identification marks.
LU-02014
LU-02015
LU-02016
ME-02734
LU(H6DO)-10
Oil Pump
LUBRICATION
When replacing any one of the inner rotor, outer
rotor and rear chain cover with new part, select
suitable size from the following table so that side
clearance meets the standard.
4. OIL PUMP CASE
Check the worn shaft hole, clogged oil passage,
crank and other parts for faults.
Inner rotor
Classification Part No.
Rotor thickness
mm (in)
A 15015AA250
12.993 13.006
(0.51153 0.51205)
No 15015AA300
12.980 12.993
(0.51102 0.51153)
C 15015AA310
12.967 12.980
(0.51051 0.51102)
Outer rotor
Rotor thickness
mm (in)
A 15016AA250
12.993 13.006
(0.51153 0.51205)
No 15016AA300
12.980 12.993
(0.51102 0.51153)
C 15016AA310
12.967 12.980
(0.51051 0.51102)
Rear chain cover
Rotor thickness
mm (in)
A 13119AA020
13.026 13.039
(0.51295 0.51335)
B 13119AA050
13.013 13.026
(0.51232 0.51284)
C 13119AA060
13.000 13.013
(0.51181 0.51232)
LU(H6DO)-11
Oil Pump Relief Valve
LUBRICATION
5. Oil Pump Relief Valve
A: REMOVAL
1. REAR CHAIN COVER SIDE
Oil pump relief valve is integrated into oil pump cover
as one unit; therefore, refer to Oil Pump for remov-
al procedure. <Ref. to LU(H6DO)-8, REMOVAL, Oil
Pump.>
2. OIL PAN UPPER SIDE
1) Remove the oil pan. <Ref. to LU(H6DO)-12, RE-
MOVAL, Oil Pan and Strainer.>
2) Remove the plug, relief valve spring and relief
valve.
B: INSTALLATION
1. REAR CHAIN COVER SIDE
Oil pump relief valve is integrated into oil pump cover
as one unit; therefore, refer to Oil Pump for instal-
lation procedure. <Ref. to LU(H6DO)-8, INSTALLA-
TION, Oil Pump.>
2. OIL PAN UPPER SIDE
1) Install the relief valve, relief valve spring and
plug.
NOTE:
Apply engine oil to the relief valve.
Tightening torque:
T: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
2) Install the oil pan. <Ref. to LU(H6DO)-12, IN-
STALLATION, Oil Pan and Strainer.>
C: INSPECTION
Check the worn shaft hole of oil pump relief valve
case, clogged oil passage, crank and other parts
for faults.
(1) Relief valve
(2) Relief valve spring
(3) Plug
(1)
LU-02033
(2)
(3)
LU-02034
T
LU(H6DO)-12
LUBRICATION
A: REMOVAL
NOTE:
Before removing the oil pan upper, remove the en-
gine from vehicle. <Ref. to ME(H6DO)-32, RE-
MOVAL, Engine Assembly.> <Ref. to ME(H6DO)-
64, REMOVAL, Cylinder Block.>
4) Drain the engine oil. <Ref. to LU(H6DO)-7, RE-
5) Insert the oil pan cutter blade between oil pan
upper and oil pan lower.
CAUTION:
of oil pan cutter.
6) Remove the oil pan lower.
B: INSTALLATION
NOTE:
Before installing the oil pan, wipe clean the mating
surface of oil pan lower and oil pan upper.
1) Install the oil strainer onto oil pan upper.
NOTE:
Use new O-rings.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Liquid gasket:
or equivalent
5.01.0 mm (0.1970.039 in)
LU-00123
LU-02108
LU-02108
LU-00125
LU(H6DO)-13
LUBRICATION
3) Tighten the oil pan lower installing bolts in the
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6) Refill the engine oil. <Ref. to LU(H6DO)-7, IN-
C: INSPECTION
Visually check that the oil pan, oil strainer and oil
strainer stay are not damaged.
(1) (2)
(3)
(4)
(5)
(6)
(7)
(8) (9)
(10)
(11)
(12)
(13)
(14)
(15)
LU-00126
LU(H6DO)-14
Oil Pressure Switch
LUBRICATION
A: REMOVAL
B: INSTALLATION
threads.
Liquid gasket:
equivalent
2) Install the oil pressure switch.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
3) Connect the terminal of the oil pressure switch.
C: INSPECTION
Make sure oil does not leak or seep from where the
oil pressure switch is installed.
IN-00203
LU-02126
LU-02127
LU-00129
LU-02127
LU-02126
LU(H6DO)-15
Engine Oil Filter
LUBRICATION
A: REMOVAL
ST 4985447000 OIL FILTER WRENCH
B: INSTALLATION
CAUTION:
Do not overtighten. Doing so may cause an oil
leak.
1) Clean the oil filter installing surface of oil cooler.
4) Tighten more (approx. 3/4 turn) after the seal
rubber contacts the oil cooler. When using a torque
wrench, tighten to 14 Nm (1.4 kgf-m, 10.3 ft-lb).
7) Refill the engine oil. <Ref. to LU(H6DO)-7, IN-
C: INSPECTION
NOTE:
sary.
2) Check the engine oil level. <Ref. to LU(H6DO)-
7, INSPECTION, Engine Oil.>
LU-02035
LU(H6DO)-16
Oil Cooler
LUBRICATION
9. Oil Cooler
A: REMOVAL
4) Drain engine coolant. <Ref. to CO(H6DO)-11,
DRAINING OF ENGINE COOLANT, REPLACE-
6) Remove the bolts which hold the water pipe to
engine.
7) Disconnect the water hose from oil cooler.
8) Remove the oil filter using the ST. <Ref. to
LU(H6DO)-15, REMOVAL, Engine Oil Filter.>
9) Remove the oil cooler connector and remove the
oil cooler.
B: INSTALLATION
1) Install the oil cooler to oil pan upper with oil cool-
er connector.
NOTE:
Use a new gasket.
Tightening torque:
T: 54 Nm (5.5 kgf-m, 40 ft-lb)
2) Install the oil filter. <Ref. to LU(H6DO)-15, IN-
STALLATION, Engine Oil Filter.>
3) Connect the water hose.
4) Install the water pipe onto engine.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6) Refill the engine oil. <Ref. to LU(H6DO)-7, RE-
(A) Oil cooler connector
(B) Oil cooler
(C) Gasket
LU-02128
LU-02129
LU-02130
(A)
(B)
(C)
(A) Oil cooler connector
(B) Oil cooler
(C) Gasket
LU-02131
(A)
(B)
(C)
T
LU-02129
LU-02128
LU(H6DO)-17
Oil Cooler
LUBRICATION
7) Fill engine coolant. <Ref. to CO(H6DO)-11,
8) Check the engine oil level. <Ref. to LU(H6DO)-
7, INSPECTION, Engine Oil.>
C: INSPECTION
1) Check that coolant passages are not clogged
using an compressed air.
2) Check that the oil pan upper and O-ring installing
surface of oil filter are not damaged.
LU(H6DO)-18
LUBRICATION
10.Engine Lubrication System Trouble in General
A: INSPECTION
Symptom Possible cause Corrective action
on.
failure
2) Low oil pressure
pump rotor and gear
Replace.
3) No oil pressure
Insufficient engine oil (including deterioration) Replace.
not turn on.
momentarily.
3) Low oil pressure
Check for the same
possible causes as
listed 1. 2).
SP(H6DO)-2
General Description
A: SPECIFICATION
B: COMPONENT
C: CAUTION
any work.
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, dis-
assembly and replacement.
tery.
Accelerator pedal Stroke At pedal pad 52 57 mm (2.05 2.24 in)
(1) Accelerator pedal ASSY (4) Stopper Tightening torque:Nm (kgf-m, ft-lb)
(2) Clip (5) Accelerator pedal bracket T: 18 (1.8, 13.3)
(3) Accelerator plate
SP-02049
T
T
(1)
(5)
(4)
T
T
(3)
(2)
SP(H6DO)-3
Accelerator Pedal
2. Accelerator Pedal
A: REMOVAL
2) Disconnect the connector (A).
3) Remove the nut (B) securing accelerator pedal
assembly.
B: INSTALLATION
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
C: DISASSEMBLY
NOTE:
The accelerator pedal cannot be disassembled.
SP-02050
(B)
(A)
SP(H6DO)-4
Accelerator Pedal
IG(H6DO)-2
General Description
IGNITION
A: SPECIFICATION
B: COMPONENT
Item Specification
Ignition coil
Type FK0140
Ignition system Independent ignition coil
Spark plug
Manufacturer and type NGK: ILFR6B
Thread size (diameter, pitch, length) mm 14, 1.25, 26.5
Electrode Iridium
(1) Spark plug (2) Ignition coil Tightening torque:Nm (kgf-m, ft-lb)
T1: 16 (1.6, 11.8)
T2: 21 (2.1, 15.5)
IG-00052
(1)
(1)
(2)
(2)
T1
T2
T2
T1
IG(H6DO)-3
General Description
IGNITION
C: CAUTION
forming any work.
points.
the battery.
IG(H6DO)-4
Spark Plug
IGNITION
2. Spark Plug
A: REMOVAL
Spark plug:
Refer to SPECIFICATION for the spark
plug. <Ref. to IG(H6DO)-2, SPECIFICATION,
1. RH SIDE
3) Remove the air cleaner case. <Ref. to IN(H6DO)-
5, REMOVAL, Air Cleaner Case.>
4) Remove the bracket (A).
5) Disconnect the connector (B) from ignition coil.
NOTE:
Turn the #5 ignition coil to remove it.
IN-00203
IG-02004
(B)
(A)
(A) Ratchet handle
(B) Extension bar
(C) Universal joint
(D) Spark plug socket
IG-02005
(D) (C) (B) (B)
(A)
IG-02011
IG(H6DO)-5
Spark Plug
IGNITION
2. LH SIDE
3) Remove the bracket (A).
4) Disconnect the connector (B) from ignition coil.
NOTE:
Turn the #6 ignition coil to remove it.
B: INSTALLATION
1. RH SIDE
21 Nm (2.1 kgf-m, 15.5 ft-lb)
16 Nm (1.6 kgf-m, 11.8 ft-lb)
2. LH SIDE
21 Nm (2.1 kgf-m, 15.5 ft-lb)
16 Nm (1.6 kgf-m, 11.8 ft-lb)
C: INSPECTION
1) Normal:
(A) Ratchet handle
(B) Extension bar
(C) Universal joint
(D) Spark plug socket
IG-02006
(A)
(B)
IG-02007
(D) (C) (B) (B)
(A)
IG-02011
(A) Spark plug gap
(C) Crack
(D) Damage
(E) Damaged gasket
IG-00010
(A)
(B)
(C)
(D)
(E)
IG-00011
IG(H6DO)-6
Spark Plug
IGNITION
2) Carbon fouled:
air cleaner.
3) Oil fouled:
bustion chamber through worn rings and excessive
clearance between valve guides and stems.
4) Overheating:
D: ADJUSTMENT
Clean up the spark plug using nylon brush or equiv-
alent. Clean and remove the carbon or oxide de-
posits. If deposits are too stubborn, replace the
spark plugs.
NOTE:
Never use a plug cleaner.
Never use a metal brush because it makes insu-
lator worn.
Spark plug gap L:
0.7 0.8 mm (0.028 0.031 in)
IG-00012
IG-00013
IG-00014
IG-02035
L
IG(H6DO)-7
Ignition Coil
IGNITION
3. Ignition Coil
A: REMOVAL
Direct ignition type has been adopted. Refer to Spark
Plug for removal procedure. <Ref. to IG(H6DO)-4,
B: INSTALLATION
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
C: INSPECTION
For inspection procedure, refer to Diagnostics for
Engine Starting Failure. <Ref. to EN(H6DO)(diag)-
78, IGNITION CONTROL SYSTEM, Diagnostics
for Engine Starting Failure.>
IG(H6DO)-8
Ignition Coil
IGNITION
SC(H6DO)-2
General Description
A: SPECIFICATION
Specifications for the 3.0 L DOHC non-turbo model
are included in the SC(H4SO) section. <Ref. to
SC(H4SO)-2, General Description.>
EN(H6DO)(diag)-2
A: PROCEDURE
1. ENGINE
Step Check Yes No
EN(H6DO)(diag)-3, CHECK, Check List for
Interview.>
Diagnostics for
Engine Start Fail-
ure. <Ref. to
EN(H6DO)(diag)-
71, Diagnostics for
Engine Starting
Failure.>
INDICATOR LIGHT.
light illuminate?
General Diagnos-
tic Table. <Ref. to
EN(H6DO)(diag)-
356, INSPEC-
TION, General
Diagnostic Table.>
3 CHECK INDICATION OF DTC ON DISPLAY.
general scan tool.
NOTE:
EN(H6DO)(diag)-44, Read Diagnostic Trouble
Code (DTC).>
General scan tool
tool?
Record the DTC.
Repair the trouble
cause. <Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).> Go to step 4.
Repair the related
parts.
NOTE:
If DTC is not
shown on display
although the mal-
function indicator
light illuminates,
perform the diag-
nosis of malfunc-
circuit or combina-
tion meter. <Ref. to
EN(H6DO)(diag)-
62, Malfunction In-
dicator Light.>
EN(H6DO)(diag)-57, Clear Memory Mode.>
EN(H6DO)(diag)-45, Inspection Mode.>
tool?
Inspect using
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).
<Ref. to
EN(H6DO)(diag)-
92, Diagnostic Pro-
cedure with Diag-
nostic Trouble
Code (DTC).>
Finish the diagno-
sis.
EN(H6DO)(diag)-3
A: CHECK
1. CHECK LIST NO. 1
NOTE:
Date of repair
Odometer reading
km
V.I.N. miles
Weather Fine
Cloudy
Rainy
Snowy
Various/Others:
Hot
Warm
Cool
Cold
Place Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others:
Warming-up
After warming-up
Any temperature
Others:
Engine speed rpm
At starting
While idling
At racing
While accelerating
While cruising
While decelerating
Rear wiper ON/ OFF
EN(H6DO)(diag)-4
2. CHECK LIST NO. 2
NOTE:
ABS warning light
b) Fuel level
What:
What:
What:
Where:
From where:
What kind:
From where:
What kind:
Rough idling
Poor acceleration
Back fire
After fire
Does not shift.
EN(H6DO)(diag)-5
General Description
A: CAUTION
CAUTION:
All airbag system wiring harnesses and con-
nectors are yellow. Do not use electrical test
equipment on these circuits.
aged.
etc.
necting the connectors. <Ref. to EN(H4DOTC)(di-
more into the part.
CAUTION:
NOTE:
When replacing the ECM of the models with Immo-
OPERATION MANUAL.
sembly as the grounding point to chassis when
compartment.
drop them.
CAUTION:
ness.
matching.
above.
fuel pressure. <Ref. to FU(H6DO)-42, RELEASING
OF FUEL PRESSURE, PROCEDURE, Fuel.>
(A) Stud bolt
EN-00001
(A)
EN-02473
EN(H6DO)(diag)-6
General Description
diagnosis function.
B: INSPECTION
1. BATTERY
of the electrolyte.
proper grounding.
2. ENGINE GROUND
C: NOTE
of the complex electronic throttle control. Malfunc-
tion indicator light in the combination meter indi-
cates occurrence of a fault or trouble.
board computer.
EN-02473
EN(H6DO)(diag)-7
General Description
2. ENGINE AND EMISSION CONTROL SYSTEM
The Multipoint Fuel Injection (MFI) system is a system that supplies the optimum air-fuel mixture to the en-
gine 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.
Reduced emission of harmful exhaust gases
Increased engine output
Superior startability and warm-up performance in cold weather since compensation is made for engine
coolant and intake air temperature
D: PREPARATION TOOL
MONITOR III KIT
18252AA000 CRANKSHAFT
SOCKET
ST1B021XU0
ST18252AA000
EN(H6DO)(diag)-8
A: LOCATION
1. ENGINE
Control module
(1)
(4)
(3)
(2)
EN-05722
(1)
EN-01147 EN-03104
CHECK
ENGINE
(2)
EN-02975
(3)
AT-01877
(4)
EN(H6DO)(diag)-9
Sensor
perature sensor
(3) Engine coolant temperature sensor (6) Camshaft position sensor
(4) Electronic throttle control (7) Crankshaft position sensor
(2) Manifold absolute pressure sensor (5) Knock sensor (8) Oil temperature sensor
EN-02478
(1)
(2) (3)
(5) (4) (7) (5) (6) (8)
(6)
EN(H6DO)(diag)-10
EN-02479
(1)
EN-02535
(2)
(3)
EN-00895 EN-02536
(4)
(5)
(5)
EN-00897 EN-02537
(6)
(7)
EN-00899 EN-02538
(8)
EN(H6DO)(diag)-11
(1) Front oxygen (A/F) sensor LH (4) Rear oxygen sensor RH (6) Front catalytic converter RH
(2) Front oxygen (A/F) sensor RH (5) Front catalytic converter LH (7) Rear catalytic converter
(3) Rear oxygen sensor LH
EN-02480
(2)
(1) (3)
(4) (6)
(7)
(5)
EN-02539
(5)
(1)
EN-02540
(2)
(6)
EN-02541
(3)
EN-02542
(4)
(7)
EN-02543
EN(H6DO)(diag)-12
(1)
(4)
EN-05723
(2) (3)
EN-05725
(2)
(1)
EN-03003
(3)
EN-03132
(4)
EN(H6DO)(diag)-13
(1) Purge control solenoid valve (4) Oil switching solenoid valve (6) EGR valve
(2) Ignition coil and ignitor ASSY (5) Variable valve lift diagnosis oil
pressure switch
(3) Oil flow control solenoid valve
(2)
(3)
(3)
(1) (4) (5)
(4) (5)
(2)
(6)
EN-05643
EN(H6DO)(diag)-14
(1)
EN-02482
(2)
EN-02960
(3)
EN-02961
(5)
EN-02962
(4)
EN-05006
(6)
EN(H6DO)(diag)-15
(2) Canister
EN-05724
(1)
(2) (3)
(4)
EN-02980
(1)
EN-02981
(4)
(3)
(2)
EN(H6DO)(diag)-16
(1) Starter (3) Main relay (5) Electronic throttle control relay
(2) Fuel pump (4) Fuel pump relay (6) Radiator fan relay
(6)
(3) (2)
(1)
(4) (5)
EN-05719
EN-05614
(1)
(2)
EN-05726
EN-02544
(3)
(4)
(5)
EN-02489
(6)
EN(H6DO)(diag)-17
Contents
Connec-
tor No.
Termi-
nal No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
Crankshaft position
sensor
Signal () B134 14 0 0
Shield B134 24 0 0
Camshaft position
sensor (LH)
Power
supply
B134 21 0.275 0 or 5 Waveform
GND B134 22 0 0
Camshaft position
sensor (RH)
Power
supply
B134 11 0.275 0 or 5 Waveform
GND B134 22 0 0
Electronic throttle
control
Main B134 18
0.64 0.94
Fully opened: 4.01
0.64 0.72
(After engine is
warmed-up.)
Fully closed: 0.6
Fully opened: 4.01
Sub B134 28
1.51 1.76
Fully opened: 4.23
1.51 1.58
(After engine is
warmed-up.)
Fully closed: 1.48
Fully opened: 4.23
(+)
()
power supply
B136 1 10 13 12 14
relay
B136 21
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
turned to ON: ON
EGR solenoid valve
Signal A+ B134 8 10 13 12 14
Signal A B134 9 10 13 12 14
Signal B+ B134 10 10 13 12 14
Signal B B134 20 10 13 12 14
EN-05288
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H6DO)(diag)-18
Accelerator pedal
position sensor
Main sen-
sor signal
B135 23
Fully closed: 1
Fully opened: 3.6
Fully closed: 1
Fully opened: 3.3

Main
power
supply
B135 21 5 5
GND
(main sen-
sor)
B135 29 0 0
Sub sen-
sor signal
B135 31
Fully closed: 1
Fully opened: 3.7
Fully closed: 1
Fully opened: 3.3

Sub power
supply
B135 22 5 5
GND
(sub sen-
sor)
B135 30 0 0
Engine coolant temperature sen-
sor
B134 34 1.0 1.4 1.0 1.4
After engine is warmed-
up.
Starter switch B136 32 0 0 Cranking: 8 14
Starter relay B136 20
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14

A/C switch B136 24
ON: 10 13
OFF: 0
ON: 12 14
OFF: 0

A/C lock sensor B135 14 Duty waveform Duty waveform
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14

Neutral position switch B136 31
ON: 0
OFF: 120.5
Switch is ON when
select lever is shifted
into P or N range.
Delivery (test) mode connector B135 27 12 14 12 14 When connected: 0
Knock sensor 1
Signal B134 15 2.4 2.4
Shield B134 25 0 0
Knock sensor 2
Signal B134 16 2.4 2.4
Shield B134 25 0 0
Ignition switch OFF: 10
13
Control module power supply
B135 2 10 13 12 14
B134 7 10 13 12 14
Sensor power supply B134 19 5 5
Ignition control
#1 B137 18 0 0 14 Waveform
#2 B137 19 0 0 14 Waveform
#3 B137 20 0 0 14 Waveform
#4 B137 21 0 0 14 Waveform
#5 B137 22 0 0 14 Waveform
#6 B137 23 0 0 14 Waveform
Fuel injector
#1 B137 8 10 13 1 14 Waveform
#2 B137 9 10 13 1 14 Waveform
#3 B137 10 10 13 1 14 Waveform
#4 B137 11 10 13 1 14 Waveform
#5 B137 12 10 13 1 14 Waveform
#6 B137 13 10 13 1 14 Waveform
Contents
Connec-
tor No.
Termi-
nal No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
EN(H6DO)(diag)-19
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 12 14

Radiator fan control B136 18
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 12 14

Radiator fan control power supply B136 29
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 12 14

Self-shutoff control B136 23 0 0
Light ON: 1 or less
Light OFF: 10 14
Purge control solenoid valve B137 29
ON: 1 or less
OFF: 10 13
ON: 1 or less
OFF: 12 14

Power steering switch B134 33
ON: 1 or less
OFF: 10 13
ON: 1 or less
OFF: 12 14

Manifold absolute pressure sen-
sor
B134 6 3.5 4.8 1.1 1.9
Air flow sensor
Signal B135 26 0.74 0.3 4.5
Shield B135 35 0 0
GND B135 34 0 0
Intake air temperature sensor B135 18 3.15 3.33 3.15 3.33
Intake air temperature:
25C (77F)
Front oxygen (A/F)
sensor RH
Signal (+) B135 9 2.8 3.2 2.8 3.2
Signal () B135 8 2.4 2.7 2.4 2.7
Shield B135 1 0 0
Front oxygen (A/F)
sensor heater RH
Signal 1 B136 3 12 14 Waveform
Front oxygen (A/F)
sensor LH
Signal (+) B135 11 2.8 3.2 2.8 3.2
Signal () B135 10 2.4 2.7 2.4 2.7
Shield B135 1 0 0
Front oxygen (A/F)
sensor heater LH
Rear oxygen sensor
RH
Signal B135 4 0 0 0.9
Shield B135 1 0 0
Rear oxygen sensor heater RH
signal
B136 4 12 14 Waveform
Rear oxygen sensor
LH
Signal B135 15 0 0 0.9
Shield B135 1 0 0
Rear oxygen sensor heater LH
signal
B136 5 12 14 Waveform
Immobilizer communication 1 B136 26 10 10
Immobilizer communication 2 B136 34 10 10
Fuel pump control
unit
Signal 1 B135 33 0 12 14
Signal 2 B136 12 0 0 or 5
When brake pedal is
depressed: 0
When brake pedal is
released: 10 13
When brake pedal is
depressed: 0
When brake pedal is
released: 12 14

When brake pedal is
depressed: 10 13
When brake pedal is
released: 0
When brake pedal is
depressed: 12 14
When brake pedal is
released: 0

Contents
Connec-
tor No.
Termi-
nal No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
EN(H6DO)(diag)-20
Cruise control command switch B135 24
ing: 3.5 4.5
When operating RES/
ACC: 2.5 3.5
When operating SET/
COAST: 0.5 1.5
When operating can-
cel: 0 0.5
ing: 3.5 4.5
When operating RES/
ACC: 2.5 3.5
When operating SET/
COAST: 0.5 1.5
When operating can-
cel: 0 0.5

ON: 0
OFF: 5
ON: 0
OFF: 5

Oil flow control sole-
noid valve RH
Signal (+) B137 17 0 0.6
Signal () B137 16 0 0
Oil flow control sole-
noid valve LH
Signal (+) B137 15 0 0.6
Signal () B137 14 0 0
Oil switching sole-
noid valve RH
Signal (+) B137 25 0 1.9
Signal () B137 24 0 0
Oil switching sole-
noid valve LH
Signal (+) B137 31 0 1.9
Signal () B137 30 0 0
Oil temperature sensor signal B134 23 1.0 1.4 1.0 1.4
After engine is warmed-
up.
pressure switch RH
B134 31 0 0
pressure switch LH
B134 32 0 0
Generator control B136 10 0 6.5 0 6.5
SSM communication line B136 16 1 or less 4 or more 1 or less 4 or more
GND (sensor) B135 30 0 0
GND (ignition sys-
tem)
Ignition 1 B137 26 0 0
Ignition 2 B137 6 0 0
GND
Engine 1 B134 5 0 0
Engine 2 B137 7 0 0
Engine 3 B137 2 0 0
Engine 4 B137 1 0 0
Engine 5 B137 3 0 0
Engine 6 B134 3 0 0
Body B136 6 0 0
Sensor GND (engine side) B134 29 0 0
Fuel tank pressure sensor B135 32 2.3 2.7
Pressure control solenoid valve 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

Ambient temperature:
25C (77F)
CAN communication (+) B136 27 2.0 4.5 2.0 4.5 Waveform
CAN communication () B136 35 0.5 3.0 0.5 3.0 Waveform
Contents
Connec-
tor No.
Termi-
nal No.
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON
(idling)
EN(H6DO)(diag)-21
EN-05357
ONE CRANK ROTATION
5V
10ms
0
EN-05358
ONE CAM ROTATION
ONE CAM ROTATION
LH
5V
40ms
0
RH
0
EN(H6DO)(diag)-22
JOINT
CONNECTOR
2 1 3 4
DELIVERY
(TEST) MODE
CONNECTOR
A
C
C
E
L
E
R
A
T
O
R

P
E
D
A
L

P
O
S
I
T
I
O
N

S
E
N
S
O
R
JOINT
CONNECTOR
GENERATOR
STARTER
RELAY
IGNITION SWITCH
STARTER MOTOR
FUEL PUMP
FUEL PUMP
CONTROL UNIT
FUEL
PUMP
RELAY
POWER STEERING
OIL PRESSURE
SWITCH
C16
C6
B21
B29
B22
B30
B31
B27
B23
M/B FUSE No. 13
M/B FUSE No. 11
F/B FUSE No. 4
F/B FUSE No. 21
F/B FUSE No. 12
TCM
DATA LINK
CONNECTOR
INHIBITOR
RELAY
C32
B5
B19
C12
C10
C31
A33
B33
C20
EN-05644
10
EN(H6DO)(diag)-23
EN-05645
D18
D6
C11
C22
D23
D26
C1
C21
C23
B2
D29
A21
A11
A22
A7
COMBINATION METER
TACHO-
METER
M
I
C
R
O

C
O
M
P
U
T
E
R
MALFUNCTION
INDICATOR LIGHT
C
A
N
T
R
A
N
S
C
E
I
V
E
R

&
R
E
C
E
I
V
E
R
POWER
SUPPLY
CIRCUIT I/F
ELECTRONIC
THROTTLE CONTROL
RELAY
MAIN
RELAY
RELAY
BLOCK
D19
D20
D21
D22
5 6
SBF No. 5
SBF No. 7
CAMSHAFT POSITION
SENSOR RH
CAMSHAFT POSITION
SENSOR LH
PURGE CONTROL
SOLENOID VALVE
F/B FUSE No. 5
F/B FUSE No. 7
IGNITION
COIL No. 1
B
O
D
Y

I
N
T
E
G
R
A
T
E
D

U
N
I
T
(
C
A
N
C
O
M
M
U
N
I
C
A
T
I
O
N
)
C17
DRAIN VALVE
C28 PRESSURE CONTROL
SOLENOID VALVE
MAIN
RELAY2
I/F
IGNITION
COIL No. 2
IGNITION
COIL No. 3
IGNITION
COIL No. 4
IGNITION
COIL No. 5
IGNITION
COIL No. 6
ENGINE
COOLANT
TEMPER-
ATURE
GAUGE
EN(H6DO)(diag)-24
EN-05646
A18
D11
D10
D9
D8
D12
D13
A23
A34
A29
A6
A19
D4
A28
D5
6 8
6
FUEL INJECTOR No. 1
FUEL INJECTOR No. 2
FUEL INJECTOR No. 3
FUEL INJECTOR No. 4
FUEL INJECTOR No. 5
FUEL INJECTOR No. 6
4
OIL
TEMPERATURE
SENSOR
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
ELECTRONIC
THROTTLE
CONTROL
ENGINE
COOLANT
TEMPERATURE
SENSOR
EGR VALVE
A10
A20
A9
A8
7
EN(H6DO)(diag)-25
EN-05647
A32
B6
B11
B10
B9
B8
B1
B35
B7
B26
B34
B18
B32
C3
B15
B4
C5
C4
C2
A15
A16
A25
A24
A14
A13
D25
D24
D31
D30
D16
D17
D14
D15
A31
5
2
3
6
MASS
AIR FLOW &
INTAKE AIR
TEMPER-
ATURE
SENSOR
FRONT
OXYGEN
(A/F)
SENSOR LH
FRONT
OXYGEN
(A/F)
SENSOR RH
REAR
OXYGEN
SENSOR
LH
9
REAR
OXYGEN
SENSOR
RH
8
FUEL TANK
PRESSURE
SENSOR
1 10
VVL DIAGNOSIS
OIL PRESSURE
SWITCH LH
VVL DIAGNOSIS
OIL PRESSURE
SWITCH RH
OIL FLOW
CONTROL
SOLENOID VALVE LH
OIL FLOW
CONTROL
SOLENOID VALVE RH
OIL SWITCHING
SOLENOID VALVE LH
OIL SWITCHING
SOLENOID VALVE RH
CRANKSHAFT
POSITION SENSOR
KNOCK SENSOR
No. 1
KNOCK SENSOR
No. 2
EN(H6DO)(diag)-26
EN-05648
C24
C33
C9
A3
D5
D7
D3
D1
D2
B14
C26
B28
B12
B24
C35
C18
C29
C27
C34
B20
B17
7 9
STOP LIGHT SWITCH
BRAKE SWITCH
(IMMOBILIZER)
(CAN COMMUNICATION)
RADIATOR FAN
CONTROL UNIT
MAIN FAN RELAY
FUEL TEMPERATURE SENSOR
ENGINE GROUND
A/C LOCK SENSOR
A/C RELAY
A/C PRESSURE SWITCH
AUTO A/C CONTROL MODULE
EN(H6DO)(diag)-27
Engine load
17.9 38.8(%): Idling
16.6 33.7(%): 2,500 rpm racing
EN(H6DO)(diag)-28
Data Link Connector
A: NOTE
CAUTION:
1 2 3 4 5 7 6 8
9 10 11 12 13 15 14 16
EN-04893
1 Blank 9 Blank
2 Blank 10 Blank
3 Blank 11 Blank
4 Ground 12 Blank
5 Ground 13 Blank
6 CAN communication (+) 14 CAN communication ()
EN(H6DO)(diag)-29
General Scan Tool
A: OPERATION
by SAE J1978.
freeze frame data.
data
DTC
(4) MODE $04: Clear/Reset emission-related di-
agnostic information
(5) MODE $06: Request on-board monitoring test
results for intermittently monitored systems
(6) MODE $07: Request on-board monitoring test
results for continuously monitored systems
Read out the data according to repair proce-
dures. (For detailed operation procedure, refer
to the general scan tool instruction manual.)
NOTE:
nostic Trouble Code (DTC). <Ref. to EN(H6DO)(di-
EN-02533
EN(H6DO)(diag)-30
General Scan Tool
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)
ertrain system.
$01 Number of emission-related powertrain DTC and malfunction indicator light status ON/OFF
$05 Engine coolant temperature C or F
$06 Short term fuel trim (Bank 1) %
$07 Long term fuel trim (Bank 1) %
$10 Air flow rate of manifold absolute pressure sensor g/sec
$11 Throttle valve opening angle %
$15 Oxygen sensor output voltage (Bank 1 Sensor 2) V
$15 Oxygen sensor compensation (Bank 1 Sensor 2) %
$1C On-board diagnostic system
$21 Travel distance after the malfunction indicator light illuminates km
$24 Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (bank 1) V and %
$28 Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (bank 2) V and %
$2C Target EGR %
$2D EGR deviation %
$2F Fuel level %
$34 A/F sensor lambda value (Bank 1 Sensor 1)
$34 A/F sensor current value (Bank 1 Sensor 1) mA
$38 A/F sensor lambda value (Bank 2 Sensor 1)
$38 A/F sensor current value (Bank 2 Sensor 1) mA
$3C Catalyst temperature #1 C
$3D Catalyst temperature #2 C
$43 Absolute load %
EN(H6DO)(diag)-31
General Scan Tool
NOTE:
$4D Engine operating time while malfunction indicator light lit min
$51 Fuel used
EN(H6DO)(diag)-32
General Scan Tool
NOTE:
ertrain DTC. <Ref. to EN(H6DO)(diag)-84, List of Diagnostic Trouble Code (DTC).>
$02 DTC that caused the freeze frame data storage required by CARB
$0D Vehicle speed km/h
$10 Air flow rate of manifold absolute pressure sensor g/sec
$11 Throttle valve opening angle %
$13 Air fuel ratio sensor
$1C On-board diagnostic system
$2C Target EGR %
$2D EGR deviation %
$2F Fuel level %
$43 Absolute load %
EN(H6DO)(diag)-33
General Scan Tool
information).
NOTE:
mation (MODE $04).
6. MODE $06
$01
$81 $0A
A/F sensor conduction abnormal (Bank 1 Sensor 1) $82 $8D
$83 $14
$84 $1E
$85 $1E
$02
$87 $0B
$88 $0B
$07 $0B
$A5 $0B
$05 $10
$06 $10
$05
$81 $0A
A/F sensor conduction abnormal (Bank 2 Sensor 1) $82 $8D
$83 $14
$84 $1E
$85 $1E
$06
$87 $0B
$88 $0B
$07 $0B
$A5 $0B
$05 $10
$06 $10
$21 $89 $20 Catalyst degradation diagnosis (Bank 1)
$31 $8A $FD EGR system diagnosis
$39 $93 $FE Evaporative emission control system (Cap off)
$3B
$94 $FE
$95 $FE
$3C
$96 $FE
$97 $FE
$41
$99 $24
$9A $24
$9B $14 A/F sensor heater characteristic abnormal (Bank 1 Sensor 1)
$42
$9C $24
$9D $24
EN(H6DO)(diag)-34
General Scan Tool
7. MODE $07
8. MODE $09
Refer to the data of vehicle specification (V.I.N., calibration ID, diagnosis frequency, etc.).
$45
$99 $24
$9A $24
$9B $14 A/F sensor heater characteristic abnormal (Bank 2 Sensor 1)
$46
$9C $24
$9D $24
$A1
$0B $24
$0C $24
$A2
$0B $24
$0C $24
$A3
$0B $24
$0C $24
$A4
$0B $24
$0C $24
$A5
$0B $24
$0C $24
$A6
$1B $24
$1C $24
$A7
$1B $24
$1C $24
EN(H6DO)(diag)-35
A: OPERATION
MONITOR
EN(H6DO)(diag)-7, PREPARATION TOOL, Gen-
eral Description.>
Monitor).
NOTE:
drivers side).
CAUTION:
Monitor.
NOTE:
mation about how to indicate DTC. <Ref. to
Code (DTC).>
mation about how to indicate DTC. <Ref. to
Code (DTC).>
EN-05692
EN-02533
EN(H6DO)(diag)-36
Contents Display
Unit of
measure
Note (at idling)
Engine load Engine Load % 2.4%
85C or 185F (After
engine is warmed-up.)
A/F correction 1 A/F Compensation #1 % 10% +10%
A/F learning 1 A/F Learning #1 % 10% +10%
A/F correction 2 A/F Compensation #2 % 10% +10%
A/F learning 2 A/F Learning #2 % 10% +10%
mmHg, kPa,
inHg or psig
210 mmHg, 28 kPa,
8.3 inHg or 4.1 psig
600 800 rpm (After
Meter vehicle speed signal Vehicle Speed
km/h or
MPH
0 km/h or 0 MPH
Intake air temperature signal Intake Air Temp. C or F (Ambient air temperature)
2.5 g/s 5.0 g/s or
0.31 lb/m 0.71 lb/m
Throttle opening angle signal Throttle Opening Angle % 2%
Front oxygen sensor voltage value 1
Front oxygen sensor
voltage value 1
V 0.900 V
Front oxygen sensor voltage value 2
Front oxygen sensor
voltage value 2
V 0.900 V
Mass air flow voltage Air Flow Sensor Voltage V 1.2 1.3 V
Injection 1 pulse width Injection 1 pulse width ms 2.5 ms 3.5 ms
Injection 2 pulse width Injection 2 pulse width ms 2.5 ms 3.5 ms
Atmospheric pressure signal Atmosphere pressure
mmHg, kPa,
inHg or psig
(Atmosphere pressure)
mmHg, kPa,
inHg or psig
(Intake manifold absolute
pressure atmosphere
pressure)
Ignition learning value Learned Ignition Timing deg +0.0 deg
Acceleration opening angle signal Accel. Opening Angle % 0%
Purge control solenoid valve duty ratio CPC duty % 18%
Fuel pump duty Fuel pump duty % 33%
Variable valve timing advance angle amount R
VVT advance angle
amount R
deg +0 deg +1 deg
Variable valve timing advance angle amount L
VVT advance angle
amount L
deg +0 deg +1 deg
Oil flow control solenoid valve duty R OCV duty R % 9.4%
Oil flow control solenoid valve duty L OCV duty L % 9.4%
Oil flow control solenoid valve current R OCV current R mA 64 mA
Oil flow control solenoid valve current L OCV current L mA 64 mA
EN(H6DO)(diag)-37
Front oxygen (A/F) sensor current value 1 A/F Sensor #1 Current mA 0.0 mA
Front oxygen (A/F) sensor current value 2 A/F Sensor #2 Current mA 0.0 mA
Front oxygen (A/F) sensor resistance value 1
A/F Sensor #1 Resis-
tance
31
Front oxygen (A/F) sensor resistance value 2
A/F Sensor #2 Resis-
tance
31
Front oxygen (A/F) sensor output lambda 1
A/F sensor output
lambda 1
1.01
Front oxygen (A/F) sensor output lambda 2
A/F sensor output
lambda 2
1.01
A/F correction 3 A/F Correction #3 % 0% 1%
Throttle motor duty Throttle Motor Duty % 20% +20%
Throttle power supply voltage Throttle Motor Voltage V (Battery voltage)
Sub throttle sensor voltage Sub-throttle Sensor V 1.4 V 1.5 V
Main throttle sensor voltage Main-throttle Sensor V 0.62 V 0.70 V
Sub accelerator sensor voltage Sub-accelerator Sensor V 1.0 V 1.2 V
Main accelerator sensor voltage Main-accelerator Sensor V 0.9 V 1.1 V
Memorized Cruise
Speed
km/h or
MPH
0 km/h or 0 MPH
A/F correction 4 A/F Correction #4 % 1% 1%
Fuel level sensor resistance Fuel level resistance 4 96
Engine oil temperature Oil Temperature C or F
85C or 185F (After
Oil switching solenoid valve duty R OSV Duty R % 18.4%
Oil switching solenoid valve duty L OSV Duty L % 18.8%
Oil switching solenoid valve current R OSV Current R mA 192 mA
Oil switching solenoid valve current L OSV Current L mA 192 mA
Knock sensor correction Knock Correction deg 0 deg
AT/MT identification AT Vehicle ID Signal OFF
System operation check mode D-check Require Flag OFF
Delivery (test) mode terminal
Delivery Mode Connec-
tor (Test Mode Connec-
tor)
OFF
Neutral position switch signal Neutral SW Neutral
Idle switch signal Soft idle SW At idle
Ignition switch signal Ignition SW ON input
Power steering switch signal P/S Switch OFF input (when OFF)
Air conditioning switch signal A/C SW OFF input (when OFF)
Front oxygen monitor 1 Front oxygen monitor 1 Rich, Lean
Front oxygen monitor 2 Front oxygen monitor 2 Rich, Lean
Knocking signal Knock Signal None
Crankshaft position sensor signal Crankshaft angle signal Provided
Contents Display
Unit of
measure
Note (at idling)
EN(H6DO)(diag)-38
NOTE:
Camshaft position sensor signal Camshaft angle signal Provided
Rear defogger switch signal Rear Defogger SW OFF input (when OFF)
Blower fan switch signal Blower fan SW OFF input (when OFF)
Light switch signal Light SW OFF input (when OFF)
A/C middle pressure switch signal A/C middle pressure SW
OFF input (when air con-
ditioner is OFF)
A/C compressor relay signal
A/C compressor relay
output

OFF output (when air
conditioner is OFF)
Variable valve lift diagnosis oil pressure switch signal 1 Oil Pressure SW1 ON
Variable valve lift diagnosis oil pressure switch signal 2 Oil Pressure SW2 ON
AT coordinate retard angle demand signal
AT coordinate retard
angle demand
None
AT coordinate fuel cut demand signal
AT coordinate fuel cut
demand
None
Vehicle dynamics control (VDC) torque down prohibition
output
VDC torque down prohi-
bition output
Permission
Vehicle dynamics control (VDC) torque down demand
VDC torque down
demand
None
AT cooperative permission signal
Torque Control Permis-
sion Signal
Permission
Electronic throttle control motor relay signal ETC Motor Relay ON
Stop light switch signal Stop light SW OFF (when brake is OFF)
SET/COAST switch signal SET/CST SW
OFF (when levers are not
operated)
RESUME/ACCEL switch signal RES/ACC SW
operated)
Brake switch signal Brake SW OFF (when brake is OFF)
Main switch signal Main SW
operated)
Body integrated unit data reception Body Int. Unit Data ON
Body integrated unit counter update Body Int. Unit Count ON
Cruise control cancel switch signal CC Cancel SW
operated)
Malfunction indicator light flag MIL Lit Flag Light OFF
Radiator fan output Radiator fan output %
0%
(Water temperature 90C
(194F) when air condi-
tioner is OFF)
Fuel temperature signal Fuel Temp C or F +28C or +82F
SI drive mode SI Drive mode I, S or S#
mmHg, kPa,
inHg or psig
7.5 mmHg, 1 kPa,
0.3 inHg or 0.14 psi
Drain valve signal Vent. Solenoid Valve OFF output (when OFF)
No. of EGR steps No. of EGR Steps STEP 0 STEP
Variable valve lift mode VVL Lift Mode 1
A/C lock signal A/C lock signal OFF input
Pressure control solenoid valve signal PCV Solenoid Valve OFF output (when OFF)
Clutch switch signal Clutch SW OFF (when clutch is OFF)
Contents Display
Unit of
measure
Note (at idling)
EN(H6DO)(diag)-39
Contents Display
Referential value
(at idling)
Unit of
measure
Number of diagnosis code Number of Diag. Code: 0
Monitoring test of misfire Misfire monitoring (Supp) YES
Monitoring test of misfire Misfire monitoring (Rdy) YES
Fuel System Monitoring
(Supp)
YES
Fuel System Monitoring
(Rdy)
YES
(Supp)
YES
(Rdy)
YES
Test of catalyst
Catalyst Diagnosis
(Supp)
YES
Evaporative purge sys-
tem (Supp)
YES
tem (Rdy)
NO
(Supp)
NO
(Rdy)
N/A
(Supp)
NO
(Rdy)
N/A
Test of oxygen sensor Oxygen sensor (Supp) YES
Test of oxygen sensor Oxygen sensor (Rdy) NO
Oxygen Heater Diagnosis
(Supp)
YES
Oxygen Heater Diagnosis
(Rdy)
NO
Test of EGR system EGR system (Supp) NO
Test of EGR system EGR system (Rdy) N/A
Air fuel ratio control system for bank 1 Fuel system for Bank 1 Normal CLOSE
Air fuel ratio control system for bank 2 Fuel system for Bank 2 Normal CLOSE
Engine load data Load 21.0 %
Short term fuel trim by front oxygen (A/F) sensor (Bank 1) A/F Compensation #1 17.2 %
Long term fuel trim by front oxygen (A/F) sensor (Bank 1) A/F Learning #1 5.5 %
EN(H6DO)(diag)-40
Short term fuel trim by front oxygen (A/F) sensor (Bank 2) A/F Compensation #2 17.2 %
Long term fuel trim by front oxygen (A/F) sensor (Bank 2) A/F Learning #2 5.5 %
#1 Cylinder ignition timing Ignition Timing #1 16.5
Oxygen sensor (Bank 1 Sensor 2) Oxygen sensor #12 0.1 0.7 V
A/F correction (Bank 1 Sensor 2) Short term fuel trim #12 0.0 %
Oxygen sensor (Bank 2 Sensor 2) Oxygen sensor #22 0.1 0.7 V
A/F correction (Bank 2 Sensor 2) Short term fuel trim #22 0.0 %
On-board diagnostic system OBD System OBD/OBD2
Elapsed time after engine start Time Since Engine Start sec
Driving distance after the malfunction indicator light illu-
minates
Lighted MI lamp History km
A/F lambda signal (Bank 1 Sensor 1) A/F Sensor #11 1.001
A/F sensor output signal (Bank 1 Sensor 1) A/F Sensor #11 2.805 V
A/F lambda signal (Bank 2 Sensor 1) A/F Sensor #21 1.001
A/F sensor output signal (Bank 2 Sensor 1) A/F Sensor #21 2.805 V
Evaporative purge Commanded Evap Purge 0 %
Number of warm ups after DTC clear Number of warm-ups
Travel distance after DTC clear Meter since DTC cleared km
Barometric pressure signal Atmospheric pressure Atmospheric pressure mmHg
Misfire monitoring
(Enable)
YES
Misfire monitoring
(Comp)
NO
(Enable)
YES
(Comp)
NO
(Enable)
YES
(Comp)
NO
Contents Display
Referential value
(at idling)
Unit of
measure
EN(H6DO)(diag)-41
NOTE:
Test of catalyst
Catalyst Diagnosis
(Enable)
YES
Test of catalyst
Catalyst Diagnosis
(Enable)
NO
tem (Enable)
NO
tem (Comp)
NO
(Enable)
N/A
(Comp)
N/A
(Enable)
N/A
(Comp)
N/A
Test of oxygen sensor Oxygen senor (Enable) YES
Test of oxygen sensor Oxygen senor (Comp) NO
Oxygen sensor heater
(Enable)
YES
Oxygen sensor heater
(Comp)
NO
Test of EGR system EGR system (Enable) N/A
Test of EGR system EGR system (Comp) N/A
ECM power voltage Control module voltage 13.789 V
Absolute load Absolute Load Value 22 %
A/F target lambda Target Equivalence Ratio 0.976
Relative throttle opening angle Relative Throttle Pos. 2 %
Ambient temperature Ambient Temperature Ambient air temperature C
Absolute throttle opening angle 2 Absolute Throttle Pos.#2 32 %
Target throttle opening angle Target Throt. Act. Cont. 0 %
Engine operating time while malfunction indicator light lit Time while MIL lighted min
Elapsed time after DTC clear Time since DTC cleared min
Fuel used Type of fuel GAS
Relative accelerator opening angle Relative Accelera. Pos. 0 %
Contents Display
Referential value
(at idling)
Unit of
measure
EN(H6DO)(diag)-42
NOTE:
DTC of freeze frame data Freeze frame data DTC
Engine load data Engine Load %
Intake manifold absolute pressure signal Mani.Absolute Pressure mmHg, kPa, inHg or psig
Ignition timing adv. #1 Ignition timing adv. #1
Intake air temperature Intake Air Temp. C or F
Amount of intake air Mass Air Flow g/s
Throttle opening angle Throttle Opening Angle %
A/F correction value #12 Short term fuel trim #12 %
A/F correction value #22 Short term fuel trim #22 %
On-board diagnostic system OBD System
Elapsed time after engine start Time Since Engine Start sec
EGR deviation EGR Error %
Evaporative purge Commanded Evap Purge %
Fuel tank pressure signal Fuel Tank Pressure mmHg, kPa, inHg or psig
Atmospheric pressure Atmospheric pressure mmHg, kPa, inHg or psig
ECM power voltage Control module voltage V
Absolute load Absolute Load Value %
A/F target lambda Target Equivalence Ratio
Relative throttle opening angle Relative Throttle Pos. %
Ambient temperature Ambient Temperature C or F
Absolute throttle opening angle 2 Absolute Throttle Pos.#2 %
Target throttle opening angle Target Throt. Act. Cont. %
EN(H6DO)(diag)-43
7. V.I.N. REGISTRATION
NOTE:
EN(H6DO)(diag)-44
Code (DTC)
A: OPERATION
MODE)
5) On the Diagnostic Code(s) Display screen,
select the {Temporary Diagnostic Code(s)} or
{Memorized Diagnostic Code(s)}.
NOTE:
MODE)
NOTE:
Refer to the data denoting emission-related power-
train DTC.
NOTE:
Refer to the general scan tool manufacturers oper-
ation manual to access powertrain DTC (MODE
$03).
EN(H6DO)(diag)-45
Inspection Mode
11.Inspection Mode
A: PROCEDURE
When performing the diagnosis not listed in List of Diagnostic Trouble Code (DTC), refer the item on the
drive cycle. <Ref. to EN(H6DO)(diag)-50, Drive Cycle.>
DTC Item Condition
(Bank 1)

(Bank 2)

P0197 Engine Oil Temperature Sensor Low
P0198 Engine Oil Temperature Sensor High
P0230 Fuel Pump Primary Circuit
EN(H6DO)(diag)-46
Inspection Mode
P0400 Exhaust Gas Recirculation Flow
P1570 Antenna
P1572 IMM Circuit Failure (Except Antenna Circuit)
P1578 Meter Failure
DTC Item Condition
EN(H6DO)(diag)-47
Inspection Mode
MODE
10.6 US gal, 4.4 8.8 Imp gal)].
ers.
WARNING:
brakes are applied.
id rack.
wheels.
and vehicle.
P2227 Barometric Pressure Circuit Range/Performance
P2228 Barometric Pressure Circuit Low
P2229 Barometric Pressure Circuit High
DTC Item Condition
(A) Rigid rack
(B) Free roller
EN-00041
(A)
(B)
EN(H6DO)(diag)-48
Inspection Mode
1) After clearing the memory, check for any remain-
ing unresolved trouble data. <Ref. to EN(H6DO)(di-
eral Description.>
Monitor).
NOTE:
drivers side).
CAUTION:
Monitor.
lect the {D Check}.
ton.
NOTE:
this indicates no malfunctions. When engine
control diagnosis is finished, perform the ABS
memory clearance procedure of self-diagnosis
function. <Ref. to ABS(diag)-24, Clear Memory
Mode.>
EN-05692
PI-00201
(A)
EN-02533
EN(H6DO)(diag)-49
Inspection Mode
ble data. <Ref. to EN(H6DO)(diag)-57, Clear Mem-
ory Mode.>
CAUTION:
NOTE:
Ensure the selector lever is placed in P range be-
fore starting.
6) Using the select lever, turn the P position
switch and the N position switch to ON.
ON.
9) Shift the select lever in the D range and drive
the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
clearance procedure of the self-diagnosis system.
10) Using the general scan tool, check for DTC and
NOTE:
<Ref. to EN(H6DO)(diag)-84, List of Diagnostic
PI-00201
(A)
EN-02533
EN(H6DO)(diag)-50
Drive Cycle
12.Drive Cycle
A: PROCEDURE
For the troubleshooting, there are driving patterns described below. 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) Check that the battery voltage is 12 V or more and fuel remains approx. half [20 40 2 (5.3 10.6 US gal,
4.4 8.8 Imp gal)].
2) After performing the diagnostics and clearing the memory, check for any remaining unresolved trouble da-
ta. <Ref. to EN(H6DO)(diag)-57, Clear Memory Mode.>
NOTE:
Perform the diagnosis after warming up the engine except when the engine coolant temperature at starting
is specified.
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(H6DO)(diag)-51
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
engine start is less than 20C
(68F).
*P0128
Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulat-
ing Temperature)

cycle B or C as well.
*P0196 Engine Oil Temperature Sensor Circuit Range/Performance
(77F).
(77F).
*P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off)
(77F).
EN(H6DO)(diag)-52
Drive Cycle
NOTE:
Drive the vehicle at 10 km/h (6 MPH) or faster before diagnosis.
DTC Item Condition
*P0459 Evaporative Emission System Purge Control Valve Circuit High
*P0483 Fan Rationality Check
EN(H6DO)(diag)-53
Drive Cycle
more.
(D) Decelerate the vehicle to 64 km/h
(40 MPH) with throttle fully closed.
(G) Stop the vehicle with throttle fully
closed.
(B) Accelerate the vehicle to 97 km/h
(60 MPH) within 20 seconds.
(E) Drive the vehicle at 64 km/h
(I) Sec.
(C) Drive the vehicle at 97 km/h
(F) Accelerate the vehicle to 97 km/h
(60 MPH) within 10 seconds.
EN-00842
(C)
(H)
(I)
(60) 97
64 (40)
(B)
(A)
(F) (D)
(E)
150 100 50
0
(G)
EN(H6DO)(diag)-54
Drive Cycle
DTC Item Condition
*P0068 MAP/MAF - Throttle Position Correlation
*P0400 Exhaust Gas Recirculation Flow
EN(H6DO)(diag)-55
Drive Cycle
5. DRIVE CYCLE D
DRIFT DIAGNOSIS
more.
STUCK DIAGNOSIS
2) Perform the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-57, Clear Memory Mode.>
3) Drive for approximately 50 2 (13.2 US gal, 11 Imp gal) of fuel.
NOTE:
tery terminals.)
6. DRIVE CYCLE E
3) Drive for approximately 30 2 (7.9 US gal, 6.6 Imp gal) of fuel.
NOTE:
tery terminals.)
7. DRIVE CYCLE F
2) Start the engine, and warm it up until engine coolant temperature reaches to 95C (203F) or more.
NOTE:
terminals.)
DTC Item Condition
DTC Item Condition
DTC Item Condition
EN(H6DO)(diag)-56
Drive Cycle
8. DRIVE CYCLE H
ature. <Ref. to EN(H6DO)(diag)-36, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERA-
Condition:
NOTE:
DTC Item Condition
*
EN(H6DO)(diag)-57
Clear Memory Mode
A: OPERATION
MODE)
tion switch to OFF.
NOTE:
MODE)
6) When the Clear Diagnostic Code? is shown
on the screen, click the [Yes] button.
OFF are shown on the display screen, click the
[OK] button.
NOTE:
For procedures clearing memory using the general
scan tool, refer to the general scan tool operation
manual.
NOTE:
EN(H6DO)(diag)-58
Check Mode
A: OPERATION
eral Description.>
Monitor).
NOTE:
drivers side).
CAUTION:
8) Turn the ignition switch to ON (engine OFF), and run
the PC application help for Subaru Select Monitor.
screen, select the {Actuator ON/OFF Operation}.
14) Select the desired actuator on the Actuator
ON/OFF Operation display screen and click the
[Next] button.
play will then return to the Actuator ON/OFF Oper-
ation screen.
table.
NOTE:
functional.
EN-05692
(A)
EN-02424
EN-02533
Description Display
Compulsory fuel pump relay oper-
ation check
Fuel Pump
Compulsory purge control sole-
noid valve operation check
CPC Solenoid
Compulsory radiator fan relay
operation check
Radiator Fan Relay
operation check
A/C Compressor Relay
Display
EGR Solenoid
ASV Solenoid
PCV Solenoid Valve
Vent Solenoid Valve
FICD Solenoid
AAI Solenoid
Wastegate solenoid
Exhaust Bypass Valve Control Permit Flag
Secondary Air Combination Valve 1
EN(H6DO)(diag)-59
Mode
A: OPERATION
eral Description.>
Monitor).
NOTE:
drivers side).
CAUTION:
run the Application for Subaru Select Monitor.
1. FUEL PUMP CONTROL
(OFF OPERATION)
CAUTION:
the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-
57, OPERATION, Clear Memory Mode.>
screen.
NOTE:
2. FUEL PUMP CONTROL
(ON/OFF OPERATION)
CAUTION:
Control screen.
NOTE:
EN-05692
EN-02097
Display
Security System
Fuel Pump Control
Idle Speed Control
Injector Control
EGR Valve Control
EN(H6DO)(diag)-60
CAUTION:
screen, select the {Idling Ignition Timing Fixed}.
NOTE:
CAUTION:
screen, select the {Idle Speed Control}.
2000 rpm, in increments of 50 rpm. However, the
vary depending on the vehicle or auxiliary load con-
dition.
NOTE:
5. INJECTOR CONTROL (INJECTION STOP
MODE)
CAUTION:
trol screen.
NOTE:
6. INJECTOR CONTROL (INJECTION
QUANTITY CONTROL)
CAUTION:
increments of 1%.
NOTE:
EN(H6DO)(diag)-61
7. EGR VALVE CONTROL
CAUTION:
select the {EGR Valve Control}.
3) In the EGR Valve Control screen, click the [ ]
button or the [ ] button to change the setting val-
ues, then click the [OK] button.
Setting is possible in 1 STEP increments. However,
the number of STEPs that can actually be con-
trolled will vary depending on the vehicle.
4) Click the [Cancel] button to end the EGR valve
NOTE:
EN(H6DO)(diag)-62
A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H6DO)(diag)-63, ACTIVATION OF MALFUNCTION INDICATOR LIGHT,
2. Malfunction indicator light does not come on. <Ref. to EN(H6DO)(diag)-64, MALFUNCTION INDICATOR LIGHT DOES NOT
3. Malfunction indicator light does not go off. <Ref. to EN(H6DO)(diag)-66, MALFUNCTION INDICATOR LIGHT DOES NOT GO
OFF, Malfunction Indicator Light.>
4. Malfunction indicator light does not blink. <Ref. to EN(H6DO)(diag)-67, MALFUNCTION INDICATOR LIGHT DOES NOT
5. Malfunction indicator light remains blinking. <Ref. to EN(H6DO)(diag)-69, MALFUNCTION INDICATOR LIGHT REMAINS
EN(H6DO)(diag)-63
INDICATOR LIGHT
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(H6DO)(diag)-64, MALFUNCTION INDICA-
TOR LIGHT DOES NOT COME ON, Malfunction
Indicator Light.>
luminates.
sis)
(1) No faulty
(2) Trouble occurs
(3) ON
(4) OFF
(6) Engine start
EN-03112
CHECK
ENGINE
(A)
EN-01679
(1)
(2)
(5)
(6)
(3)
(4)
(3)
(4)
(1) ON
(2) OFF
(4) 1 second
EN-01681
(2)
(1)
(4)
(3)
EN(H6DO)(diag)-64
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
1 3
4 5 6
2 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
2 1 3 4 6 7 8 9
22 21 20 19 18 17 16 15 14 13 12 11
5
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
SBF-6 MAIN SBF
3 1
B72
BATTERY
E
No.5
i10
3
i3
B38
8
1
6
B136
1
1
ECM
B72 B136 i10
B38
10
EN-05649
IGNITION
SWITCH
COMBINATION
METER
EN(H6DO)(diag)-65
Step Check Yes No
light illuminate?
Repair poor con-
tact of the ECM
connector.
Go to step 3.
connected?
Replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
Repair the connec-
tion of ECM con-
nector.
combination meter.
ECM connector and combination meter con-
nector.
(B136) No. 11 (i10) No. 16:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and combi-
nation meter con-
nector
Poor contact of
coupling connector
nector.
Repair the poor
contact of combi-
nation meter con-
nector.
Go to step 6.
NECTOR.
bination meter cir-
IDI-19, Combina-
tion Meter.>
Check the follow-
ing item and repair
if necessary.
NOTE:
Blown out of fuse
(No. 5)
Open or short
circuit of harness
between fuse (No.
5) and battery ter-
minal
Poor contact of
nector
EN(H6DO)(diag)-66
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
Step Check Yes No
light illuminate?
Repair the short
circuit of harness
between combina-
tion meter and
ECM connector.
Replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
1 3
4 5 6
2 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
2 1 3 4 6 7 8 9
22 21 20 19 18 17 16 15 14 13 12 11
5
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
SBF-6 MAIN SBF
3 1
B72
BATTERY
E
No.5
i10
3
i3
B38
8
1
6
B136
1
1
ECM
B72 B136 i10
B38
10
EN-05649
IGNITION
SWITCH
COMBINATION
METER
EN(H6DO)(diag)-67
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
3
B72
B75 B76
i10
B135 B:
SBF-6
1
C
1
1
C
6
B
2
7
ECM
B72
8
MAIN SBF No.5
*
1 1
B75
1
2
1
2
1
6
i3
B38
E
3
B136 C:
B135
B136
B:
C:
1 3
4 5 6
2
i10 B38
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
1 2 3 4
5 6 7 8
B122
*
*
ARRANGEMENT
B122
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
EN-05650
BATTERY
IGNITION
SWITCH
COMBINATION
METER
EN(H6DO)(diag)-68
Step Check Yes No
CATOR LIGHT.
tor.
light illuminate?
Go to step 2. Repair the mal-
function indicator
light circuit. <Ref.
to
EN(H6DO)(diag)-
64, MALFUNC-
TION INDICATOR
LIGHT DOES NOT
COME ON, Mal-
function Indicator
Light.>
light illuminate?
Repair the short
circuit of harness
between combina-
tion meter and
ECM connector.
Go to step 3.
3 CHECK HARNESS BETWEEN DELIVERY
(TEST) MODE CONNECTOR AND ECM CON-
NECTOR.
delivery (test) mode connector and ECM con-
nector.
(B76) No. 1 (B136) No. 6
and connector.
NOTE:
the following item:
Open circuit of
harness between
delivery (test)
mode connector
and chassis
ground
connector?
Repair poor con-
tact of the ECM
connector.
Go to step 5.
circuit of harness
between ECM and
delivery (test)
mode connector.
connector?
Repair poor con-
tact of the ECM
connector.
Replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-69
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
3
B72
B75 B76
i10
B135 B:
SBF-6
1
C
1
1
C
6
B
2
7
ECM
B72
8
MAIN SBF No.5
*
1 1
B75
1
2
1
2
1
6
i3
B38
E
3
B136 C:
B135
B136
B:
C:
1 3
4 5 6
2
i10 B38
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
1 2 3 4
5 6 7 8
B122
*
*
ARRANGEMENT
B122
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
EN-05650
BATTERY
IGNITION
SWITCH
COMBINATION
METER
EN(H6DO)(diag)-70
Step Check Yes No
TOR.
tor.
light blink?
NOTE:
Malfunction indica-
tor light blinks
when delivery
(test) mode con-
nector is connect-
ed.
2 CHECK HARNESS BETWEEN ECM CON-
NECTOR AND CHASSIS GROUND TERMI-
NAL.
circuit of harness
between ECM and
delivery (test)
mode connector.
Replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-71
A: PROCEDURE
1. Check of the fuel amount
2. Inspection of starter motor circuit. <Ref. to EN(H6DO)(diag)-72, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
3. Inspection of ECM power supply and ground line. <Ref. to EN(H6DO)(diag)-76, 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(H6DO)(diag)-78, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
5. Inspection of fuel pump circuit <Ref. to EN(H6DO)(diag)-81, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
6. Inspection of fuel indicator circuit <Ref. to EN(H6DO)(diag)-82, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
EN(H6DO)(diag)-72
CAUTION:
After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-57,
OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-45, PROCEDURE,
Inspection Mode.>.
WIRING DIAGRAM:
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
3
2
3
1
2
0
N
o
.
2
1
B225
MAIN SBF SBF-6
E
1
5
1
3
1
6
1
4
ECM
B136
TCM
B55
B72
B14
M
2
3
B225 B72 B136
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 39 40
37
38
1 2 9
3 4
5 6
7 8
1 3
4 5 6
2
B226
9
1
1
7
1
0
11
EN-05651
B226 B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
2
3 4
8
10
11
7
5
6
1 9
IGNITION
SWITCH
INHIBITOR
RELAY
STARTER
RELAY
STARTER MOTOR
BATTERY
EN(H6DO)(diag)-73
Step Check Yes No
1 CHECK BATTERY.
the battery.
2 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper-
ate?
EN(H6DO)(diag)-44, OPERA-
TION, Read Diagnostic Trouble
Code (DTC).>
Check the appro-
priate DTC using
tic Trouble Code
(DTC). <Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
The circuit has
returned to a nor-
mal condition at this
time. Reproduce
the fault condition,
and reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
TOR.
motor.
3) Place the select lever in P or N range.
5) Measure the voltage between the starter
motor connector and the engine ground.
motor. <Ref. to
SC(H4SO)-6,
Starter.>
Go to step 5.
TOR.
Is the voltage 10 V or more? Repair the open
circuit of the har-
ness between
starter relay con-
nector and starter
motor.
Go to step 6.
switch.
3) Measure the voltage between ignition
ing item and repair
if necessary.
Blown out of fuse
Open or ground
ness between igni-
tion switch
connector and bat-
tery
Measure the resistance between ignition switch
terminals after turning the ignition switch to
START position.
Terminals
No. 2 No. 3:
tion switch. <Ref.
to SL-48,
REPLACEMENT,
Ignition Key Lock.>
EN(H6DO)(diag)-74
LAY.
1) Remove the starter relay.
circuit of harness
between starter
relay connector
and ignition switch
connector.
relay terminals.
Terminals
No. 13 No. 14:
relay.
STARTER RELAY CONNECTOR.
ECM and starter relay connector.
(B136) No. 20 (B225) No. 16:
circuit of harness
between ECM and
starter relay con-
nector.
LAY.
HIBITOR RELAY CONNECTOR.
ECM and inhibitor relay connector.
(B136) No. 31 (B226) No. 7:
(B136) No. 32 (B226) No. 10:
power supply and
ground line. <Ref. to
EN(H6DO)(diag)-
76, CHECK
POWER SUPPLY
AND GROUND
LINE OF ENGINE
CONTROL MOD-
ULE (ECM), Diag-
nostics for Engine
Starting Failure.>
Repair the open
circuit of harness
between ECM and
nector.
13 CHECK INPUT VOLTAGE OF INHIBITOR RE-
LAY.
4) Measure the voltage between inhibitor relay
ing item and repair
if necessary.
Blown out of fuse
Open or ground
ness between igni-
tion switch
connector and
nector
Step Check Yes No
EN(H6DO)(diag)-75
14 CHECK INHIBITOR RELAY.
1) Connect the battery to inhibitor relay termi-
relay terminals.
Terminals
No. 10 No. 11:
Is the resistance less than 1 ? Go to step 15. Replace the inhibi-
tor relay.
RELAY CONNECTOR AND STARTER RE-
LAY CONNECTOR.
inhibitor relay connector and starter relay con-
nector.
(B226) No. 10 (B225) No. 15:
circuit of harness
between TCM and
nector.
Repair the open
circuit of harness
between inhibitor
relay connector
and starter relay
connector.
Step Check Yes No
EN(H6DO)(diag)-76
MODULE (ECM)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
Step Check Yes No
1 CHECK MAIN RELAY.
No. 1 and No. 2.
terminals.
Terminals
No. 3 No. 5:
No. 4 No. 6:
relay. <Ref. to
EN(H6DO)(diag)-
8, Electrical Com-
ponent Location.>
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
SBF-6 MAIN SBF
SBF-7
B72
A
7
B
2
C
2
3
A
3
D
2
D
1
D
7
B
5
B
1
9
No.12 B47
E2
B21
1
2
4
6
5
3
ECM
E
E
3 1
B134
B135
A:
C: B136
D: B137
B:
3
5
3
4
5
2
3 4
1 2
5 6
B47
No.13
A
5
3
6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B72
1 3
4 5 6
2
A: B:
D:
E
SBF-5
D
3
3
7
EN-05652
MAIN RELAY
BATTERY
IGNITION
SWITCH
TO OXYGEN SENSOR
EN(H6DO)(diag)-77
circuit of harness
between ECM con-
nector and engine
grounding termi-
nal.
Measure the voltage between ECM connector
and chassis ground.
of power supply
circuit.
of power supply
circuit.
circuit of harness
between ECM con-
nector and main
relay connector.
2) Connect the connectors to ECM and main
relay.
of harness
between ECM con-
nector and main
relay connector.
of harness of
power supply cir-
cuit.
trol system. <Ref. to
EN(H6DO)(diag)-
78, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Starting
Failure.>
Repair the open or
of harness
between ECM con-
nector and main
relay connector.
Step Check Yes No
EN(H6DO)(diag)-78
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
E34
E45
E31
E32
E46 E33
1
2
3
ECM B137
2
3
1
9
1
8
2
1
2
2
2
0
SBF-7
4 6
B327
E46
E2
B21
E32
1
8
1
4
1
3
1
6
1
7
32 312
E34
32
E45
32
1
5
6
2
6
5
4
4
9
1 1 1
E31
312
E33
312
1 2
B225
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
9
10
1 2
3 4
5 6
7 8
11 12
14
15 16
13
18
19 20
17
22
23 24
21
38
39 40
37
34
35 36
33
30
31 32
29
26
27 28
25
B225
B327
3 4
1 2
5 6
E
MAIN RELAY2
IGNITION COIL
No. 1
RELAY BLOCK
IGNITION COIL
No. 2
IGNITION COIL
No. 3
IGNITION COIL
No. 4
IGNITION COIL
No. 5
IGNITION COIL
No. 6
EN-05653
BATTERY
EN(H6DO)(diag)-79
Step Check Yes No
1 CHECK SPARK PLUG CONDITION.
1) Remove the spark plug. <Ref. to IG(H6DO)-
2) Check the spark plug condition. <Ref. to
IG(H6DO)-5, INSPECTION, Spark Plug.>
Is the spark plug condition nor-
mal?
Go to step 2. Replace the spark
plug.
1) Connect the spark plug to ignition coil.
engine.
4) While opening the throttle valve fully, start
the engine to check if spark occurs at each cyl-
inder.
der?
Check fuel pump
system. <Ref. to
EN(H6DO)(diag)-
81, FUEL PUMP
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
Go to step 3.
NITION COIL AND IGNITOR ASSEMBLY.
ignition coil and ignitor assembly connector and
engine ground.
and connector.
NOTE:
the following item:
Open circuit in
harness between
the ignition coil and
ignitor assembly
and ignition switch
connector
Poor contact of
coupling connector
4 CHECK HARNESS OF IGNITION COIL AND
IGNITOR ASSEMBLY GROUND CIRCUIT.
2) Measure the resistance between the igni-
tion coil and ignitor assembly connector and
engine ground.
(E31) No. 2 (B137) No. 6:
(E32) No. 2 (B137) No. 6:
(E33) No. 2 (B137) No. 6:
(E34) No. 2 (B137) No. 6:
(E45) No. 2 (B137) No. 6:
(E46) No. 2 (B137) No. 6:
(E31) No. 2 (B137) No. 26:
(E32) No. 2 (B137) No. 26:
(E33) No. 2 (B137) No. 26:
(E34) No. 2 (B137) No. 26:
(E45) No. 2 (B137) No. 26:
(E46) No. 2 (B137) No. 26:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ignition coil and ig-
nitor assembly
connector and en-
gine grounding ter-
minal
EN(H6DO)(diag)-80
CONNECTOR.
ECM and ignition coil and ignitor assembly con-
nector.
(B137) No. 18 (E31) No. 1:
(B137) No. 19 (E32) No. 1:
(B137) No. 20 (E33) No. 1:
(B137) No. 21 (E34) No. 1:
(B137) No. 22 (E45) No. 1:
(B137) No. 23 (E46) No. 1:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and ignition
coil and ignitor as-
sembly connector
Poor contact of
coupling connector
CONNECTOR.
ECM connector and engine ground.
Connector & terminal:
more?
ness between
ECM and ignition
coil and ignitor
assembly connec-
tor.
connector?
Repair poor con-
tact of the ECM
connector.
Check the fuel
pump circuit. <Ref.
to
EN(H6DO)(diag)-
81, FUEL PUMP
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
Step Check Yes No
EN(H6DO)(diag)-81
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
Step Check Yes No
PUMP.
NOTE:
EN(H6DO)(diag)-58, Compulsory Valve Opera-
tion Check Mode.>
ating sound?
Check the fuel
injector circuit.
<Ref. to
EN(H6DO)(diag)-
82, FUEL INJEC-
TOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
Display the DTC.
<Ref. to
EN(H6DO)(diag)-
44, OPERATION,
Read Diagnostic
Trouble Code
(DTC).>
E
E
M
1
0
76
56
No.11
B362
R122
B135 B:
B136 C:
R58
7
B
3
3
C
1
2
1 2
985
FUEL PUMP CONTROL UNIT
FUEL PUMP
ECM
BATTERY
FUEL PUMP
RELAY
B362
5
6
7 8
3
4
1 2
R1
B97
1
9
8
2
0
B97
R1
R46
R67
35
R58
2
5
4
6
1
3
B135 B:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
R122
3 4 1 2
5 8 9 10 6 7
B97
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
R67
1 2
3 4 5 6
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
EN-05654
EN(H6DO)(diag)-82
CAUTION:
After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-
57, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-45, PROCE-
DURE, Inspection Mode.>.
WIRING DIAGRAM:
3 4
1 2
5 6
1 2
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B47 B21 B137
E6 E17
E5 E16
E43 E44
1 2
E5
8
4
2
B47
1
2
3
5
4
6
4
8
1 2
E16
1 2
E6
1
0
ECM
SBF-7
B137
9
4
3
4
4
FUEL INJECTOR
No.1
FUEL INJECTOR
No.2
FUEL INJECTOR
No.3
FUEL INJECTOR
No.4
FUEL INJECTOR
No.5
FUEL INJECTOR
No.6
1 2
E17
1 2
E43
1
1
4
5
1
2
4
6
1 2
E44
E
B21
E2
1
3
4
7
EN-05059
BATTERY
MAIN RELAY
EN(H6DO)(diag)-83
Step Check Yes No
TOR.
this check.
ating sound?
Check the fuel
pressure. <Ref. to
ME(H6DO)-26,
INSPECTION,
Fuel Pressure.>
Go to step 2.
JECTOR.
and connector.
NOTE:
the following item:
Open circuit of
harness between
main relay and fuel
injector connector
Poor contact of
main relay connec-
tor
Poor contact of
coupling connector
Poor contact of
fuel injector con-
nector
#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:
#5 (B137) No. 12 (E43) No. 1:
#6 (B137) No. 13 (E44) No. 1:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel in-
jector connector
Poor contact of
coupling connector
more?
ness between
ECM and fuel
injector connector.
injector terminals.
Terminals
No. 1 No. 2:
20 ?
fuel injector.
connector?
Repair poor con-
tact of the ECM
connector.
Inspection using
General Diagnos-
tic Table. <Ref. to
EN(H6DO)(diag)-
356, INSPEC-
TION, General
Diagnostic Table.>
EN(H6DO)(diag)-84
A: LIST
DTC Item Reference
mance (Bank 1)
<Ref. to EN(H6DO)(diag)-92, DTC P0011 INTAKE CAMSHAFT POSITION -
tion Correlation (Bank1)
<Ref. to EN(H6DO)(diag)-93, DTC P0016 CRANKSHAFT POSITION - CAM-
SHAFT POSITION CORRELATION (BANK1), Diagnostic Procedure with
<Ref. to EN(H6DO)(diag)-94, DTC P0018 CRANKSHAFT POSITION - CAM-
SHAFT POSITION CORRELATION (BANK2), Diagnostic Procedure with
mance (Bank 2)
<Ref. to EN(H6DO)(diag)-95, DTC P0021 INTAKE CAMSHAFT POSITION -
<Ref. to EN(H6DO)(diag)-96, DTC P0026 INTAKE VALVE CONTROL SOLE-
<Ref. to EN(H6DO)(diag)-98, DTC P0028 INTAKE VALVE CONTROL SOLE-
Sensor 1)
<Ref. to EN(H6DO)(diag)-100, DTC P0030 HO2S HEATER CONTROL CIR-
Code (DTC).>
(Bank 1 Sensor 1)
CUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
(Bank 1 Sensor 1)
CUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
(Bank 1 Sensor 2)
(Bank 1 Sensor 2)
Sensor 1)
Code (DTC).>
(Bank 2 Sensor 1)
(Bank 2 Sensor 1)
(Bank 2 Sensor 2)
(Bank 2 Sensor 2)
tion
<Ref. to EN(H6DO)(diag)-120, DTC P0068 MAP/MAF - THROTTLE POSI-
TION CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
EN(H6DO)(diag)-85
Low (Bank 1)
<Ref. to EN(H6DO)(diag)-122, DTC P0076 INTAKE VALVE CONTROL
SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic
High (Bank 1)
SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic
Low (Bank 2)
SOLENOID CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic
High (Bank 2)
SOLENOID CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic
Range/Performance
<Ref. to EN(H6DO)(diag)-130, DTC P0101 MASS OR VOLUME AIR FLOW
Input
CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Input
CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H6DO)(diag)-136, DTC P0107 MANIFOLD ABSOLUTE PRES-
SURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Pro-
<Ref. to EN(H6DO)(diag)-138, DTC P0108 MANIFOLD ABSOLUTE PRES-
SURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Pro-
<Ref. to EN(H6DO)(diag)-140, DTC P0111 INTAKE AIR TEMPERATURE
SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with
cuit Low
SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
cuit High
SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Low
<Ref. to EN(H6DO)(diag)-146, DTC P0117 ENGINE COOLANT TEMPERA-
TURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
High
<Ref. to EN(H6DO)(diag)-148, DTC P0118 ENGINE COOLANT TEMPERA-
TURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H6DO)(diag)-150, DTC P0122 THROTTLE/PEDAL POSITION
SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Procedure with Diagnos-
SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Procedure with Diagnos-
<Ref. to EN(H6DO)(diag)-154, DTC P0125 INSUFFICIENT COOLANT
TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Proce-
<Ref. to EN(H6DO)(diag)-155, DTC P0126 INSUFFICIENT ENGINE COOL-
ANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Procedure
DTC Item Reference
EN(H6DO)(diag)-86
<Ref. to EN(H6DO)(diag)-156, DTC P0128 COOLANT THERMOSTAT
(ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULAT-
ING TEMPERATURE), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0131 O2 Sensor Circuit Low Voltage (Bank
1 Sensor 1)
<Ref. to EN(H6DO)(diag)-157, DTC P0131 O2 SENSOR CIRCUIT LOW
ble Code (DTC).>
(Bank 1 Sensor 1)
<Ref. to EN(H6DO)(diag)-159, DTC P0132 O2 SENSOR CIRCUIT HIGH
ble Code (DTC).>
(Bank 1 Sensor 1)
<Ref. to EN(H6DO)(diag)-161, DTC P0133 O2 SENSOR CIRCUIT SLOW
<Ref. to EN(H6DO)(diag)-163, DTC P0134 O2 SENSOR CIRCUIT NO
1 Sensor 2)
ble Code (DTC).>
(Bank 1 Sensor 2)
ble Code (DTC).>
(Bank 1 Sensor 2)
2 Sensor 1)
ble Code (DTC).>
(Bank 2 Sensor 1)
ble Code (DTC).>
(Bank 2 Sensor 1)
2 Sensor 2)
ble Code (DTC).>
(Bank 2 Sensor 2)
ble Code (DTC).>
(Bank 2 Sensor 2)
P0171 System Too Lean (Bank 1) <Ref. to EN(H6DO)(diag)-190, DTC P0171 SYSTEM TOO LEAN (BANK 1),
P0172 System Too Rich (Bank 1) <Ref. to EN(H6DO)(diag)-190, DTC P0172 SYSTEM TOO RICH (BANK 1),
DTC Item Reference
EN(H6DO)(diag)-87
P0174 System Too Lean (Bank 2) <Ref. to EN(H6DO)(diag)-190, DTC P0174 SYSTEM TOO LEAN (BANK 2),
P0175 System Too Rich (Bank 2) <Ref. to EN(H6DO)(diag)-191, DTC P0175 SYSTEM TOO RICH (BANK 2),
Range/Performance
<Ref. to EN(H6DO)(diag)-193, DTC P0181 FUEL TEMPERATURE SEN-
Low Input
SOR A CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
High Input
SOR A CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
<Ref. to EN(H6DO)(diag)-199, DTC P0196 ENGINE OIL TEMPERATURE
SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with
P0197 Engine Oil Temperature Sensor Low <Ref. to EN(H6DO)(diag)-201, DTC P0197 ENGINE OIL TEMPERATURE
SENSOR LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0198 Engine Oil Temperature Sensor High <Ref. to EN(H6DO)(diag)-203, DTC P0198 ENGINE OIL TEMPERATURE
SENSOR HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Procedure with Diagnos-
SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Procedure with Diagnos-
P0230 Fuel Pump Primary Circuit <Ref. to EN(H6DO)(diag)-209, DTC P0230 FUEL PUMP PRIMARY CIR-
CUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0301 Cylinder 1 Misfire Detected <Ref. to EN(H6DO)(diag)-211, DTC P0301 CYLINDER 1 MISFIRE
P0327 Knock Sensor 1 Circuit Low (Bank 1
or Single Sensor)
<Ref. to EN(H6DO)(diag)-219, DTC P0327 KNOCK SENSOR 1 CIRCUIT
LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnos-
P0328 Knock Sensor 1 Circuit High (Bank 1
or Single Sensor)
<Ref. to EN(H6DO)(diag)-221, DTC P0328 KNOCK SENSOR 1 CIRCUIT
HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnos-
P0332 Knock Sensor 2 Circuit Low (Bank 2) <Ref. to EN(H6DO)(diag)-223, DTC P0332 KNOCK SENSOR 2 CIRCUIT
LOW (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0333 Knock Sensor 2 Circuit High (Bank 2) <Ref. to EN(H6DO)(diag)-225, DTC P0333 KNOCK SENSOR 2 CIRCUIT
HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
cuit
<Ref. to EN(H6DO)(diag)-227, DTC P0335 CRANKSHAFT POSITION SEN-
SOR A CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
DTC Item Reference
EN(H6DO)(diag)-88
<Ref. to EN(H6DO)(diag)-229, DTC P0336 CRANKSHAFT POSITION SEN-
<Ref. to EN(H6DO)(diag)-231, DTC P0340 CAMSHAFT POSITION SEN-
SOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure
(Bank 2)
<Ref. to EN(H6DO)(diag)-233, DTC P0345 CAMSHAFT POSITION SEN-
SOR A CIRCUIT (BANK 2), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0400 Exhaust Gas Recirculation Flow <Ref. to EN(H6DO)(diag)-235, DTC P0400 EXHAUST GAS RECIRCULA-
TION FLOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Threshold (Bank 1)
<Ref. to EN(H6DO)(diag)-237, DTC P0420 CATALYST SYSTEM EFFI-
CIENCY BELOW THRESHOLD (BANK 1), Diagnostic Procedure with Diag-
<Ref. to EN(H6DO)(diag)-241, DTC P0442 EVAPORATIVE EMISSION
CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Proce-
CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Proce-
CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic
tem Pressure Sensor
CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Procedure with
CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Proce-
CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Proce-
Leak)
CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic
Off)
CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diag-
<Ref. to EN(H6DO)(diag)-260, DTC P0458 EVAPORATIVE EMISSION SYS-
TEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Procedure with
<Ref. to EN(H6DO)(diag)-262, DTC P0459 EVAPORATIVE EMISSION SYS-
TEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Procedure with
Performance
<Ref. to EN(H6DO)(diag)-264, DTC P0461 FUEL LEVEL SENSOR A CIR-
ble Code (DTC).>
P0462 Fuel Level Sensor A Circuit Low <Ref. to EN(H6DO)(diag)-264, DTC P0462 FUEL LEVEL SENSOR A CIR-
P0463 Fuel Level Sensor A Circuit High <Ref. to EN(H6DO)(diag)-264, DTC P0463 FUEL LEVEL SENSOR A CIR-
P0464 Fuel Level Sensor Circuit Intermittent <Ref. to EN(H6DO)(diag)-265, DTC P0464 FUEL LEVEL SENSOR CIR-
CUIT INTERMITTENT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0500 Vehicle Speed Sensor A <Ref. to EN(H6DO)(diag)-265, DTC P0500 VEHICLE SPEED SENSOR A,
DTC Item Reference
EN(H6DO)(diag)-89
Than Expected
<Ref. to EN(H6DO)(diag)-266, DTC P0506 IDLE AIR CONTROL SYSTEM
RPM LOWER THAN EXPECTED, Diagnostic Procedure with Diagnostic
Than Expected
<Ref. to EN(H6DO)(diag)-268, DTC P0507 IDLE AIR CONTROL SYSTEM
RPM HIGHER THAN EXPECTED, Diagnostic Procedure with Diagnostic
P0512 Starter Request Circuit <Ref. to EN(H6DO)(diag)-270, DTC P0512 STARTER REQUEST CIRCUIT,
P0513 Incorrect Immobilizer Key <Ref. to IM(diag)-16, DTC P0513 INCORRECT IMMOBILIZER KEY, Diag-
P0600 Serial Communication Link <Ref. to EN(H6DO)(diag)-271, DTC P0600 SERIAL COMMUNICATION
LINK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-272, DTC P0604 INTERNAL CONTROL MODULE
RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with
Memory (ROM) Error
<Ref. to EN(H6DO)(diag)-273, DTC P0605 INTERNAL CONTROL MODULE
READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with Diagnos-
P0607 Control Module Performance <Ref. to EN(H6DO)(diag)-274, DTC P0607 CONTROL MODULE PERFOR-
MANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0638 Throttle Actuator Control Range/Per-
formance (Bank 1)
<Ref. to EN(H6DO)(diag)-275, DTC P0638 THROTTLE ACTUATOR CON-
TROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with Diag-
Request)
<Ref. to EN(H6DO)(diag)-275, DTC P0700 TRANSMISSION CONTROL
SYSTEM (MIL REQUEST), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H6DO)(diag)-276, DTC P1152 O2 SENSOR CIRCUIT RANGE/
PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Procedure with
PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Procedure with
PERFORMANCE (LOW) (BANK 2 SENSOR 1), Diagnostic Procedure with
PERFORMANCE (HIGH) (BANK 2 SENSOR 1), Diagnostic Procedure with
P1160 Return Spring Failure <Ref. to EN(H6DO)(diag)-283, DTC P1160 RETURN SPRING FAILURE,
Valve Circuit Low
<Ref. to EN(H6DO)(diag)-284, DTC P1400 FUEL TANK PRESSURE CON-
TROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Procedure with Diag-
Valve Circuit High
<Ref. to EN(H6DO)(diag)-286, DTC P1420 FUEL TANK PRESSURE CON-
TROL SOL. VALVE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic
Problem
<Ref. to EN(H6DO)(diag)-288, DTC P1443 VENT CONTROL SOLENOID
VALVE FUNCTION PROBLEM, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P1492 EGR Solenoid Valve Signal #1 Cir-
cuit Malfunction (Low Input)
<Ref. to EN(H6DO)(diag)-290, DTC P1492 EGR SOLENOID VALVE SIG-
NAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with
cuit Malfunction (High Input)
NAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure
DTC Item Reference
EN(H6DO)(diag)-90
P1560 Back-up Voltage Circuit Malfunction <Ref. to EN(H6DO)(diag)-296, DTC P1560 BACK-UP VOLTAGE CIRCUIT
MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1570 Antenna <Ref. to IM(diag)-17, DTC P1570 ANTENNA, Diagnostic Procedure with
P1571 Reference Code Incompatibility <Ref. to IM(diag)-19, DTC P1571 REFERENCE CODE INCOMPATIBILITY,
Circuit)
(DTC).>
P1574 Key Communication Failure <Ref. to IM(diag)-22, DTC P1574 KEY COMMUNICATION FAILURE, Diag-
P1576 EGI Control Module EEPROM <Ref. to IM(diag)-23, DTC P1576 EGI CONTROL MODULE EEPROM, Diag-
P1577 IMM Control Module EEPROM <Ref. to IM(diag)-23, DTC P1577 IMM CONTROL MODULE EEPROM,
P1602 Control Module Programming Error <Ref. to EN(H6DO)(diag)-298, DTC P1602 CONTROL MODULE PRO-
GRAMMING ERROR, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H6DO)(diag)-307, DTC P2088 INTAKE CAMSHAFT POSITION
ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Procedure with
ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Procedure
ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Procedure with
ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Procedure
Lean Bank 1
<Ref. to EN(H6DO)(diag)-314, DTC P2096 POST CATALYST FUEL TRIM
Code (DTC).>
DTC Item Reference
EN(H6DO)(diag)-91
Rich Bank 1
Code (DTC).>
Lean Bank 2
Code (DTC).>
Rich Bank 2
Code (DTC).>
TROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure
cuit Low
TROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
cuit High
TROL MOTOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Procedure with
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
SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Procedure with
SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Procedure
SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Proce-
Performance
<Ref. to EN(H6DO)(diag)-349, DTC P2227 BAROMETRIC PRESSURE
P2228 Barometric Pressure Circuit Low <Ref. to EN(H6DO)(diag)-349, DTC P2228 BAROMETRIC PRESSURE
CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2229 Barometric Pressure Circuit High <Ref. to EN(H6DO)(diag)-350, DTC P2229 BAROMETRIC PRESSURE
CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
DTC Item Reference
EN(H6DO)(diag)-92
GENERAL DESCRIPTION <Ref. to GD(H6DO)-10, DTC P0011 INTAKE CAMSHAFT POSITION - TIM-
ING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
CAUTION:
Inspection Mode.>.
Step Check Yes No
scan tool.
NOTE:
to EN(H6DO)(diag)-35, Subaru Select Moni-
tor.>
General scan tool
angle approx. 0?
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
NOTE:
tool.
NOTE:
tor.>
General scan tool
Check the follow-
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
Perform the follow-
ing procedures,
and clean the oil
routing.
Replace the
engine oil and idle
the engine for 5
minutes, then
and engine oil.
<Ref. to
LU(H6DO)-7,
REPLACEMENT,
Engine Oil.> <Ref.
to LU(H6DO)-15,
Engine Oil Filter.>
EN(H6DO)(diag)-93
CORRELATION (BANK1)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-12, DTC P0016 CRANKSHAFT POSITION - CAMSHAFT
POSITION CORRELATION (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
CAUTION:
Inspection Mode.>.
Step Check Yes No
tool.
NOTE:
tor.>
General scan tool
put approx. 10%?
Perform the follow-
ing procedures,
and clean the oil
routing.
Replace the
engine oil and idle
the engine for 5
minutes, then
and engine oil.
<Ref. to
LU(H6DO)-7,
REPLACEMENT,
Engine Oil.> <Ref.
to LU(H6DO)-15,
Engine Oil Filter.>
Check the follow-
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
Timing chain
(matching of timing
mark)
EN(H6DO)(diag)-94
C: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION
CORRELATION (BANK2)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-13, DTC P0018 CRANKSHAFT POSITION - CAMSHAFT
POSITION CORRELATION (BANK2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
CAUTION:
Inspection Mode.>.
Step Check Yes No
tool.
NOTE:
tor.>
General scan tool
put approx. 10%?
Perform the follow-
ing procedures,
and clean the oil
routing.
Replace the
engine oil and idle
the engine for 5
minutes, then
and engine oil.
<Ref. to
LU(H6DO)-7,
REPLACEMENT,
Engine Oil.> <Ref.
to LU(H6DO)-15,
Engine Oil Filter.>
Check the follow-
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
Timing chain
(matching of timing
mark)
EN(H6DO)(diag)-95
GENERAL DESCRIPTION <Ref. to GD(H6DO)-14, DTC P0021 INTAKE CAMSHAFT POSITION - TIM-
ING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
CAUTION:
Inspection Mode.>.
Step Check Yes No
scan tool.
NOTE:
tor.>
General scan tool
angle approx. 0?
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
NOTE:
tool.
NOTE:
tor.>
General scan tool
Check the follow-
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
routing, setting of
spring)
Intake camshaft
(dirt, damage of
camshaft)
Perform the follow-
ing procedures,
and clean the oil
routing.
Replace the
engine oil and idle
the engine for 5
minutes, then
and engine oil.
<Ref. to
LU(H6DO)-7,
REPLACEMENT,
Engine Oil.> <Ref.
to LU(H6DO)-15,
Engine Oil Filter.>
EN(H6DO)(diag)-96
E: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/
PERFORMANCE (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-14, DTC P0026 INTAKE VALVE CONTROL SOLENOID
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03913
B134
3
1
B20
E1
9
ECM
B134
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1
VVL DIAGNOSIS OIL
PRESSURE SWITCH RH
E71
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
EN(H6DO)(diag)-97
Step Check Yes No
PRESSURE SWITCH.
switch.
(B134) No. 31 (E71) No. 1:
circuit of harness
between ECM and
variable valve lift
diagnosis oil pres-
sure switch con-
nector.
PRESSURE SWITCH.
more?
ness between
ECM and variable
oil pressure switch
connector.
PRESSURE SWITCH.
circuit to power of
the harness
between the ECM
and variable valve
lift diagnosis oil
pressure switch
connector.
Go to step 4.
4 CHECK DTC.
NOTE:
Mode. <Ref. to EN(H6DO)(diag)-57, Clear
Memory Mode.>
switching solenoid
valve. <Ref. to
ME(H6DO)-81, Oil
Switching Solenoid
END
5 CHECK DTC.
NOTE:
Memory Mode.>
ing.
END.
EN(H6DO)(diag)-98
F: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03914
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1
8
5 6
10 11 12 13 14 15
7 2 1 3 4
16
30
19 20 22
28 29
9 17
18 25 21 23 24
32 31
26 27
33 34
B134
3
2
B20
E1
1
0
ECM
E72
VVL DIAGNOSIS OIL
PRESSURE SWITCH LH
B134
B20
EN(H6DO)(diag)-99
Step Check Yes No
PRESSURE SWITCH.
switch.
(B134) No. 32 (E72) No. 1:
circuit of harness
between ECM and
variable valve lift
diagnosis oil pres-
sure switch con-
nector.
PRESSURE SWITCH.
more?
ness between
ECM and variable
oil pressure switch
connector.
PRESSURE SWITCH.
circuit to power of
the harness
between the ECM
and variable valve
lift diagnosis oil
pressure switch
connector.
Go to step 4.
4 CHECK DTC.
NOTE:
Memory Mode.>
switching solenoid
valve. <Ref. to
ME(H6DO)-81, Oil
Switching Solenoid
END
5 CHECK DTC.
NOTE:
Memory Mode.>
ing.
END.
EN(H6DO)(diag)-100
G: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-17, DTC P0030 HO2S HEATER CONTROL CIRCUIT
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
TERMINAL No. OPTIONAL
ARRANGEMENT AMONG 1, 2, 5 AND 6
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-101
Step Check Yes No
TOR.
(B136) No. 2 (E47) No. 1:
(B136) No. 3 (E47) No. 1:
circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
TOR.
(B135) No. 9 (E47) No. 3:
(B135) No. 8 (E47) No. 4:
circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
Terminals
No. 2 No. 1:
3 ?
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
nector?
Repair the poor
contact of ECM or
front oxygen (A/F)
sensor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-102
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-103
Step Check Yes No
GEN (A/F) SENSOR.
(A/F) sensor.
supply line.
NOTE:
the following item:
Open circuit of
harness between
main relay and
front oxygen (A/F)
sensor connector
Poor contact of
main relay connec-
tor
Poor contact in
coupling connector
Malfunction in
main relay
(B136) No. 2 (E47) No. 1:
(B136) No. 3 (E47) No. 1:
circuit of harness
between ECM and
front oxygen (A/F)
sensor.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
Terminals
No. 2 No. 1:
3 ?
Repair poor con-
tact of the ECM
connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-104
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-105
Step Check Yes No
chassis ground.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
nector.
Go to step 2.
chassis ground.
contact of the ECM
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact of
coupling connector
EN(H6DO)(diag)-106
J: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-107
Step Check Yes No
GEN SENSOR.
gen sensor.
supply line.
NOTE:
the following item:
Open circuit of
harness between
main relay and rear
oxygen sensor
Poor contact of
main relay connec-
tor
Poor contact in
coupling connector
Malfunction in
main relay
REAR OXYGEN SENSOR.
(B136) No. 4 (E61) No. 1:
circuit of the har-
ness between
ECM and rear oxy-
gen sensor.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
Terminals
No. 2 No. 1:
7 ?
Repair poor con-
tact of the ECM
connector.
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
EN(H6DO)(diag)-108
K: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-109
Step Check Yes No
REAR OXYGEN SENSOR.
chassis ground.
circuit to power in
the harness
between ECM and
rear oxygen sensor
connector.
Go to step 2.
chassis ground.
contact of the ECM
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact of
coupling connector
EN(H6DO)(diag)-110
L: DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-111
Step Check Yes No
TOR.
(B135) No. 6 (E24) No. 1:
(B135) No. 7 (E24) No. 1:
circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
TOR.
(B135) No. 11 (E24) No. 3:
(B135) No. 10 (E24) No. 4:
circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
Terminals
No. 2 No. 1:
3 ?
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
nector?
Repair the poor
contact of ECM or
front oxygen (A/F)
sensor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-112
M: DTC P0051 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-113
Step Check Yes No
GEN (A/F) SENSOR.
(A/F) sensor.
supply line.
NOTE:
the following item:
Open circuit of
harness between
main relay and
front oxygen (A/F)
sensor connector
Poor contact of
main relay connec-
tor
Poor contact in
coupling connector
Malfunction in
main relay
(B135) No. 6 (E24) No. 1:
(B135) No. 7 (E24) No. 1:
circuit of harness
between ECM and
front oxygen (A/F)
sensor.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
Terminals
No. 2 No. 1:
3 ?
Repair poor con-
tact of the ECM
connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-114
N: DTC P0052 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-115
Step Check Yes No
chassis ground.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
nector.
Go to step 2.
chassis ground.
contact of the ECM
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact of
coupling connector
EN(H6DO)(diag)-116
O: DTC P0057 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-117
Step Check Yes No
GEN SENSOR.
gen sensor.
supply line.
NOTE:
the following item:
Open circuit of
harness between
main relay and rear
oxygen sensor
Poor contact of
main relay connec-
tor
Poor contact in
coupling connector
Malfunction in
main relay
REAR OXYGEN SENSOR.
(B136) No. 5 (E25) No. 1:
circuit of the har-
ness between
ECM and rear oxy-
gen sensor.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
Terminals
No. 2 No. 1:
7 ?
Repair poor con-
tact of the ECM
connector.
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
EN(H6DO)(diag)-118
P: DTC P0058 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-119
Step Check Yes No
REAR OXYGEN SENSOR.
chassis ground.
circuit to power in
the harness
between ECM and
rear oxygen sensor
connector.
Go to step 2.
chassis ground.
contact of the ECM
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact of
coupling connector
EN(H6DO)(diag)-120
Q: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
GENERAL DESCRIPTION <Ref. to GD(H6DO)-28, DTC P0068 MAP/MAF - THROTTLE POSITION
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 2 3
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
13 2
581
2
9
6
1
9
1
9
2
0
7
ECM B134
E21
E77
B21
E2
E76
B134
B21
E21
E77
1 2 3 4
5 6 7
8 9 10
EN-05657
EN(H6DO)(diag)-121
Step Check Yes No
intake system?
Repair the air
intake system.
Go to step 2.
SENSOR.
(167F).
general scan tool.
NOTE:
tor.>
General scan tool
106.6 kPa (550 800 mmHg,
46.7 kPa (150 350 mmHg,
idling?
fold absolute pres-
sure sensor. <Ref.
to FU(H6DO)-24,
Manifold Absolute
Pressure Sensor.>
NOTE:
tor.>
General scan tool
closed?
trol. <Ref. to
FU(H6DO)-12,
Throttle Body.>
open?
Replace the mani-
fold absolute pres-
sure sensor. <Ref.
to FU(H6DO)-24,
Manifold Absolute
Pressure Sensor.>
Replace the elec-
trol. <Ref. to
FU(H6DO)-12,
Throttle Body.>
EN(H6DO)(diag)-122
R: DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03918
B21
E2
B137
E69
2
4
2 1
2
6
2
5E69
B21
1 2
2
5
ECM
OIL SWITCHING
SOLENOID VALVE RH
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H6DO)(diag)-123
Step Check Yes No
ECM and oil switching solenoid valve.
(B137) No. 25 (E69) No. 1:
(B137) No. 24 (E69) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and oil
switching solenoid
valve connector
Poor contact of
coupling connector
chassis ground.
more?
ness between
ECM and oil
switching solenoid
valve connector.
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of ECM
and oil switching
solenoid valve con-
nector.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H6DO)-81, Oil
Switching Solenoid
Valve.>
EN(H6DO)(diag)-124
S: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03918
B21
E2
B137
E69
2
4
2 1
2
6
2
5E69
B21
1 2
2
5
ECM
OIL SWITCHING
SOLENOID VALVE RH
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H6DO)(diag)-125
Step Check Yes No
chassis ground.
circuit to power in
the harness
between ECM and
oil switching sole-
noid valve connec-
tor.
ECM and oil switching solenoid valve connec-
tor.
(B137) No. 25 (E69) No. 1:
(B137) No. 24 (E69) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and oil
switching solenoid
valve connector
Poor contact of
coupling connector
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of ECM
and oil switching
solenoid valve con-
nector.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H6DO)-81, Oil
Switching Solenoid
Valve.>
EN(H6DO)(diag)-126
T: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03919
B21
E2
B137
E70
3
0
2 1
3
0
2
9E70
B21
1 2
3
1
ECM
OIL SWITCHING
SOLENOID VALVE LH
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H6DO)(diag)-127
Step Check Yes No
oil switching solenoid valve.
(B137) No. 31 (E70) No. 1:
(B137) No. 30 (E70) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and oil
switching solenoid
valve connector
Poor contact of
coupling connector
chassis ground.
more?
ness between
ECM and oil
switching solenoid
valve connector.
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of ECM
and oil switching
solenoid valve con-
nector.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H6DO)-81, Oil
Switching Solenoid
Valve.>
EN(H6DO)(diag)-128
U: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03919
B21
E2
B137
E70
3
0
2 1
3
0
2
9E70
B21
1 2
3
1
ECM
OIL SWITCHING
SOLENOID VALVE LH
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H6DO)(diag)-129
Step Check Yes No
chassis ground.
circuit to power in
the harness
between ECM and
oil switching sole-
noid valve connec-
tor.
oil switching solenoid valve connector.
(B137) No. 31 (E70) No. 1:
(B137) No. 30 (E70) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and oil
switching solenoid
valve connector
Poor contact of
coupling connector
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of ECM
and oil switching
solenoid valve con-
nector.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H6DO)-81, Oil
Switching Solenoid
Valve.>
EN(H6DO)(diag)-130
V: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/
PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H6DO)-34, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03920
B83 B3
BATTERY
E
B83
1
B3
MASS AIR FLOW & INTAKE
AIR TEMPERATURE SENSOR
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B135 B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
MAIN RELAY
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
*
: TERMINAL No.
OPTIONAL ARRANGEMENT
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN(H6DO)(diag)-131
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
EN(H6DO)(diag)-132
W: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03920
B83 B3
BATTERY
E
B83
1
B3
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B135 B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
MAIN RELAY
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
*
: TERMINAL No.
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN(H6DO)(diag)-133
Step Check Yes No
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the failure,
and then reperform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector
may be the cause.
SENSOR.
and engine ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
the main relay and
the mass air flow
and intake air tem-
perature sensor
connector.
Poor contact of
main relay connec-
tor
MASS AIR FLOW AND INTAKE AIR TEM-
PERATURE SENSOR CONNECTOR.
(B135) No. 26 (B3) No. 3:
circuit of harness
between the ECM
and the mass air
flow and intake air
temperature sen-
sor connector.
chassis ground.
more?
ness between the
ECM and the mass
air flow and intake
air temperature
sensor connector.
connector.
connector?
Repair any poor
contact in the ECM
and intake air tem-
perature sensor
connector.
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
EN(H6DO)(diag)-134
X: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03920
B83 B3
BATTERY
E
B83
1
B3
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B135 B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
MAIN RELAY
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
*
: TERMINAL No.
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN(H6DO)(diag)-135
Step Check Yes No
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the failure,
and then reperform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector
may be the cause.
NOTE:
tor.>
General scan tool
circuit to power in
the harness
between the ECM
and the mass air
flow and intake air
temperature sen-
sor connector.
Go to step 3.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and the mass
air flow and intake
air temperature
sensor connector.
Poor contact in
ECM connector
Check for any poor contact in the mass air flow
and intake air temperature sensor connector.
temperature sensor connector?
Repair any poor
contact of the
mass air flow and
intake air tempera-
ture sensor con-
nector.
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
EN(H6DO)(diag)-136
Y: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT LOW INPUT
GENERAL DESCRIPTION <Ref. to GD(H6DO)-41, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 2 3
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
13 2
581
2
9
6
1
9
1
9
2
0
7
ECM B134
E21
E77
B21
E2
E76
B134
B21
E21
E77
1 2 3 4
5 6 7
8 9 10
EN-05657
EN(H6DO)(diag)-137
Step Check Yes No
general scan tool.
NOTE:
tor.>
General scan tool
13.3 kPa
(100 mmHg, 3.94 inHg) ?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the failure,
and then reperform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector
may be the cause.
engine ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and manifold
absolute pressure
sensor connector.
Poor contact in
ECM connector
Poor contact of
coupling connector
SOR CONNECTOR.
connector.
(B134) No. 6 (E21) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and manifold
absolute pressure
sensor connector.
Poor contact of
coupling connector
SOR CONNECTOR.
chassis ground.
more?
ness between
ECM and manifold
absolute pressure
sensor connector.
Repair the poor
contact in the ECM
or manifold abso-
lute pressure sen-
sor connector.
Replace the mani-
fold absolute pres-
sure sensor. <Ref.
to FU(H6DO)-24,
Manifold Absolute
Pressure Sensor.>
EN(H6DO)(diag)-138
Z: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT HIGH INPUT
GENERAL DESCRIPTION <Ref. to GD(H6DO)-43, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 2 3
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
13 2
581
2
9
6
1
9
1
9
2
0
7
ECM B134
E21
E77
B21
E2
E76
B134
B21
E21
E77
1 2 3 4
5 6 7
8 9 10
EN-05657
EN(H6DO)(diag)-139
Step Check Yes No
general scan tool.
NOTE:
tor.>
General scan tool
(896.5 mmHg, 35.29 inHg) or
more?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the failure,
and then reperform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector
may be the cause.
SOR CONNECTOR.
general scan tool.
NOTE:
tor.>
General scan tool
(896.5 mmHg, 35.29 inHg) or
more?
Repair the short
circuit to power in
the harness
between ECM and
manifold absolute
pressure sensor
connector.
Go to step 3.
SOR CONNECTOR.
and engine ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and manifold
absolute pressure
sensor connector.
Poor contact in
ECM connector
Poor contact of
coupling connector
connector?
Repair the poor
contact of mani-
fold absolute pres-
sure sensor
connector.
Replace the mani-
fold absolute pres-
sure sensor. <Ref.
to FU(H6DO)-24,
Manifold Absolute
Pressure Sensor.>
EN(H6DO)(diag)-140
AA:DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/
PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H6DO)-45, DTC P0111 INTAKE AIR TEMPERATURE SENSOR
1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03920
B83 B3
BATTERY
E
B83
1
B3
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B135 B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
MAIN RELAY
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
*
: TERMINAL No.
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN(H6DO)(diag)-141
Step Check Yes No
TURE.
scan tool.
NOTE:
tor.>
General scan tool
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Check DTC P0125
using List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
EN(H6DO)(diag)-142
AB:DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03920
B83 B3
BATTERY
E
B83
1
B3
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B135 B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
MAIN RELAY
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
*
: TERMINAL No.
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN(H6DO)(diag)-143
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
and the mass air flow and intake air temperature
sensor.
chassis ground.
more?
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Repair the ground
ness between the
ECM and the mass
air flow and intake
air temperature
sensor connector.
EN(H6DO)(diag)-144
AC:DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03920
B83 B3
BATTERY
E
B83
1
B3
ECM B135
SBF-7
1 2 3 4 5
3 4
1 2
5 6
B135 B47
*
*
2 4 3 5
3
4
1
8
2
6
3
0
3
5
MAIN RELAY
B47
1
2
4
6
3
5
1 2 3 4
5 6 7 8
*
: TERMINAL No.
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN(H6DO)(diag)-145
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Check for poor contact in the ECM or the mass
nector.
connector?
Check for poor
contact in the ECM
and intake air tem-
perature sensor
connector.
Go to step 3.
and the mass air flow and intake air temperature
sensor.
(B135) No. 18 (B3) No. 4:
(B135) No. 30 (B3) No. 5:
circuit of harness
between the ECM
and the mass air
flow and intake air
temperature sen-
sor connector.
chassis ground.
circuit to power in
the harness
between the ECM
and the mass air
flow and intake air
temperature sen-
sor connector.
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
EN(H6DO)(diag)-146
AD:DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
GENERAL DESCRIPTION <Ref. to GD(H6DO)-51, DTC P0117 ENGINE COOLANT TEMPERATURE
TROUBLE SYMPTOM:
Hard to start
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03921
2
9
3
4
1
9
8
B134 ECM
1 2
E2
B21
E8
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H6DO)(diag)-147
Step Check Yes No
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
CONNECTOR.
chassis ground.
more?
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H6DO)-19,
Engine Coolant
Temperature Sen-
sor.>
Repair the ground
harness between
the ECM and
engine coolant
temperature sen-
sor.
EN(H6DO)(diag)-148
AE:DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H6DO)-53, DTC P0118 ENGINE COOLANT TEMPERATURE
TROUBLE SYMPTOM:
Hard to start
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03921
2
9
3
4
1
9
8
B134 ECM
1 2
E2
B21
E8
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H6DO)(diag)-149
Step Check Yes No
NOTE:
tor.>
General scan tool
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Repair any poor
contact between
the ECM and
engine coolant
temperature sen-
sor connectors.
Go to step 3.
CONNECTOR.
(B134) No. 34 (E8) No. 2:
(B134) No. 29 (E8) No. 1:
circuit of the har-
ness between the
ECM and engine
coolant tempera-
ture sensor con-
nector.
CONNECTOR.
chassis ground.
circuit to power in
the harness
between the ECM
and engine coolant
temperature sen-
sor connector.
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H6DO)-19,
Engine Coolant
Temperature Sen-
sor.>
EN(H6DO)(diag)-150
AF:DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT
LOW
GENERAL DESCRIPTION <Ref. to GD(H6DO)-55, DTC P0122 THROTTLE/PEDAL POSITION SEN-
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B20 E57
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
5
2
3
4
3
5
3
7
E
E2
B21
E
A
5
C
2
1
C
1
A
2
9
1
9
E1
B20
A
1
8
C
6
A
2
8
6 4
1
5
*
*
B122
1
6
E
3
8
3
9
2
0
D
5
D
4
A
1
9
D
7
D
1
A
3
D
2
D
3
3
E57
2 1 5
B134
B362
5
7
6
A: B137 B136 D: C:
ECM
*
E
SBF-7
8
6 4
B47
B47
3 4
1 2
5 6
EN-05658
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-151
Step Check Yes No
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
more?
Replace the elec-
trol. <Ref. to
FU(H6DO)-12,
Throttle Body.>
Repair the ground
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-152
AG:DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT
HIGH
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B20 E57
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
5
2
3
4
3
5
3
7
E
E2
B21
E
A
5
C
2
1
C
1
A
2
9
1
9
E1
B20
A
1
8
C
6
A
2
8
6 4
1
5
*
*
B122
1
6
E
3
8
3
9
2
0
D
5
D
4
A
1
9
D
7
D
1
A
3
D
2
D
3
3
E57
2 1 5
B134
B362
5
7
6
A: B137 B136 D: C:
ECM
*
E
SBF-7
8
6 4
B47
B47
3 4
1 2
5 6
EN-05658
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-153
Step Check Yes No
(B134) No. 18 (E57) No. 6:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 4.
nectors.
(B134) No. 19 (B134) No. 18:
more?
Repair poor con-
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H6DO)-12,
Throttle Body.>
Repair the short
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
EN(H6DO)(diag)-154
AH:DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP
FUEL CONTROL
GENERAL DESCRIPTION <Ref. to GD(H6DO)-59, DTC P0125 INSUFFICIENT COOLANT TEMPERA-
TURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
Inspection Mode.>.
Step Check Yes No
1 CHECK TIRE SIZE. Is the tire size as specified, and
wheels?
engine coolant.
<Ref. to
CO(H6DO)-12,
INSPECTION,
Engine Coolant.>
opened?
Replace the ther-
mostat. <Ref. to
CO(H6DO)-14,
Thermostat.>
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H6DO)-19,
Engine Coolant
Temperature Sen-
sor.>
EN(H6DO)(diag)-155
AI: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR
STABLE OPERATION
GENERAL DESCRIPTION <Ref. to GD(H6DO)-62, DTC P0126 INSUFFICIENT ENGINE COOLANT
TROUBLE SYMPTOM:
Hard to start
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03921
2
9
3
4
1
9
8
B134 ECM
1 2
E2
B21
E8
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H6DO)(diag)-156
AJ:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE
GENERAL DESCRIPTION <Ref. to GD(H6DO)-64, DTC P0128 COOLANT THERMOSTAT (ENGINE
TROUBLE SYMPTOM:
CAUTION:
Inspection Mode.>.
Step Check Yes No
SENSOR.
Terminals
No. 1 No. 2:
warmed-up?
Repair the poor
contact of the ECM
connector.
Replace the
engine coolant
temperature sen-
sor. <Ref. to
FU(H6DO)-19,
Engine Coolant
Temperature Sen-
sor.>
Step Check Yes No
engine coolant.
<Ref. to
CO(H6DO)-11,
REPLACEMENT,
Engine Coolant.>
more during idling?
Repair radiator fan
circuit. <Ref. to
CO(H6DO)-20,
Radiator Main Fan
and Fan
Motor.>and <Ref.
to CO(H6DO)-23,
Radiator Sub Fan
and Fan Motor.>
Replace the ther-
mostat. <Ref. to
CO(H6DO)-14,
Thermostat.>
EN(H6DO)(diag)-157
AK:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-66, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-158
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
connector.
tor?
Repair the poor
oxygen (A/F) sen-
sor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-159
AL:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-68, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-160
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
(A/F) sensor.
chassis ground.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
nector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-161
AM:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-70, DTC P0133 O2 SENSOR CIRCUIT SLOW RE-
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-162
Step Check Yes No
NOTE:
system?
Repair the exhaust
system.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-163
AN:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-73, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-164
Step Check Yes No
TOR.
(B135) No. 9 (E47) No. 3:
(B135) No. 8 (E47) No. 4:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact of
coupling connector
nector?
Repair the poor
contact of ECM or
front oxygen (A/F)
sensor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-165
AO:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-166
Step Check Yes No
maximum)
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 3.
rear oxygen sensor.
(B135) No. 4 (E61) No. 3:
(B135) No. 30 (E61) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
REAR OXYGEN SENSOR.
gen sensor.
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
NOTE:
haust system
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
EN(H6DO)(diag)-167
AP:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-168
Step Check Yes No
rpm.
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 3.
rear oxygen sensor.
(B135) No. 4 (E61) No. 3:
(B135) No. 30 (E61) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
REAR OXYGEN SENSOR.
gen sensor.
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
NOTE:
haust system
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
EN(H6DO)(diag)-169
AQ:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-170
Step Check Yes No
rear oxygen sensor.
(B135) No. 4 (E61) No. 3:
circuit of harness
between ECM and
rear oxygen sensor
connector.
(E61) No. 3 Chassis ground
more?
ness between
ECM and rear oxy-
gen sensor con-
nector.
sensor terminals.
Terminals
No. 3 No. 4
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
EN(H6DO)(diag)-171
AR:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-172
Step Check Yes No
maximum)
tool.
NOTE:
tor.>
General scan tool
rpm.
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 4.
rear oxygen sensor.
(B135) No. 4 (E61) No. 3:
(B135) No. 30 (E61) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
EN(H6DO)(diag)-173
REAR OXYGEN SENSOR.
gen sensor.
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
NOTE:
haust system
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Step Check Yes No
EN(H6DO)(diag)-174
AS:DTC P0151 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-175
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
connector.
tor?
Repair the poor
oxygen (A/F) sen-
sor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-176
AT:DTC P0152 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-177
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
(A/F) sensor.
chassis ground.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
nector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-178
AU:DTC P0153 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 1)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-179
Step Check Yes No
NOTE:
system?
Repair the exhaust
system.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-180
AV:DTC P0154 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 2 SENSOR 1)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-181
Step Check Yes No
TOR.
(B135) No. 11 (E24) No. 3:
(B135) No. 10 (E24) No. 4:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact of
coupling connector
nector?
Repair the poor
contact of ECM or
front oxygen (A/F)
sensor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-182
AW:DTC P0157 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-183
Step Check Yes No
maximum)
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 3.
rear oxygen sensor.
(B135) No. 15 (E25) No. 3:
(B135) No. 30 (E25) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
REAR OXYGEN SENSOR.
gen sensor.
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
NOTE:
haust system
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
EN(H6DO)(diag)-184
AX:DTC P0158 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-185
Step Check Yes No
rapidly reduce the engine speed from 3,000 rpm.
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 3.
rear oxygen sensor.
(B135) No. 15 (E25) No. 3:
(B135) No. 30 (E25) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
REAR OXYGEN SENSOR.
gen sensor.
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
NOTE:
haust system
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
EN(H6DO)(diag)-186
AY:DTC P0159 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-187
Step Check Yes No
rear oxygen sensor.
(B135) No. 15 (E25) No. 3:
circuit of harness
between ECM and
rear oxygen sensor
connector.
more?
ness between
ECM and rear oxy-
gen sensor con-
nector.
sensor terminals.
Terminals
No. 3 No. 4
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
EN(H6DO)(diag)-188
AZ:DTC P0160 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 2 SENSOR 2)
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-189
Step Check Yes No
maximum)
tool.
NOTE:
tor.>
General scan tool
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 4.
rear oxygen sensor.
(B135) No. 15 (E25) No. 3:
(B135) No. 30 (E25) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
REAR OXYGEN SENSOR.
gen sensor.
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the rear oxygen
sensor connector
Poor contact in
ECM connector
EN(H6DO)(diag)-190
BA:DTC P0171 SYSTEM TOO LEAN (BANK 1)
NOTE:
Refer to DTC P0175 for diagnostic procedure. <Ref. to EN(H6DO)(diag)-191, DTC P0175 SYSTEM TOO
BB:DTC P0172 SYSTEM TOO RICH (BANK 1)
NOTE:
BC:DTC P0174 SYSTEM TOO LEAN (BANK 2)
NOTE:
NOTE:
haust system
sor
system?
Repair or replace
faulty parts.
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Step Check Yes No
EN(H6DO)(diag)-191
BD:DTC P0175 SYSTEM TOO RICH (BANK 2)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-92, DTC P0175 SYSTEM TOO RICH (BANK 2), Diagnos-
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Inspection Mode.>.
Step Check Yes No
on exhaust system?
Repair the exhaust
system.
Go to step 2.
intake system?
Repair the air
intake system.
Go to step 3.
WARNING:
working area.
CAUTION:
Measure the fuel pressure. <Ref. to
ME(H6DO)-26, INSPECTION, Fuel Pressure.>
CAUTION:
363 kPa (3.4 3.7 kgf/cm
2
, 48
53 psi)?
ing item.
Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
SENSOR.
NOTE:
tor.>
General scan tool
engine coolant
temperature sen-
sor. <Ref. to
FU(H6DO)-19,
Engine Coolant
Temperature Sen-
sor.>
EN(H6DO)(diag)-192
TEMPERATURE SENSOR SIGNAL.
(167F).
NOTE:
tor.>
General scan tool
5.0 g/s (0.26 0.66 lb/m)?
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
(18 90F)?
Repair the poor
contact of the ECM
connector.
Check the mass air
flow and intake air
temperature sen-
sor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Step Check Yes No
EN(H6DO)(diag)-193
BE:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFOR-
MANCE
GENERAL DESCRIPTION <Ref. to GD(H6DO)-93, DTC P0181 FUEL TEMPERATURE SENSOR A
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B83
3
0
1
7
B135
R58
R67
R46
R1
B97
B97 R67 R58 B135
23
14
4
1
8
B83
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 19 20
3 4
5 6
1 2
7 8
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN-05659
FUEL PUMP ASSY
FUEL TEMPERATURE
SENSOR
ECM
ARRANGEMENT
EN(H6DO)(diag)-194
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Replace the fuel
temperature sen-
sor. <Ref. to
EC(H6DO)-9, Fuel
Temperature Sen-
sor.>
EN(H6DO)(diag)-195
BF:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B83
3
0
1
7
B135
R58
R67
R46
R1
B97
B97 R67 R58 B135
23
14
4
1
8
B83
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 19 20
3 4
5 6
1 2
7 8
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN-05659
FUEL PUMP ASSY
FUEL TEMPERATURE
SENSOR
ECM
ARRANGEMENT
EN(H6DO)(diag)-196
Step Check Yes No
NOTE:
tor.>
(248F) or higher?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
TOR.
chassis ground.
more?
Replace the fuel
temperature sen-
sor. <Ref. to
EC(H6DO)-9, Fuel
Temperature Sen-
sor.>
Repair the ground
ness between
ECM and fuel
pump.
EN(H6DO)(diag)-197
BG:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B83
3
0
1
7
B135
R58
R67
R46
R1
B97
B97 R67 R58 B135
23
14
4
1
8
B83
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 19 20
3 4
5 6
1 2
7 8
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN-05659
FUEL PUMP ASSY
FUEL TEMPERATURE
SENSOR
ECM
ARRANGEMENT
EN(H6DO)(diag)-198
Step Check Yes No
NOTE:
tor.>
40C (40F)?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
sor connectors?
Repair any poor
contact between
the ECM and fuel
temperature sen-
sor connectors.
Go to step 3.
TOR.
connector.
(B135) No. 17 (R58) No. 2:
(B135) No. 30 (R58) No. 3:
circuit of the har-
ness between the
ECM and fuel tem-
perature sensor
connector.
TOR.
chassis ground.
circuit to power in
the harness
between the ECM
and fuel tempera-
ture sensor con-
nector.
Replace the fuel
temperature sen-
sor. <Ref. to
EC(H6DO)-9, Fuel
Temperature Sen-
sor.>
EN(H6DO)(diag)-199
BH:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/
PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H6DO)-100, DTC P0196 ENGINE OIL TEMPERATURE SEN-
SOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Hard to start
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03924
E75
E2
B21
B134 ECM
1
1
9
2
9
E1
B20
2
3
2
3
E75
1 2
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
OIL
TEMPERATURE
SENSOR
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H6DO)(diag)-200
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Replace the oil
temperature sen-
sor. <Ref. to
FU(H6DO)-30, Oil
Temperature Sen-
sor.>
EN(H6DO)(diag)-201
BI: DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW
SOR LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Hard to start
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03924
E75
E2
B21
B134 ECM
1
1
9
2
9
E1
B20
2
3
2
3
E75
1 2
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
OIL
TEMPERATURE
SENSOR
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H6DO)(diag)-202
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
Is the oil temperature 215C
(419F) or more?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
chassis ground.
more?
Replace the oil
temperature sen-
sor. <Ref. to
FU(H6DO)-30, Oil
Temperature Sen-
sor.>
Repair the ground
ness between
ECM and oil tem-
perature sensor.
EN(H6DO)(diag)-203
BJ:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH
SOR HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Hard to start
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03924
E75
E2
B21
B134 ECM
1
1
9
2
9
E1
B20
2
3
2
3
E75
1 2
B20
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B134
OIL
TEMPERATURE
SENSOR
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
EN(H6DO)(diag)-204
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
Is the oil temperature less than
40C (40F)?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Check for poor contact of the ECM and oil tem-
ECM or oil temperature sensor
connector?
Repair the poor
contact in the ECM
or the oil tempera-
ture sensor con-
nector.
Go to step 3.
between the ECM and oil temperature sensor
connector.
(B134) No. 23 (E75) No. 2:
(B134) No. 29 (E75) No. 1:
circuit of harness
between ECM and
oil temperature
sensor connector.
chassis ground.
circuit to power
supply in the har-
ness between the
ECM and oil tem-
perature sensor
connector.
Replace the oil
temperature sen-
sor. <Ref. to
FU(H6DO)-30, Oil
Temperature Sen-
sor.>
EN(H6DO)(diag)-205
BK:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
LOW
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B20 E57
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
5
2
3
4
3
5
3
7
E
E2
B21
E
A
5
C
2
1
C
1
A
2
9
1
9
E1
B20
A
1
8
C
6
A
2
8
6 4
1
5
*
*
B122
1
6
E
3
8
3
9
2
0
D
5
D
4
A
1
9
D
7
D
1
A
3
D
2
D
3
3
E57
2 1 5
B134
B362
5
7
6
A: B137 B136 D: C:
ECM
*
E
SBF-7
8
6 4
B47
B47
3 4
1 2
5 6
EN-05658
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-206
Step Check Yes No
chassis ground.
more?
ness between
ECM and elec-
trol connector.
more?
Replace the elec-
trol. <Ref. to
FU(H6DO)-12,
Throttle Body.>
Repair the ground
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-207
BL:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
HIGH
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B20 E57
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
5
2
3
4
3
5
3
7
E
E2
B21
E
A
5
C
2
1
C
1
A
2
9
1
9
E1
B20
A
1
8
C
6
A
2
8
6 4
1
5
*
*
B122
1
6
E
3
8
3
9
2
0
D
5
D
4
A
1
9
D
7
D
1
A
3
D
2
D
3
3
E57
2 1 5
B134
B362
5
7
6
A: B137 B136 D: C:
ECM
*
E
SBF-7
8
6 4
B47
B47
3 4
1 2
5 6
EN-05658
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-208
Step Check Yes No
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 4.
nectors.
(B134) No. 19 (B134) No. 28:
more?
Repair poor con-
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H6DO)-12,
Throttle Body.>
Repair the short
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
EN(H6DO)(diag)-209
BM:DTC P0230 FUEL PUMP PRIMARY CIRCUIT
GENERAL DESCRIPTION <Ref. to GD(H6DO)-108, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Di-
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
E
E
M
1
0
76
56
No.11
B362
R122
B135 B:
B136 C:
R58
7
B
3
3
C
1
2
1 2
985
FUEL PUMP CONTROL UNIT
FUEL PUMP
ECM
BATTERY
FUEL PUMP
RELAY
B362
5
6
7 8
3
4
1 2
R1
B97
1
9
8
2
0
B97
R1
R46
R67
35
R58
2
5
4
6
1
3
B135 B:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
R122
3 4 1 2
5 8 9 10 6 7
B97
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
R67
1 2
3 4 5 6
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
EN-05654
EN(H6DO)(diag)-210
Step Check Yes No
1 CHECK POWER SUPPLY CIRCUIT TO FUEL
PUMP CONTROL UNIT.
2) Disconnect the connector from fuel pump
control unit.
4) Measure the voltage between fuel pump
supply circuit.
NOTE:
the following item:
Open or ground
ness between fuel
pump relay and
fuel pump control
unit
Poor contact of
fuel pump control
unit connector
Poor contact of
fuel pump relay
connector
2 CHECK GROUND CIRCUIT OF FUEL PUMP
CONTROL UNIT.
fuel pump control unit and chassis ground.
and connector.
NOTE:
the following item:
Open circuit be-
tween fuel pump
control unit and
chassis ground
Poor contact of
fuel pump control
unit connector
TOR.
fuel pump control unit and fuel pump connector.
(R122) No. 7 (R58) No. 5:
(R122) No. 6 (R58) No. 6:
circuit between fuel
pump control unit
and fuel pump.
TOR.
more?
ness between fuel
pump control unit
and fuel pump.
between the ECM and fuel pump control unit.
(B136) No. 12 (R122) No. 8:
(B135) No. 33 (R122) No. 9:
and connector.
NOTE:
the following item:
Open circuit be-
tween the ECM
and fuel pump con-
trol unit
Poor contact be-
tween ECM and
fuel pump control
unit
EN(H6DO)(diag)-211
BN:DTC P0301 CYLINDER 1 MISFIRE DETECTED
NOTE:
For the diagnostic procedure, refer to DTC P0306. <Ref. to EN(H6DO)(diag)-212, DTC P0306 CYLINDER 6
BO:DTC P0302 CYLINDER 2 MISFIRE DETECTED
NOTE:
BP:DTC P0303 CYLINDER 3 MISFIRE DETECTED
NOTE:
BQ:DTC P0304 CYLINDER 4 MISFIRE DETECTED
NOTE:
BR:DTC P0305 CYLINDER 5 MISFIRE DETECTED
NOTE:
more?
ness between
ECM and fuel
pump control unit.
Check poor contact of ECM and fuel pump con-
Is there poor contact of ECM
and fuel pump control unit con-
nector?
Repair the poor
contact of ECM
and fuel pump con-
Go to step 8.
8 CHECK EXPERIENCE OF RUNNING OUT OF
FUEL.
Has the vehicle experienced
running out of fuel?
Finish the diagno-
sis.
NOTE:
DTC may be re-
corded as a result
of fuel pump idling
while running out
of fuel.
Replace the fuel
pump control unit.
<Ref. to
FU(H6DO)-41,
Fuel Pump Control
Unit.>
Step Check Yes No
EN(H6DO)(diag)-212
BS:DTC P0306 CYLINDER 6 MISFIRE DETECTED
GENERAL DESCRIPTION <Ref. to GD(H6DO)-115, DTC P0306 CYLINDER 6 MISFIRE DETECTED, Di-
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
Rough driving
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
1 2
5 6
1 2
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B47 B21 B137
E6 E17
E5 E16
E43 E44
1 2
E5
8
4
2
B47
1
2
3
5
4
6
4
8
1 2
E16
1 2
E6
1
0
ECM
SBF-7
B137
9
4
3
4
4
FUEL INJECTOR
No.1
FUEL INJECTOR
No.2
FUEL INJECTOR
No.3
FUEL INJECTOR
No.4
FUEL INJECTOR
No.5
FUEL INJECTOR
No.6
1 2
E17
1 2
E43
1
1
4
5
1
2
4
6
1 2
E44
E
B21
E2
1
3
4
7
EN-05059
BATTERY
MAIN RELAY
EN(H6DO)(diag)-213
Step Check Yes No
FUEL INJECTOR.
cylinders.
more?
ness between
ECM and fuel
injector.
FUEL INJECTOR.
#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:
#5 (B137) No. 12 (E43) No. 1:
#6 (B137) No. 13 (E44) No. 1:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel in-
jector connector
Poor contact of
coupling connector
Terminals
No. 1 No. 2:
20 ?
to FU(H6DO)-27,
Fuel Injector.>
EN(H6DO)(diag)-214
contact of all con-
nectors in fuel
injector circuit.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
main relay and fuel
injector on faulty
cylinders
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
Poor contact of
fuel injector con-
nector on faulty
cylinders
FUEL INJECTOR.
circuit to power in
the harness
between the ECM
and fuel injector.
Go to step 7.
Terminals
No. 1 No. 2:
to FU(H6DO)-27,
Fuel Injector.>
Go to step 8.
SENSOR.
loosely installed?
Tighten the cam-
shaft position sen-
sor or crankshaft
position sensor.
Go to step 9.
9 CHECK CRANK PLATE. Is the crank sprocket rusted or
the teeth of crank plate broken?
Replace the crank
plate. <Ref. to
ME(H6DO)-64,
Cylinder Block.>
Go to step 10.
TIMING CHAIN.
ST 18252AA000 CRANKSHAFT
SOCKET
Is the timing chain dislocated
Correct the instal-
lation condition of
timing chain. <Ref.
to ME(H6DO)-44,
Timing Chain
Assembly.>
Go to step 11.
Step Check Yes No
EN(H6DO)(diag)-215
lower than the Lower level?
Replenish fuel so
cation is higher
than the Lower
level. After replen-
ishing fuel, Go to
step 13.
Go to step 12.
CATOR LIGHT.
NOTE:
tor.>
General scan tool
minutes or more.
13 CHECK CAUSE OF MISFIRE. Has the cause of misfire been
detected while running the
engine?
Finish diagnostics
operation, if the
engine has no
abnormality.
Repair the poor
contact of connec-
tor.
NOTE:
the following item:
Poor contact of
ignition coil connec-
tor
Poor contact of
fuel injector con-
nector on faulty
cylinders
Poor contact in
ECM connector
Poor contact of
coupling connector
system?
Repair the air
intake system.
NOTE:
Check the follow-
ing items.
Are there air
caused by loose or
dislocated nuts
and bolts?
Are there cracks
or any disconnec-
tion of hoses?
Go to step 15.
Step Check Yes No
EN(H6DO)(diag)-216
2) Read the DTC.
NOTE:
tor.>
General scan tool
only one DTC?
16 CHECK ANY OTHER DTC ON DISPLAY. Are DTCs P0301 and P0302
displayed?
17 CHECK DTC ON DISPLAY. Are DTCs P0303 and P0304
displayed?
18 CHECK DTC ON DISPLAY. Are DTC P0305 and P0306 dis-
played?
19 CHECK DTC ON DISPLAY. Are DTC P0301, P0303 and
P0305 displayed?
20 CHECK DTC ON DISPLAY. Are DTC P0302, P0304 and
P0306 displayed?
der?
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Compression ra-
tio
Check DTC
P0171, P0172,
P0174 or P0175
using List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
#2 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the fol-
lowing items.
Spark plug
Fuel injector
Ignition coil
Compression
ratio
If any fault are not
found, check the
IGNITION CON-
TROL SYSTEM of
#1 and #2 cylinders
side. <Ref. to
EN(H6DO)(diag)-
78, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Starting
Failure.>
Check DTC
P0171, P0172,
P0174 or P0175
using List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Step Check Yes No
EN(H6DO)(diag)-217
#4 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the fol-
lowing items.
Spark plug
Fuel injector
Ignition coil
Compression
ratio
If any fault are
not found, check
the IGNITION
CONTROL SYS-
TEM of #3 and #4
cylinders side.
<Ref. to
EN(H6DO)(diag)-
78, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Starting
Failure.>
Check DTC
P0171, P0172,
P0174 or P0175
using List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
#6 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the fol-
lowing items.
Spark plug
Fuel injector
Ignition coil
Compression
ratio
If any fault are
not found, check
the IGNITION
CONTROL SYS-
TEM of #5 and #6
cylinders side.
<Ref. to
EN(H6DO)(diag)-
78, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Starting
Failure.>
Check DTC
P0171, P0172,
P0174 or P0175
using List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
25 GROUP OF #1, #3 AND #5 CYLINDERS. Is there any fault in #1, #3 and
#5 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Compression ra-
tio
Skipping timing
chain teeth
Check DTC
P0171, P0172,
P0174 or P0175
using List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Step Check Yes No
EN(H6DO)(diag)-218
26 GROUP OF #2, #4 AND #6 CYLINDERS. Is there any fault in #2, #4 and
#6 cylinders?
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Compression ra-
tio
Skipping timing
chain teeth
Check DTC
P0171, P0172,
P0174 or P0175
using List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
27 CYLINDER AT RANDOM. Is the engine idle rough? Check DTC
P0171, P0172,
P0174 or P0175
using List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Repair or replace
faulty parts.
NOTE:
Check the follow-
ing items.
Spark plug
Fuel injector
Compression ra-
tio
Step Check Yes No
EN(H6DO)(diag)-219
BT:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW
GENERAL DESCRIPTION <Ref. to GD(H6DO)-116, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW
TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03925
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
KNOCK
SENSOR
1 (RH)
2 1
E14
KNOCK
SENSOR
2 (LH)
2 1
E48
1
3
B20
E1
B21
E2
1
4
1
5
2
5
ECM B134
1
6
2
9
E14
E48 B134 B20
B21
1
9
EN(H6DO)(diag)-220
Step Check Yes No
KNOCK SENSOR.
nectors.
(B134) No. 15 (B134) No. 29:
more?
tact of the ECM
connector.
sor.
sensor terminals.
Terminals
No. 1 No. 2:
more?
Replace the knock
sensor. <Ref. to
FU(H6DO)-22,
Knock Sensor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and knock
sensor
Poor contact of
the knock sensor
connector
Poor contact of
coupling connector
EN(H6DO)(diag)-221
BU:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H6DO)-118, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH
TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03925
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
KNOCK
SENSOR
1 (RH)
2 1
E14
KNOCK
SENSOR
2 (LH)
2 1
E48
1
3
B20
E1
B21
E2
1
4
1
5
2
5
ECM B134
1
6
2
9
E14
E48 B134 B20
B21
1
9
EN(H6DO)(diag)-222
Step Check Yes No
KNOCK SENSOR.
nectors.
(B134) No. 15 (B134) No. 29:
Is the resistance less than
500 k?
sor.
sensor connectors.
Terminals
No. 1 No. 2:
500 k?
Replace the knock
sensor. <Ref. to
FU(H6DO)-22,
Knock Sensor.>
Repair the ground
ness between the
ECM and knock
sensor connector.
NOTE:
The harness be-
tween both connec-
tors are shielded.
Remove the shield
and repair the short
circuit of the har-
ness circuit.
chassis ground.
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Repair poor con-
tact of the ECM
connector.
EN(H6DO)(diag)-223
BV:DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW (BANK 2)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-119, DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW
(BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Driving performance problem
Knocking is occurred.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03925
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
KNOCK
SENSOR
1 (RH)
2 1
E14
KNOCK
SENSOR
2 (LH)
2 1
E48
1
3
B20
E1
B21
E2
1
4
1
5
2
5
ECM B134
1
6
2
9
E14
E48 B134 B20
B21
1
9
EN(H6DO)(diag)-224
Step Check Yes No
KNOCK SENSOR.
nectors.
(B134) No. 16 (B134) No. 29:
more?
tact of the ECM
connector.
sor.
sensor terminals.
Terminals
No. 1 No. 2:
more?
Replace the knock
sensor. <Ref. to
FU(H6DO)-22,
Knock Sensor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and knock
sensor
Poor contact of
the knock sensor
connector
Poor contact of
coupling connector
EN(H6DO)(diag)-225
BW:DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH (BANK 2)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-119, DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH
TROUBLE SYMPTOM:
Driving performance problem
Knocking occurs.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03925
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
KNOCK
SENSOR
1 (RH)
2 1
E14
KNOCK
SENSOR
2 (LH)
2 1
E48
1
3
B20
E1
B21
E2
1
4
1
5
2
5
ECM B134
1
6
2
9
E14
E48 B134 B20
B21
1
9
EN(H6DO)(diag)-226
Step Check Yes No
KNOCK SENSOR.
nectors.
(B134) No. 16 (B134) No. 29:
500 k?
sor.
sensor connectors.
Terminals
No. 1 No. 2:
500 k?
Replace the knock
sensor. <Ref. to
FU(H6DO)-22,
Knock Sensor.>
Repair the ground
ness between the
ECM and knock
sensor connector.
NOTE:
The harness be-
tween both con-
nectors are
shielded. Remove
the shield and re-
pair the short cir-
cuit of the harness
circuit.
chassis ground.
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Repair poor con-
tact of the ECM
connector.
EN(H6DO)(diag)-227
BX:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT
GENERAL DESCRIPTION <Ref. to GD(H6DO)-120, DTC P0335 CRANKSHAFT POSITION SENSOR
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03926
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
87
1
4
2
4
B20
E1
E10
E10
1 2
B134 ECM
CRANKSHAFT
POSITION
SENSOR
1
3
E
B20
B134
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
EN(H6DO)(diag)-228
Step Check Yes No
SITION SENSOR.
securely?
shaft position sen-
securely.
Terminals
No. 1 No. 2:
4 k?
shaft position sen-
sor. <Ref. to
FU(H6DO)-20,
Crankshaft Posi-
tion Sensor.>
nector.
(B134) No. 13 (E10) No. 1:
(B134) No. 14 (E10) No. 2:
contact of the ECM
and crankshaft
position sensor
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and crank-
shaft position sen-
sor connector
Poor contact of
coupling connector
EN(H6DO)(diag)-229
BY:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/
PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H6DO)-122, DTC P0336 CRANKSHAFT POSITION SENSOR
A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03926
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
87
1
4
2
4
B20
E1
E10
E10
1 2
B134 ECM
CRANKSHAFT
POSITION
SENSOR
1
3
E
B20
B134
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
EN(H6DO)(diag)-230
Step Check Yes No
SITION SENSOR.
securely?
shaft position sen-
securely.
2 CHECK CRANKSHAFT PLATE. Are the crankshaft plate teeth
cracked or damaged?
Replace the crank-
shaft plate.
Go to step 3.
TIMING CHAIN.
der block.
SOCKET
Correct the instal-
lation condition of
timing chain. <Ref.
to ME(H6DO)-44,
Timing Chain
Assembly.>
Replace the crank-
shaft position sen-
sor. <Ref. to
FU(H6DO)-20,
Crankshaft Posi-
tion Sensor.>
EN(H6DO)(diag)-231
BZ:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT
GENERAL DESCRIPTION <Ref. to GD(H6DO)-124, DTC P0340 CAMSHAFT POSITION SENSOR A
CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03927
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B47
1
2
4
6
3
5
E
E2
B21
3
2
2
SBF-7
E74
E1
B20
2
E73
B21 E2
1
6
3
1
1
2 1
ECM B134
48
1
3 4
1 2
5 6
B20
E74
B47
1 2 3
B134
E73
BATTERY
CAMSHAFT
POSITION
SENSOR RH
CAMSHAFT
POSITION
SENSOR LH
MAIN RELAY
2
2
1
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
EN(H6DO)(diag)-232
Step Check Yes No
POSITION SENSOR.
of harness
between main
relay connector
and camshaft posi-
tion sensor con-
nector.
TOR.
(B134) No. 11 (E73) No. 2:
(B134) No. 22 (E73) No. 3:
circuit of harness
between the ECM
and camshaft posi-
tion sensor.
TOR.
more?
harness between
the ECM and cam-
shaft position sen-
sor.
TOR.
circuit to power in
the harness
between the ECM
and camshaft posi-
tion sensor.
Go to step 5.
TION SENSOR.
securely?
shaft position sen-
securely.
Check the waveform of the camshaft position
sensor. <Ref. to EN(H6DO)(diag)-17, Engine
Control Module (ECM) I/O Signal.>
waveform?
Replace the cam-
shaft position sen-
sor. <Ref. to
FU(H6DO)-21,
Camshaft Position
Sensor.>
Repair the follow-
ing item.
Poor contact in
ECM connector
Poor contact of
camshaft position
sensor connector
Poor contact of
coupling connector
EN(H6DO)(diag)-233
CA:DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-126, DTC P0345 CAMSHAFT POSITION SENSOR A
CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03927
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B47
1
2
4
6
3
5
E
E2
B21
3
2
2
SBF-7
E74
E1
B20
2
E73
B21 E2
1
6
3
1
1
2 1
ECM B134
48
1
3 4
1 2
5 6
B20
E74
B47
1 2 3
B134
E73
BATTERY
CAMSHAFT
POSITION
SENSOR RH
CAMSHAFT
POSITION
SENSOR LH
MAIN RELAY
2
2
1
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
EN(H6DO)(diag)-234
Step Check Yes No
POSITION SENSOR.
of harness
between main
relay connector
and camshaft posi-
tion sensor con-
nector.
TOR.
(B134) No. 21 (E74) No. 2:
(B134) No. 22 (E74) No. 3:
circuit of harness
between the ECM
and camshaft posi-
tion sensor.
TOR.
more?
harness between
the ECM and cam-
shaft position sen-
sor.
TOR.
circuit to power in
the harness
between the ECM
and camshaft posi-
tion sensor.
Go to step 5.
TION SENSOR.
securely?
shaft position sen-
securely.
Check the waveform of the camshaft position
sensor. <Ref. to EN(H6DO)(diag)-17, Engine
Control Module (ECM) I/O Signal.>
waveform?
Replace the cam-
shaft position sen-
sor. <Ref. to
FU(H6DO)-21,
Camshaft Position
Sensor.>
Repair the follow-
ing item.
Poor contact in
ECM connector
Poor contact of
camshaft position
sensor connector
Poor contact of
coupling connector
EN(H6DO)(diag)-235
CB:DTC P0400 EXHAUST GAS RECIRCULATION FLOW
GENERAL DESCRIPTION <Ref. to GD(H6DO)-127, DTC P0400 EXHAUST GAS RECIRCULATION
TROUBLE SYMPTOM:
Movement performance problem when engine is low speed.
Erroneous idling
Movement performance problem
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
E
B47
E18
2 5
1 4 3 6
B21
E2
E76
E77
4
8
3 47 6
SBF-7
B134
B47
3 4
1 2
5 6
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B134
1
0
E76
E77
2
1
3
2
3
3
2
2
B21
E2
E18
1 3
4 5 6
2
1 2 3 4
5 6 7
8 9 10
E77
6
4
9
1
0
8
2
0
EN-05660
MAIN RELAY
BATTERY
EGR VALVE
ECM
EN(H6DO)(diag)-236
Step Check Yes No
2) Read data of intake manifold absolute pres-
sure signal using Subaru Select Monitor or gen-
eral scan tool.
NOTE:
SUBARU SELECT MONITOR
tor.>
GENERAL SCAN TOOL
(400 mmHg, 15.75 inHg) or
more?
Make sure that the
EGR valve, mani-
fold absolute pres-
sure sensor and
throttle body are
installed securely.
Go to step 2.
2 CHECK EGR VALVE.
Remove the EGR valve.
Are there holes, plugged piping
or foreign objects caught in the
EGR system?
Repair the EGR
system.
Replace the EGR
valve. <Ref. to
FU(H6DO)-26,
EGR Valve.>
EN(H6DO)(diag)-237
CC:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-131, DTC P0420 CATALYST SYSTEM EFFICIENCY BE-
LOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-238
Step Check Yes No
NOTE:
pipe
converter
catalytic converter
system?
Repair or replace
the exhaust sys-
tem. <Ref. to
EX(H6DO)-2, Gen-
eral Description.>
Go to step 2.
112 km/h (50 70 MPH).
played?
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the failure,
and then perform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector
may be the cause.
Go to step 3.
RrO2 SENSOR
RrO2 SENSOR
A/F LAMBDA 1
A/F LAMBDA 1
EN-04895
EN(H6DO)(diag)-239
played?
aged?
Replace the cata-
lytic converter.
<Ref. to
EC(H6DO)-3,
Front Catalytic
Converter.>
Go to step 5.
tor?
Completely
remove any water
inside.
Go to step 6.
rear oxygen sensor.
(B135) No. 4 (E61) No. 3:
(B135) No. 30 (E61) No. 4:
(B135) No. 15 (E25) No. 3:
(B135) No. 30 (E25) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
Step Check Yes No
RrO2 SENSOR
RrO2 SENSOR
EN-04896
EN(H6DO)(diag)-240
and connector.
NOTE:
Repair the follow-
ing locations.
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact of
the ECM and rear
oxygen sensor
Poor contact in
ECM connector
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Repair the open
circuit in the rear
oxygen sensor har-
ness.
Step Check Yes No
EN(H6DO)(diag)-241
CD:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK
GENERAL DESCRIPTION <Ref. to GD(H6DO)-134, DTC P0442 EVAPORATIVE EMISSION CONTROL
SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Fuel odor
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
SBF-7
E4
B47
E
5
3
6
4
2
1
ECM
2 1
C
1
7
C
2
8
D
2
9
R15
R213
R68 R144
R1
B97
1
4
7
22 11
1
5
15
PURGE CONTROL
SOLENOID VALVE
DRAIN VALVE
PRESSURE
CONTROL
SOLENOID VALVE
MAIN RELAY
R68
R144 E4
B47
R67 B97 R213
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
BATTERY
B21
E2
E76
E77
4
1
4
8
2 3
E77
1 3
4 5 6
2
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
EN-05287
EN(H6DO)(diag)-242
Step Check Yes No
NOTE:
tightening.
securely?
cap securely.
genuine fuel filler
cap.
filler pipe?
Repair or replace
the fuel filler cap
<Ref. to
FU(H6DO)-51,
Fuel Filler Pipe.>
Go to step 4.
Select Monitor.
NOTE:
Check Mode. <Ref. to EN(H6DO)(diag)-58,
valve. <Ref. to
EC(H6DO)-15,
Drain Valve.>
VALVE.
NOTE:
tion Check Mode.>
noid valve operate?
control solenoid
valve. <Ref. to
EC(H6DO)-7,
Purge Control
Solenoid Valve.>
VALVE.
NOTE:
tion Check Mode.>
noid valve operate?
sure control sole-
EC(H6DO)-12,
Pressure Control
Solenoid Valve.>
TROL SYSTEM LINE.
tor.
ration line?
Repair or replace
the evaporation
line. <Ref. to
FU(H6DO)-60,
Fuel Delivery and
Evaporation
Lines.>
Go to step 8.
EN(H6DO)(diag)-243
there a hole of more than
1.0 mm (0.04 in) dia. in it?
Repair or replace
the canister. <Ref.
to EC(H6DO)-6,
Canister.>
Go to step 9.
9 CHECK FUEL TANK.
Remove the fuel tank. <Ref. to FU(H6DO)-44,
Fuel Tank.>
there any hole of more than
1.0 mm (0.04 in) dia. in it?
Repair or replace
to FU(H6DO)-44,
Fuel Tank.>
Go to step 10.
TROL SYSTEM.
Repair or replace
the hoses or pipes.
Repair the poor
contact of the ECM
connector.
Step Check Yes No
EN(H6DO)(diag)-244
CE:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL
CIRCUIT OPEN
SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
SBF-7
R144
R67
R213
R46
R15
R1
R1
B97
B97
B47
ECM
E
1
7
1
2
5
3
6
4
2
1
6
1
1
4
B136
CANISTER
DRAIN
VALVE
MAIN RELAY
BATTERY
7
R144
R67
B97
B47
3 4
1 2
5 6
B136 R213
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
1 2 1 2 3
4 5 6 7 8
EN-05232
EN(H6DO)(diag)-245
Step Check Yes No
chassis ground.
Is the voltage 10 V or more? Check for poor
contact of the ECM
connector.
Go to step 2.
DRAIN VALVE.
and drain valve.
more?
ness between
ECM and drain
valve connector.
DRAIN VALVE.
(B136) No. 17 (R144) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and drain
valve connector
Poor contact of
coupling connector
terminals.
Terminals
No. 1 No. 2:
100 ?
valve. <Ref. to
EC(H6DO)-15,
Drain Valve.>
and chassis ground.
tact of the drain
valve connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
main relay and
drain valve
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
EN(H6DO)(diag)-246
CF:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL
CIRCUIT SHORTED
SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
SBF-7
R144
R67
R213
R46
R15
R1
R1
B97
B97
B47
ECM
E
1
7
1
2
5
3
6
4
2
1
6
1
1
4
B136
CANISTER
DRAIN
VALVE
MAIN RELAY
BATTERY
7
R144
R67
B97
B47
3 4
1 2
5 6
B136 R213
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
1 2 1 2 3
4 5 6 7 8
EN-05232
EN(H6DO)(diag)-247
Step Check Yes No
DRAIN VALVE.
and drain valve.
chassis ground.
circuit to power in
the harness
between ECM and
drain valve con-
nector.
Go to step 2.
2) Measure the resistance between drain valve
terminals.
Terminals
No. 1 No. 2:
valve. <Ref. to
EC(H6DO)-15,
Drain Valve.>
Repair the poor
contact of the ECM
connector.
EN(H6DO)(diag)-248
CG:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR
SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B83
31 2
2
2
3
2
3
0
ECM B135
R47
R213
R15
R1
B97
B97
1 2 3
R47
B135
74 6
6
1
3
1
7
B83 R213
FUEL
TANK
PRESSURE
SENSOR
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
3 4
5 6
1 2
7 8
1 2 3
4 5 6 7 8
ARRANGEMENT
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN-05233
EN(H6DO)(diag)-249
Step Check Yes No
securely?
cap securely.
NOTE:
air ventilation hoses and pipes between fuel fill-
er pipe and fuel tank
vacuum line?
Repair or replace
the hoses and
pipes.
Replace the fuel
tank pressure sen-
sor. <Ref. to
EC(H6DO)-11,
Fuel Tank Pres-
sure Sensor.>
EN(H6DO)(diag)-250
CH:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR LOW INPUT
SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B83
31 2
2
2
3
2
3
0
ECM B135
R47
R213
R15
R1
B97
B97
1 2 3
R47
B135
74 6
6
1
3
1
7
B83 R213
FUEL
TANK
PRESSURE
SENSOR
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
3 4
5 6
1 2
7 8
1 2 3
4 5 6 7 8
ARRANGEMENT
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN-05233
EN(H6DO)(diag)-251
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
7.45 kPa
(55.85 mmHg, inHg) ?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
POWER SOURCE.
pressure sensor.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel tank
pressure sensor
connector
Poor contact in
ECM connector
Poor contact of
coupling connector
TOR.
tor.
(B135) No. 32 (R47) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel tank
pressure sensor
connector
Poor contact of
coupling connector
TOR.
chassis ground.
more?
ness between
ECM and fuel tank
pressure sensor
connector.
sor connector?
Repair the poor
contact in the ECM
or fuel tank pres-
sure sensor con-
nector.
Replace the fuel
tank pressure sen-
sor. <Ref. to
EC(H6DO)-11,
Fuel Tank Pres-
sure Sensor.>
EN(H6DO)(diag)-252
CI: DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR HIGH INPUT
SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B83
31 2
2
2
3
2
3
0
ECM B135
R47
R213
R15
R1
B97
B97
1 2 3
R47
B135
74 6
6
1
3
1
7
B83 R213
FUEL
TANK
PRESSURE
SENSOR
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
3 4
5 6
1 2
7 8
1 2 3
4 5 6 7 8
ARRANGEMENT
*
*
*
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
EN-05233
EN(H6DO)(diag)-253
Step Check Yes No
eral scan tool.
NOTE:
tor.>
General scan tool
(59.85 mmHg, inHg) or more?
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
TOR.
pressure sensor.
eral scan tool.
NOTE:
tor.>
General scan tool
(59.85 mmHg, inHg) or more?
Repair the short
circuit to power in
the harness
between ECM and
fuel tank pressure
sensor connector.
Go to step 3.
TOR.
ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel tank
pressure sensor
connector
Poor contact in
ECM connector
Poor contact of
coupling connector
sensor connector.
Repair the poor
contact in the fuel
tank pressure sen-
sor connector.
Replace the fuel
tank pressure sen-
sor. <Ref. to
EC(H6DO)-11,
Fuel Tank Pres-
sure Sensor.>
EN(H6DO)(diag)-254
CJ: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:
Inspection Mode.>.
WIRING DIAGRAM:
SBF-7
E4
B47
E
5
3
6
4
2
1
ECM
2 1
C
1
7
C
2
8
D
2
9
R15
R213
R68 R144
R1
B97
1
4
7
22 11
1
5
15
PURGE
CONTROL
SOLENOID VALVE
CONTROL
SOLENOID VALVE
MAIN RELAY
R68
R144 E4
B47
R67 B97 R213
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
BATTERY
B21
E2
E76
E77
4
1
4
8
2 3
E77
1 3
4 5 6
2
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
EN-05234
EN(H6DO)(diag)-255
Step Check Yes No
NOTE:
tightening.
securely?
cap securely.
genuine fuel filler
cap.
filler pipe?
Repair or replace
the fuel filler cap
<Ref. to
FU(H6DO)-51,
Fuel Filler Pipe.>
Go to step 4.
Select Monitor.
NOTE:
valve. <Ref. to
EC(H6DO)-15,
Drain Valve.>
VALVE.
NOTE:
tion Check Mode.>
noid valve operate?
control solenoid
valve. <Ref. to
EC(H6DO)-7,
Purge Control
Solenoid Valve.>
VALVE.
NOTE:
tion Check Mode.>
noid valve operate?
sure control sole-
EC(H6DO)-12,
Pressure Control
Solenoid Valve.>
TROL SYSTEM LINE.
tor.
oration line?
Repair or replace
the evaporation
line. <Ref. to
FU(H6DO)-60,
Fuel Delivery and
Evaporation
Lines.>
Go to step 8.
EN(H6DO)(diag)-256
there a hole of more than
0.5 mm (0.020 in) dia. in it?
Repair or replace
the canister. <Ref.
to EC(H6DO)-6,
Canister.>
Go to step 9.
9 CHECK FUEL TANK.
Fuel Tank.>
there any hole of more than
0.5 mm (0.020 in) dia. in it?
Repair or replace
to FU(H6DO)-44,
Fuel Tank.>
Go to step 10.
TROL SYSTEM.
Repair or replace
the hoses or pipes.
Repair the poor
contact of the ECM
connector.
Step Check Yes No
EN(H6DO)(diag)-257
CK:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED
(FUEL CAP LOOSE/OFF)
SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Fuel odor
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
SBF-7
E4
B47
E
5
3
6
4
2
1
ECM
2 1
C
1
7
C
2
8
D
2
9
R15
R213
R68 R144
R1
B97
1
4
7
22 11
1
5
15
PURGE
CONTROL
SOLENOID VALVE
CONTROL
SOLENOID VALVE
MAIN RELAY
R68
R144 E4
B47
R67 B97 R213
1 2
3 4
1 2
5 6
B21
1 2
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 32 33
34 35
42 43
36 37 38 39
48 49 50 51 52 53 54
40 41
44 45 46 47
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
R46
R67
6
BATTERY
B21
E2
E76
E77
4
1
4
8
2 3
E77
1 3
4 5 6
2
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
B136 C: B137 D:
EN-05234
EN(H6DO)(diag)-258
Step Check Yes No
NOTE:
tightening.
securely?
cap securely.
genuine fuel filler
cap.
filler pipe?
Repair or replace
the fuel filler cap
<Ref. to
FU(H6DO)-51,
Fuel Filler Pipe.>
Go to step 4.
Select Monitor.
NOTE:
valve. <Ref. to
EC(H6DO)-15,
Drain Valve.>
VALVE.
NOTE:
tion Check Mode.>
noid valve operate?
control solenoid
valve. <Ref. to
EC(H6DO)-7,
Purge Control
Solenoid Valve.>
VALVE.
NOTE:
tion Check Mode.>
noid valve operate?
sure control sole-
EC(H6DO)-12,
Pressure Control
Solenoid Valve.>
TROL SYSTEM LINE.
tor.
Are there any disconnected,
broken or clogged evaporation
lines?
Repair or replace
the evaporation
line. <Ref. to
FU(H6DO)-60,
Fuel Delivery and
Evaporation
Lines.>
Go to step 8.
EN(H6DO)(diag)-259
the canister. <Ref.
to EC(H6DO)-6,
Canister.>
Go to step 9.
9 CHECK FUEL TANK.
Fuel Tank.>
to FU(H6DO)-44,
Fuel Tank.>
Go to step 10.
TROL SYSTEM.
system?
Repair or replace
the hoses or pipes.
Repair the poor
contact of the ECM
connector.
Step Check Yes No
EN(H6DO)(diag)-260
CL:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT LOW
GENERAL DESCRIPTION <Ref. to GD(H6DO)-160, DTC P0458 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
E4
B47
B47
3 4
1 2
5 6
SBF-7
1
2
4
6
3
5
2
9
B21
E2
4
8
4
1
B137
2 1
E4
1 2
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1
0
2
E76
E77
E77
1 2 3 4
5 6 7
8 9 10
EN-05661
MAIN RELAY
ECM
BATTERY
PURGE CONTROL
SOLENOID VALVE
EN(H6DO)(diag)-261
Step Check Yes No
chassis ground.
contact of the ECM
connector.
Go to step 2.
ground.
more?
ness between
ECM and purge
control solenoid
valve connector.
(B137) No. 29 (E4) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and purge
control solenoid
valve connector
Poor contact of
coupling connector
VALVE.
Terminals
No. 1 No. 2:
100 ?
control solenoid
valve. <Ref. to
EC(H6DO)-7,
Purge Control
Solenoid Valve.>
contact of purge
control solenoid
valve connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the main relay and
purge control sole-
noid valve
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
EN(H6DO)(diag)-262
CM:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H6DO)-162, DTC P0459 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
E4
B47
B47
3 4
1 2
5 6
SBF-7
1
2
4
6
3
5
2
9
B21
E2
4
8
4
1
B137
2 1
E4
1 2
E
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1
0
2
E76
E77
E77
1 2 3 4
5 6 7
8 9 10
EN-05661
MAIN RELAY
ECM
BATTERY
PURGE CONTROL
SOLENOID VALVE
EN(H6DO)(diag)-263
Step Check Yes No
chassis ground.
circuit to power in
the harness
between the ECM
and purge control
solenoid valve con-
nector.
Go to step 2.
VALVE.
Terminals
No. 1 No. 2:
control solenoid
valve. <Ref. to
EC(H6DO)-7,
Purge Control
Solenoid Valve.>
Repair the poor
contact of the ECM
connector.
EN(H6DO)(diag)-264
CN:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H6DO)-164, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT
CAUTION:
Inspection Mode.>.
CO:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW
NOTE:
For the diagnostic procedure, refer to DTC P0463. <Ref. to EN(H6DO)(diag)-264, DTC P0463 FUEL LEVEL
SENSOR A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CP:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H6DO)-168, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT
CAUTION:
Inspection Mode.>.
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Replace the fuel
level sensor and
fuel sub level sen-
sor. <Ref. to
FU(H6DO)-56,
Fuel Level Sen-
sor.> <Ref. to
FU(H6DO)-57,
Fuel Sub Level
Sensor.>
Step Check Yes No
Monitor?
Check the combi-
nation meter. <Ref.
to IDI-4, COMBI-
NATION METER,
INSPECTION,
Combination Meter
System.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
EN(H6DO)(diag)-265
CQ:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
GENERAL DESCRIPTION <Ref. to GD(H6DO)-170, DTC P0464 FUEL LEVEL SENSOR CIRCUIT IN-
CAUTION:
Inspection Mode.>.
CR:DTC P0500 VEHICLE SPEED SENSOR A
GENERAL DESCRIPTION <Ref. to GD(H6DO)-173, DTC P0500 VEHICLE SPEED SENSOR A, Diag-
CAUTION:
Inspection Mode.>.
Step Check Yes No
display?
Check the combi-
nation meter. <Ref.
to IDI-4, COMBI-
NATION METER,
INSPECTION,
Combination Meter
System.>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
Step Check Yes No
1 CHECK DTC OF ABS.
Check DTC of ABS.
nosis according to
DTC. <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Repair poor con-
tact of the ECM
connector.
EN(H6DO)(diag)-266
CS:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
GENERAL DESCRIPTION <Ref. to GD(H6DO)-175, DTC P0506 IDLE AIR CONTROL SYSTEM RPM
TROUBLE SYMPTOM:
Hard to start the engine
Improper idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B20 E57
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
5
2
3
4
3
5
3
7
E
E2
B21
E
A
5
C
2
1
C
1
A
2
9
1
9
E1
B20
A
1
8
C
6
A
2
8
6 4
1
5
*
*
B122
1
6
E
3
8
3
9
2
0
D
5
D
4
A
1
9
D
7
D
1
A
3
D
2
D
3
3
E57
2 1 5
B134
B362
5
7
6
A: B137 B136 D: C:
ECM
*
E
SBF-7
8
6 4
B47
B47
3 4
1 2
5 6
EN-05658
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-267
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
Replace the air
cleaner element.
<Ref. to
IN(H6DO)-4, Air
Cleaner Element.>
Go to step 3.
TROL.
Remove foreign
matter from elec-
trol.
Perform the diag-
nosis of DTC
P2101. <Ref. to
EN(H6DO)(diag)-
327, DTC P2101
THROTTLE
ACTUATOR CON-
TROL MOTOR
CIRCUIT RANGE/
PERFORMANCE,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
EN(H6DO)(diag)-268
CT:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
GENERAL DESCRIPTION <Ref. to GD(H6DO)-177, DTC P0507 IDLE AIR CONTROL SYSTEM RPM
TROUBLE SYMPTOM:
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B20 E57
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
5
2
3
4
3
5
3
7
E
E2
B21
E
A
5
C
2
1
C
1
A
2
9
1
9
E1
B20
A
1
8
C
6
A
2
8
6 4
1
5
*
*
B122
1
6
E
3
8
3
9
2
0
D
5
D
4
A
1
9
D
7
D
1
A
3
D
2
D
3
3
E57
2 1 5
B134
B362
5
7
6
A: B137 B136 D: C:
ECM
*
E
SBF-7
8
6 4
B47
B47
3 4
1 2
5 6
EN-05658
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-269
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
throttle body
body gasket
system?
Repair air suction
and leaks.
Go to step 3.
TROL.
Remove foreign
matter from elec-
trol.
Perform the diag-
nosis of DTC
P2101. <Ref. to
EN(H6DO)(diag)-
327, DTC P2101
THROTTLE
ACTUATOR CON-
TROL MOTOR
CIRCUIT RANGE/
PERFORMANCE,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
EN(H6DO)(diag)-270
CU:DTC P0512 STARTER REQUEST CIRCUIT
GENERAL DESCRIPTION <Ref. to GD(H6DO)-179, DTC P0512 STARTER REQUEST CIRCUIT, Diag-
TROUBLE SYMPTOM:
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
3
2
3
1
2
0
N
o
.
2
1
B225
MAIN SBF SBF-6
E
1
5
1
3
1
6
1
4
ECM
B136
TCM
B55
B72
B14
M
2
3
B225 B72 B136
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 39 40
37
38
1 2 9
3 4
5 6
7 8
1 3
4 5 6
2
B226
9
1
1
7
1
0
11
EN-05651
B226 B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
2
3 4
8
10
11
7
5
6
1 9
IGNITION
SWITCH
INHIBITOR
RELAY
STARTER
RELAY
STARTER MOTOR
BATTERY
EN(H6DO)(diag)-271
CV:DTC P0600 SERIAL COMMUNICATION LINK
NOTE:
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
NITION SWITCH.
chassis ground.
circuit to power in
the harness
between the ECM
and ignition switch.
Repair the poor
contact of the ECM
connector.
EN(H6DO)(diag)-272
CW:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY
(RAM) ERROR
GENERAL DESCRIPTION <Ref. to GD(H6DO)-183, DTC P0604 INTERNAL CONTROL MODULE RAN-
DOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
SBF-6 MAIN SBF
SBF-7
B72
A
7
B
2
C
2
3
A
3
D
2
D
1
D
7
B
5
B
1
9
No.12 B47
E2
B21
1
2
4
6
5
3
ECM
E
E
3 1
B134
B135
A:
C: B136
D: B137
B:
3
5
3
4
5
2
3 4
1 2
5 6
B47
No.13
A
5
3
6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B72
1 3
4 5 6
2
A: B:
D:
E
SBF-5
D
3
3
7
EN-05652
MAIN RELAY
BATTERY
IGNITION
SWITCH
TO OXYGEN SENSOR
EN(H6DO)(diag)-273
CX:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)
ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H6DO)(diag)-274, DTC P0607 CONTROL
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Even if the mal-
function indicator
light illuminates,
the circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the fault con-
dition, and
reperform the
check.
NOTE:
In this case, there
may be a tempo-
rary connector
contact failure.
EN(H6DO)(diag)-274
CY:DTC P0607 CONTROL MODULE PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H6DO)-185, DTC P0607 CONTROL MODULE PERFORMANCE,
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135 B: B134 A: B137 B136 D:
E1
B20
C:
E E
3
8
3
9
2
0
1
9
1
6
1
5
*
*
E2
B21
E57
46 123 5
D
4
D
5
A
2
9
A
1
9
D
1
D
7
A
5
D
2
A
3
D
3
3
5
3
4
3
7
5
2
3
6
A
2
8
C
6
A
1
8
B20 B21 E57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
B122
1 2 3 4
5 6 7 8
1 2
3 4
5 6
B47
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
B136 C: 1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
B137 D:
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B122
*
B134 A:
4 5 6 7
8
2 1
9
3
10 11 12 13 16 17
26 27
28
18 19
20 21 22 23
34 35 29 30 31
25
14 15
24
33 32
B135 B:
E
SBF-6 MAIN SBF
SBF-7
B72
A
7
B
2
C
2
3
B
5
B
1
9
No.12
B47
1
2
4
6
5
3
E
3 1
No.13
SBF-5
EN-05662
B72
1 3
4 5 6
2
MAIN RELAY
TO OXYGEN SENSOR
BATTERY
IGNITION
SWITCH
ECM
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-275
CZ:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE
(BANK 1)
NOTE:
For the diagnostic procedure, refer to DTC P2101. <Ref. to EN(H6DO)(diag)-327, DTC P2101 THROTTLE
DA:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
NOTE:
Step Check Yes No
1 CHECK INPUT VOLTAGE FROM ECM.
chassis ground.
of power supply
circuit.
2 CHECK INPUT VOLTAGE FROM ECM.
chassis ground.
of power supply
circuit.
(B134) No. 19 (E57) No. 5:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
ground.
contact of the ECM
connector.
Repair the follow-
ing item.
Open circuit of
ground circuit
Retightening of
engine ground ter-
minals
Poor contact of
coupling connector
EN(H6DO)(diag)-276
DB:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW)
(BANK1 SENSOR1)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-191, DTC P1152 O2 SENSOR CIRCUIT RANGE/PER-
FORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-277
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
(B135) No. 9 (E47) No. 3:
(B135) No. 8 (E47) No. 4:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Poor contact of
coupling connector
connector.
tor?
Repair the poor
oxygen (A/F) sen-
sor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-278
DC:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH)
(BANK1 SENSOR1)
FORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-279
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
chassis ground.
ground.
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
ground.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
Repair poor con-
tact of the ECM
connector.
EN(H6DO)(diag)-280
DD:DTC P1154 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW)
(BANK 2 SENSOR 1)
FORMANCE (LOW) (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-281
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
(B135) No. 11 (E24) No. 3:
(B135) No. 10 (E24) No. 4:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Poor contact of
coupling connector
connector.
tor?
Repair the poor
oxygen (A/F) sen-
sor connector.
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
EN(H6DO)(diag)-282
DE:DTC P1155 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH)
(BANK 2 SENSOR 1)
FORMANCE (HIGH) (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-283
DF:DTC P1160 RETURN SPRING FAILURE
NOTE:
Step Check Yes No
TOR.
tor?
Completely
remove any water
inside.
Go to step 2.
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
chassis ground.
ground.
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
ground.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
Repair poor con-
tact of the ECM
connector.
EN(H6DO)(diag)-284
DG:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT
LOW
GENERAL DESCRIPTION <Ref. to GD(H6DO)-199, DTC P1400 FUEL TANK PRESSURE CONTROL
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
SBF-7
R68 B47
R67
B97 R213
1 2
3 4
1 2
5 6
R68
R213
R15
R67
R46
R1
B97
B47
E
2
8
5
3
6
4
2
1
12
7
1
5
65
B136
B136
ECM
MAIN RELAY
PRESSURE
CONTROL
SOLENOID
VALVE
BATTERY
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
1 2 3
4 5 6 7 8 16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
EN-05238
EN(H6DO)(diag)-285
Step Check Yes No
chassis ground.
contact of the ECM
connector.
Go to step 2.
more?
ness between
ECM and pressure
control solenoid
valve connector.
nector.
(B136) No. 28 (R68) No. 2:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and pressure
control solenoid
valve connector
Poor contact of
coupling connector
VALVE.
Terminals
No. 1 No. 2:
100 ?
sure control sole-
EC(H6DO)-12,
Pressure Control
Solenoid Valve.>
contact of pressure
control solenoid
valve connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
main relay and
pressure control
solenoid valve
connector
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
EN(H6DO)(diag)-286
DH:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H6DO)-201, DTC P1420 FUEL TANK PRESSURE CONTROL
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
SBF-7
R68 B47
R67
B97 R213
1 2
3 4
1 2
5 6
R68
R213
R15
R67
R46
R1
B97
B47
E
2
8
5
3
6
4
2
1
12
7
1
5
65
B136
B136
ECM
MAIN RELAY
PRESSURE
CONTROL
SOLENOID
VALVE
BATTERY
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
1 2 3
4 5 6 7 8 16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
EN-05238
EN(H6DO)(diag)-287
Step Check Yes No
chassis ground.
circuit to power in
the harness
between ECM and
pressure control
solenoid valve con-
nector.
Go to step 2.
VALVE.
Terminals
No. 1 No. 2:
sure control sole-
EC(H6DO)-12,
Pressure Control
Solenoid Valve.>
Repair the poor
contact of the ECM
connector.
EN(H6DO)(diag)-288
DI: DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM
GENERAL DESCRIPTION <Ref. to GD(H6DO)-203, DTC P1443 VENT CONTROL SOLENOID VALVE
TROUBLE SYMPTOM:
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
SBF-7
R144
R67
R213
R46
R15
R1
R1
B97
B97
B47
ECM
E
1
7
1
2
5
3
6
4
2
1
6
1
1
4
B136
CANISTER
DRAIN
VALVE
MAIN RELAY
BATTERY
7
R144
R67
B97
B47
3 4
1 2
5 6
B136 R213
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
1 2 1 2 3
4 5 6 7 8
EN-05232
EN(H6DO)(diag)-289
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
2 CHECK DRAIN HOSE.
hose?
Replace the drain
hose.
Go to step 3.
drivers side).
NOTE:
contact of the ECM
connector.
Replace the drain
valve. <Ref. to
EC(H6DO)-15,
Drain Valve.>
EN(H6DO)(diag)-290
DJ:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
For the diagnostic procedure, refer to DTC P1498. <Ref. to EN(H6DO)(diag)-291, DTC P1498 EGR SOLE-
DK:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
DL:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
DM:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
DN:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
DO:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
EN(H6DO)(diag)-291
DP:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION
(LOW INPUT)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-205, DTC P1492 EGR SOLENOID VALVE SIGNAL #1
CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to
GD(H6DO)-209, DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW IN-
PUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-209, DTC P1496 EGR SO-
LENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC)
Detecting Criteria.> <Ref. to GD(H6DO)-209, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT
MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine breathing
CAUTION:
Inspection Mode.>.
EN(H6DO)(diag)-292
WIRING DIAGRAM:
E
B47
E18
2 5
1 4 3 6
B21
E2
E76
E77
4
8
3 47 6
SBF-7
B134
B47
3 4
1 2
5 6
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B134
1
0
E76
E77
2
1
3
2
3
3
2
2
B21
E2
E18
1 3
4 5 6
2
1 2 3 4
5 6 7
8 9 10
E77
6
4
9
1
0
8
2
0
EN-05660
MAIN RELAY
BATTERY
EGR VALVE
ECM
EN(H6DO)(diag)-293
Step Check Yes No
1 CHECK POWER SUPPLY TO EGR SOLE-
NOID VALVE.
2) Disconnect the connector from EGR sole-
noid valve.
4) Measure the voltage between EGR sole-
noid valve connector and engine ground.
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and EGR so-
lenoid valve and
main relay connec-
tor
Poor contact of
coupling connector
EGR SOLENOID VALVE CONNECTOR.
EGR solenoid valve connector.
DTC P1492; (B134) No. 8 (E18) No. 3:
DTC P1494; (B134) No. 9 (E18) No. 1:
DTC P1496; (B134) No. 10 (E18) No. 4:
DTC P1498; (B134) No. 20 (E18) No. 6:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and EGR so-
lenoid valve con-
nector
Poor contact of
coupling connector
chassis ground.
ground:
ground:
ground:
ground:
more?
short in harness
between ECM and
EGR solenoid
valve connector.
Check poor contact in ECM and EGR solenoid
valve connector.
EGR solenoid valve connector?
Repair the poor
contact in ECM or
EGR solenoid
valve connector.
Replace the EGR
solenoid valve.
<Ref. to
FU(H6DO)-26,
EGR Valve.>
EN(H6DO)(diag)-294
DQ:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION
(HIGH INPUT)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-207, DTC P1493 EGR SOLENOID VALVE SIGNAL #1
CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to
GD(H6DO)-209, DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH IN-
PUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-209, DTC P1497 EGR SO-
LENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC)
Detecting Criteria.> <Ref. to GD(H6DO)-209, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT
MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine breathing
CAUTION:
Inspection Mode.>.
EN(H6DO)(diag)-295
WIRING DIAGRAM:
Step Check Yes No
2) Disconnect the connector from EGR sole-
noid valve.
chassis ground.
ground ():
ground ():
DTC P1497; (B134) No. 10 (+) Chassis
ground ():
DTC P1499; (B134) No. 20 (+) Chassis
ground ():
circuit to power in
the harness
between the ECM
and EGR solenoid
valve connectors.
Repair the poor
contact of the ECM
connector.
E
B47
E18
2 5
1 4 3 6
B21
E2
E76
E77
4
8
3 47 6
SBF-7
B134
B47
3 4
1 2
5 6
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B134
1
0
E76
E77
2
1
3
2
3
3
2
2
B21
E2
E18
1 3
4 5 6
2
1 2 3 4
5 6 7
8 9 10
E77
6
4
9
1
0
8
2
0
EN-05660
MAIN RELAY
BATTERY
EGR VALVE
ECM
EN(H6DO)(diag)-296
DR:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
GENERAL DESCRIPTION <Ref. to GD(H6DO)-210, DTC P1560 BACK-UP VOLTAGE CIRCUIT MAL-
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B136 C:
SBF-6 MAIN SBF
SBF-7
B72
A
7
B
2
C
2
3
A
3
D
2
D
1
D
7
B
5
B
1
9
No.12 B47
E2
B21
1
2
4
6
5
3
ECM
E
E
3 1
B134
B135
A:
C: B136
D: B137
B:
3
5
3
4
5
2
3 4
1 2
5 6
B47
No.13
A
5
3
6
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B72
1 3
4 5 6
2
A: B:
D:
E
SBF-5
D
3
3
7
EN-05652
MAIN RELAY
BATTERY
IGNITION
SWITCH
TO OXYGEN SENSOR
EN(H6DO)(diag)-297
Step Check Yes No
chassis ground.
tact of the ECM
connector.
Go to step 2.
chassis ground.
more?
ness between
ECM and battery
terminal.
3 CHECK FUSE NO. 13. Is the fuse blown out? Replace the fuse. Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and battery
Poor contact in
ECM connector
Poor contact of
battery terminal
EN(H6DO)(diag)-298
DS:DTC P1602 CONTROL MODULE PROGRAMMING ERROR
GENERAL DESCRIPTION <Ref. to GD(H6DO)-212, DTC P1602 CONTROL MODULE PROGRAMMING
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
1 2
5 6
1 2
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B47 B21 B137
E6 E17
E5 E16
E43 E44
1 2
E5
8
4
2
B47
1
2
3
5
4
6
4
8
1 2
E16
1 2
E6
1
0
ECM
SBF-7
B137
9
4
3
4
4
FUEL INJECTOR
No.1
FUEL INJECTOR
No.2
FUEL INJECTOR
No.3
FUEL INJECTOR
No.4
FUEL INJECTOR
No.5
FUEL INJECTOR
No.6
1 2
E17
1 2
E43
1
1
4
5
1
2
4
6
1 2
E44
E
B21
E2
1
3
4
7
EN-05059
BATTERY
MAIN RELAY
EN(H6DO)(diag)-299
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B20 E57
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
5
2
3
4
3
5
3
7
E
E2
B21
E
A
5
C
2
1
C
1
A
2
9
1
9
E1
B20
A
1
8
C
6
A
2
8
6 4
1
5
*
*
B122
1
6
E
3
8
3
9
2
0
D
5
D
4
A
1
9
D
7
D
1
A
3
D
2
D
3
3
E57
2 1 5
B134
B362
5
7
6
A: B137 B136 D: C:
ECM
*
E
SBF-7
8
6 4
B47
B47
3 4
1 2
5 6
EN-05658
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-300
Step Check Yes No
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
engine oil?
<Ref. to
LU(H6DO)-7,
REPLACEMENT,
Engine Oil.>
on exhaust system?
Repair the exhaust
system.
Go to step 4.
intake system?
Repair the air
intake system.
Go to step 5.
WARNING:
working area.
CAUTION:
Measure the fuel pressure. <Ref. to
CAUTION:
363 kPa (3.4 3.7 kgf/cm
2
, 48
53 psi)?
ing item.
Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
SENSOR.
NOTE:
tor.>
General scan tool
engine coolant
temperature sen-
sor. <Ref. to
FU(H6DO)-19,
Engine Coolant
Temperature Sen-
sor.>
EN(H6DO)(diag)-301
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
5.0 g/s (0.26 0.66 lb/m)?
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
(18 90F)?
flow and intake air
temperature sen-
sor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Step Check Yes No
EN(H6DO)(diag)-302
FUEL INJECTOR.
cylinders.
more?
ness between
ECM and fuel
injector.
FUEL INJECTOR.
#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:
#5 (B137) No. 12 (E43) No. 1:
#6 (B137) No. 13 (E44) No. 1:
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and fuel in-
jector connector
Poor contact of
coupling connector
Terminals
No. 1 No. 2:
20 ?
to FU(H6DO)-27,
Fuel Injector.>
contact of all con-
nectors in fuel
injector circuit.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
main relay and fuel
injector on faulty
cylinders
Poor contact of
coupling connector
Poor contact of
main relay connec-
tor
Poor contact of
fuel injector con-
nector on faulty
cylinders
Step Check Yes No
EN(H6DO)(diag)-303
FUEL INJECTOR.
circuit to power in
the harness
between the ECM
and fuel injector.
Go to step 15.
Terminals
No. 1 No. 2:
to FU(H6DO)-27,
Fuel Injector.>
Go to step 16.
SENSOR.
loosely installed?
Tighten the cam-
shaft position sen-
sor or crankshaft
position sensor.
Go to step 17.
17 CHECK CRANK PLATE. Is the crank sprocket rusted or
the teeth of crank plate broken?
Replace the crank
plate. <Ref. to
ME(H6DO)-64,
Cylinder Block.>
Go to step 18.
TIMING CHAIN.
SOCKET
Correct the instal-
lation condition of
timing chain. <Ref.
to ME(H6DO)-44,
Timing Chain
Assembly.>
Go to step 19.
TROL RELAY.
Terminals
No. 7 No. 8:
EN(H6DO)(diag)-
8, Electrical Com-
ponent Location.>
of power supply
circuit.
Step Check Yes No
EN(H6DO)(diag)-304
LAY.
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 22.
LAY.
ground.
more?
ness between
ECM and elec-
trol relay.
LAY.
(B136) No. 21 (B362) No. 6:
(B136) No. 1 (B362) No. 8:
circuit of harness
between ECM and
electronic throttle
control relay.
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
more?
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
Step Check Yes No
EN(H6DO)(diag)-305
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 29.
nectors.
(B134) No. 19 (B134) No. 18:
(B134) No. 19 (B134) No. 28:
more?
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
NOTE:
tor.>
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H6DO)-12,
Throttle Body.>
NOTE:
tor.>
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H6DO)-12,
Throttle Body.>
Step Check Yes No
EN(H6DO)(diag)-306
TOR.
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
circuit of harness
between ECM and
electronic throttle
control.
TOR.
circuit to power in
the harness
between the ECM
and electronic
throttle control.
Go to step 34.
TOR.
more?
ness between the
ECM and elec-
trol.
TROL MOTOR HARNESS.
(E57) No. 2 (E57) No. 1:
more?
circuit in the har-
ness between the
ECM and elec-
trol.
chassis ground.
circuit of the har-
ness between the
ECM and engine
ground.
TROL.
Terminals
No. 2 No. 1:
trol. <Ref. to
FU(H6DO)-12,
Throttle Body.>
TROL.
closed position
Repair the poor
contact of the ECM
connector.
Replace the elec-
trol. <Ref. to
FU(H6DO)-12,
Throttle Body.>
Step Check Yes No
EN(H6DO)(diag)-307
DT:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
LOW (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H6DO)-214, DTC P2088 INTAKE CAMSHAFT POSITION ACTU-
ATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03933
B21
E2
B137
E67
1
6
2 1
2
4
2
3
E67
B21
1 2
1
7
B137
ECM
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
OIL FLOW CONTROL
SOLENOID VALVE RH
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H6DO)(diag)-308
Step Check Yes No
(B137) No. 17 (E67) No. 1:
(B137) No. 16 (E67) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
the harness be-
tween the ECM
solenoid valve
connector
Poor contact of
coupling connector
chassis ground.
more?
ness between
ECM and oil flow
control solenoid
valve connector.
VALVE.
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of the ECM
solenoid valve con-
nector.
Replace the oil
flow control sole-
ME(H6DO)-80, Oil
Flow Control Sole-
noid Valve.>
EN(H6DO)(diag)-309
DU:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
HIGH (BANK 1)
ATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03933
B21
E2
B137
E67
1
6
2 1
2
4
2
3
E67
B21
1 2
1
7
B137
ECM
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
OIL FLOW CONTROL
SOLENOID VALVE RH
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H6DO)(diag)-310
Step Check Yes No
chassis ground.
circuit to power in
the harness
between the ECM
solenoid valve con-
nector.
tor.
(B137) No. 17 (E67) No. 1:
(B137) No. 16 (E67) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
the harness be-
tween the ECM
solenoid valve
connector
Poor contact of
coupling connector
VALVE.
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of the ECM
solenoid valve con-
nector.
Replace the oil
flow control sole-
ME(H6DO)-80, Oil
Flow Control Sole-
noid Valve.>
EN(H6DO)(diag)-311
DV:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
LOW (BANK 2)
ATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03934
B21
E2
B137
E68
1
4
2 1
2
8
2
7
E68
B21
1 2
1
5
B137
ECM
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
OIL FLOW CONTROL
SOLENOID VALVE LH
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H6DO)(diag)-312
Step Check Yes No
(B137) No. 15 (E68) No. 1:
(B137) No. 14 (E68) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
the harness be-
tween the ECM
solenoid valve
connector
Poor contact of
coupling connector
chassis ground.
more?
ness between
ECM and oil flow
control solenoid
valve connector.
VALVE.
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of the ECM
solenoid valve con-
nector.
Replace the oil
flow control sole-
ME(H6DO)-80, Oil
Flow Control Sole-
noid Valve.>
EN(H6DO)(diag)-313
DW:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
HIGH (BANK 2)
ATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
EN-03934
B21
E2
B137
E68
1
4
2 1
2
8
2
7
E68
B21
1 2
1
5
B137
ECM
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
OIL FLOW CONTROL
SOLENOID VALVE LH
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
EN(H6DO)(diag)-314
DX:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1
NOTE:
Refer to DTC P2097 for diagnostic procedure. <Ref. to EN(H6DO)(diag)-315, DTC P2097 POST CATALYST
FUEL TRIM SYSTEM TOO RICH BANK 1, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Step Check Yes No
chassis ground.
circuit to power in
the harness
between the ECM
solenoid valve con-
nector.
tor.
(B137) No. 15 (E68) No. 1:
(B137) No. 14 (E68) No. 2:
and connector.
NOTE:
the following item:
Open circuit of
the harness be-
tween the ECM
solenoid valve
connector
Poor contact of
coupling connector
VALVE.
Terminals
No. 1 No. 2:
12 ?
Repair the poor
contact of the ECM
solenoid valve con-
nector.
Replace the oil
flow control sole-
ME(H6DO)-80, Oil
Flow Control Sole-
noid Valve.>
EN(H6DO)(diag)-315
DY:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1
GENERAL DESCRIPTION <Ref. to GD(H6DO)-220, DTC P2097 POST CATALYST FUEL TRIM SYS-
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-316
Step Check Yes No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
TOR.
tor?
Completely
remove any water
inside.
Go to step 3.
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-317
TOR.
(B135) No. 9 (E47) No. 3:
(B135) No. 8 (E47) No. 4:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Poor contact of
coupling connector
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
Repair poor con-
tact of the ECM
connector.
on exhaust system?
Repair the exhaust
system.
Go to step 9.
intake system?
Repair the air
intake system.
Go to step 10.
Step Check Yes No
EN(H6DO)(diag)-318
WARNING:
working area.
CAUTION:
nector.
CAUTION:
363 kPa (3.4 3.7 kgf/cm
2
, 48
53 psi)?
ing item.
Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
SENSOR.
NOTE:
tor.>
General scan tool
engine coolant
temperature sen-
sor. <Ref. to
FU(H6DO)-19,
Engine Coolant
Temperature Sen-
sor.>
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
5.0 g/s (0.26 0.66 lb/m)?
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
Step Check Yes No
EN(H6DO)(diag)-319
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
(18 90F)?
flow and intake air
temperature sen-
sor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
maximum)
tool.
NOTE:
tor.>
General scan tool
rpm.
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 18.
Step Check Yes No
EN(H6DO)(diag)-320
DZ:DTC P2098 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 2
NOTE:
Refer to DTC P2099 for diagnostic procedure. <Ref. to EN(H6DO)(diag)-321, DTC P2099 POST CATALYST
FUEL TRIM SYSTEM TOO RICH BANK 2, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
tool.
NOTE:
tor.>
General scan tool
more?
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
Go to step 18.
rear oxygen sensor.
(B135) No. 4 (E61) No. 3:
(B135) No. 30 (E61) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact in
ECM connector
Poor contact of
coupling connector
Step Check Yes No
EN(H6DO)(diag)-321
EA:DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2
GENERAL DESCRIPTION <Ref. to GD(H6DO)-221, DTC P2099 POST CATALYST FUEL TRIM SYS-
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
3 4
5 6
1 2
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
3 4
1 2
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
1 2 3 4
5 6 7 8
SBF-5
BATTERY
E
E47
E3
B22
FRONT
OXYGEN
(A/F) SENSOR
RH
2
43 1
2
41 3
E24
FRONT
OXYGEN
(A/F) SENSOR
LH
B47
1
2
3
5
4
6
MAIN RELAY
E3 B22
8
5621 34 7
B138
*
*
:
*
B47
B22
E47 E24
B21
B136 C: B137 D:
B138
B135 B: B134 A:
B
1
1
B
1
0
B
7
B
6
C
2
C
3
B
8
B
9
B
1
ECM B135 B: B134 A: B137 D: B136 C:
D
3
A
3
D
2
D
1
D
7
A
5
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
EN-05655
EN(H6DO)(diag)-322
B47
3 4
5 6
1 2
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B: B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
C: B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
D:
1 2 3 4
5 6 7 8
B83 B138
3 4
1 2
E25 E61
B47
1
2
3
5
4
6
E3 B22
14
MAIN RELAY
2
43 1
REAR OXYGEN
SENSOR LH
E25
1
3
1
5
1
6
E3
B22
1
0
1
1
1
2
9
SBF-5
BATTERY
2
REAR OXYGEN
SENSOR RH
E61
43 1
*
1
*
1
*
1
B83
B138
ECM B134 A: B135 B: B136 C: B137
D
3
A
3
D
2
D
1
D
7
A
5
D:
C
5
*
*
2
2
C
4
E
B
1
B
1
5
B
4
B
3
0
3
5
3
4
5
2
3
6
3
7
B21
E2
E E
ARRANGEMENT
*
1
*
2
EN-05656
EN(H6DO)(diag)-323
Step Check Yes No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
TOR.
tor?
Completely
remove any water
inside.
Go to step 3.
TOR.
(B135) No. 11 (E24) No. 3:
(B135) No. 10 (E24) No. 4:
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and front oxy-
gen (A/F) sensor
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Poor contact of
coupling connector
TOR.
chassis ground.
more?
ness between
ECM and front oxy-
gen (A/F) sensor
connector.
EN(H6DO)(diag)-324
circuit to power in
the harness
between the ECM
and front oxygen
(A/F) sensor con-
replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
Repair poor con-
tact of the ECM
connector.
on exhaust system?
Repair the exhaust
system.
Go to step 9.
intake system?
Repair the air
intake system.
Go to step 10.
WARNING:
working area.
CAUTION:
nector.
CAUTION:
363 kPa (3.4 3.7 kgf/cm
2
, 48
53 psi)?
ing item.
Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
SENSOR.
NOTE:
tor.>
General scan tool
engine coolant
temperature sen-
sor. <Ref. to
FU(H6DO)-19,
Engine Coolant
Temperature Sen-
sor.>
Step Check Yes No
EN(H6DO)(diag)-325
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
5.0 g/s (0.26 0.66 lb/m)?
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
TEMPERATURE SENSOR.
(167F).
NOTE:
tor.>
General scan tool
(18 90F)?
flow and intake air
temperature sen-
sor. <Ref. to
FU(H6DO)-25,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
maximum)
tool.
NOTE:
tor.>
General scan tool
Step Check Yes No
EN(H6DO)(diag)-326
tool.
NOTE:
tor.>
General scan tool
tor?
Completely
remove any water
inside.
Go to step 18.
tool.
NOTE:
tor.>
General scan tool
more?
Replace the front
oxygen (A/F) sen-
sor. <Ref. to
FU(H6DO)-31,
Front Oxygen (A/F)
Sensor.>
Go to step 18.
rear oxygen sensor.
(B135) No. 15 (E25) No. 3:
(B135) No. 30 (E25) No. 4:
circuit of harness
between ECM and
rear oxygen sensor
connector.
oxygen sensor.
<Ref. to
FU(H6DO)-33,
Rear Oxygen Sen-
sor.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and rear
oxygen sensor
Poor contact in
ECM connector
Poor contact of
coupling connector
Step Check Yes No
EN(H6DO)(diag)-327
EB:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/
PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H6DO)-222, DTC P2101 THROTTLE ACTUATOR CONTROL
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B20 E57
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
5
2
3
4
3
5
3
7
E
E2
B21
E
A
5
C
2
1
C
1
A
2
9
1
9
E1
B20
A
1
8
C
6
A
2
8
6 4
1
5
*
*
B122
1
6
E
3
8
3
9
2
0
D
5
D
4
A
1
9
D
7
D
1
A
3
D
2
D
3
3
E57
2 1 5
B134
B362
5
7
6
A: B137 B136 D: C:
ECM
*
E
SBF-7
8
6 4
B47
B47
3 4
1 2
5 6
EN-05658
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-328
Step Check Yes No
TROL RELAY.
Terminals
No. 7 No. 8:
EN(H6DO)(diag)-
8, Electrical Com-
ponent Location.>
of power supply
circuit.
LAY.
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 4.
LAY.
ground.
more?
ness between
ECM and elec-
trol relay.
LAY.
(B136) No. 21 (B362) No. 6:
(B136) No. 1 (B362) No. 8:
circuit of harness
between ECM and
electronic throttle
control relay.
throttle control.
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
EN(H6DO)(diag)-329
more?
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
throttle control connectorelectronic throttle con-
trol connector and engine ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 11.
nectors.
(B134) No. 19 (B134) No. 18:
(B134) No. 19 (B134) No. 28:
more?
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
NOTE:
tor.>
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H6DO)-12,
Throttle Body.>
Step Check Yes No
EN(H6DO)(diag)-330
NOTE:
tor.>
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if defective.
<Ref. to
FU(H6DO)-12,
Throttle Body.>
TOR.
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
circuit of harness
between ECM and
electronic throttle
control.
TOR.
circuit to power in
the harness
between the ECM
and electronic
throttle control.
Go to step 16.
TOR.
more?
ness between the
ECM and elec-
trol.
TROL MOTOR HARNESS.
(E57) No. 2 (E57) No. 1:
more?
circuit of harness
between ECM and
electronic throttle
control.
chassis ground.
circuit of the har-
ness between the
ECM and engine
ground.
Step Check Yes No
EN(H6DO)(diag)-331
TROL.
Terminals
No. 2 No. 1:
trol. <Ref. to
FU(H6DO)-12,
Throttle Body.>
TROL.
closed position
Repair the poor
contact of the ECM
connector.
Replace the elec-
trol. <Ref. to
FU(H6DO)-12,
Throttle Body.>
Step Check Yes No
EN(H6DO)(diag)-332
EC:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B20 E57
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
5
2
3
4
3
5
3
7
E
E2
B21
E
A
5
C
2
1
C
1
A
2
9
1
9
E1
B20
A
1
8
C
6
A
2
8
6 4
1
5
*
*
B122
1
6
E
3
8
3
9
2
0
D
5
D
4
A
1
9
D
7
D
1
A
3
D
2
D
3
3
E57
2 1 5
B134
B362
5
7
6
A: B137 B136 D: C:
ECM
*
E
SBF-7
8
6 4
B47
B47
3 4
1 2
5 6
EN-05658
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-333
Step Check Yes No
TROL RELAY.
Terminals
No. 7 No. 8:
EN(H6DO)(diag)-
8, Electrical Com-
ponent Location.>
of power supply
circuit.
LAY.
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 4.
LAY.
ground.
more?
ness between
ECM and elec-
trol relay.
LAY.
(B136) No. 21 (B362) No. 6:
(B136) No. 1 (B362) No. 8:
contact of the ECM
connector.
Repair the open
circuit of harness
between ECM and
electronic throttle
control relay.
EN(H6DO)(diag)-334
ED:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
Immediately at fault recognition. Detected when two consecutive driving cycles with fault occur.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B20 E57
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
5
2
3
4
3
5
3
7
E
E2
B21
E
A
5
C
2
1
C
1
A
2
9
1
9
E1
B20
A
1
8
C
6
A
2
8
6 4
1
5
*
*
B122
1
6
E
3
8
3
9
2
0
D
5
D
4
A
1
9
D
7
D
1
A
3
D
2
D
3
3
E57
2 1 5
B134
B362
5
7
6
A: B137 B136 D: C:
ECM
*
E
SBF-7
8
6 4
B47
B47
3 4
1 2
5 6
EN-05658
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-335
EE:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP
PERFORMANCE
NOTE:
Step Check Yes No
TROL RELAY.
Terminals
No. 7 No. 8:
more?
EN(H6DO)(diag)-
8, Electrical Com-
ponent Location.>
PLY.
ground.
circuit to power in
the harness
between ECM and
electronic throttle
control relay.
Go to step 3.
LAY.
chassis ground.
more?
Repair the poor
contact of the ECM
connector.
Repair the ground
ness between
ECM and elec-
trol relay.
EN(H6DO)(diag)-336
EF:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT
LOW INPUT
SOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B315
E
C: B136
B137 D:
B83
B315
*
*
465132
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
A
3
D
2
B21
E2
D
1
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
C:
D:
B122
B83
D
3
A
5
C
6
B: B135
A: B134
D
7
3
7
3
5
3
4
5
2
3
6
B122
1 2 3 4 5 6
*
*
*
E
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
EN-05663
ACCELERATOR
PEDAL POSITION
SENSOR
ECM
ARRANGEMENT
EN(H6DO)(diag)-337
Step Check Yes No
chassis ground.
(B135) No. 23 (B136) No. 6:
more?
short of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
ground.
more?
Replace the accel-
erator pedal. <Ref.
to SP(H6DO)-3,
Accelerator
Pedal.>
Repair the ground
short of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
Replace the ECM if
defective. <Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-338
EG:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT
HIGH INPUT
SOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B315
E
C: B136
B137 D:
B83
B315
*
*
465132
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
A
3
D
2
B21
E2
D
1
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
C:
D:
B122
B83
D
3
A
5
C
6
B: B135
A: B134
D
7
3
7
3
5
3
4
5
2
3
6
B122
1 2 3 4 5 6
*
*
*
E
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
EN-05663
ACCELERATOR
PEDAL POSITION
SENSOR
ECM
ARRANGEMENT
EN(H6DO)(diag)-339
Step Check Yes No
connector.
(B135) No. 23 (B315) No. 6:
(B135) No. 29 (B315) No. 5:
circuit of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
ground.
circuit to power
source in the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
Go to step 4.
nectors.
(B135) No. 21 (B135) No. 23:
more?
Repair the poor
contact of acceler-
ator pedal position
sensor connector.
Replace the accel-
erator pedal if
defective. <Ref. to
SP(H6DO)-3,
Accelerator
Pedal.>
Repair the short
circuit to power
source in the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
EN(H6DO)(diag)-340
EH:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT
LOW INPUT
SOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B315
E
C: B136
B137 D:
B83
B315
*
*
465132
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
A
3
D
2
B21
E2
D
1
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
C:
D:
B122
B83
D
3
A
5
C
6
B: B135
A: B134
D
7
3
7
3
5
3
4
5
2
3
6
B122
1 2 3 4 5 6
*
*
*
E
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
EN-05663
ACCELERATOR
PEDAL POSITION
SENSOR
ECM
ARRANGEMENT
EN(H6DO)(diag)-341
Step Check Yes No
chassis ground.
more?
short of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
ground.
more?
Replace the accel-
erator pedal. <Ref.
to SP(H6DO)-3,
Accelerator
Pedal.>
Repair the ground
short of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
Replace the ECM if
defective. <Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-342
EI: DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT
HIGH INPUT
SOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B315
E
C: B136
B137 D:
B83
B315
*
*
465132
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
A
3
D
2
B21
E2
D
1
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
C:
D:
B122
B83
D
3
A
5
C
6
B: B135
A: B134
D
7
3
7
3
5
3
4
5
2
3
6
B122
1 2 3 4 5 6
*
*
*
E
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
EN-05663
ACCELERATOR
PEDAL POSITION
SENSOR
ECM
ARRANGEMENT
EN(H6DO)(diag)-343
Step Check Yes No
connector.
(B135) No. 31 (B315) No. 3:
(B135) No. 30 (B315) No. 2:
circuit of the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
ground.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
ground.
circuit to power
source in the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
Go to step 4.
nectors.
(B135) No. 22 (B135) No. 31:
more?
Repair the poor
contact of acceler-
ator pedal position
sensor connector.
Replace the accel-
erator pedal if
defective. <Ref. to
SP(H6DO)-3,
Accelerator
Pedal.>
Repair the short
circuit to power
source in the har-
ness between the
ECM and accelera-
tor pedal position
sensor connector.
EN(H6DO)(diag)-344
EJ:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B
VOLTAGE CORRELATION
SOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
1 2
7 8
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 2122
23 24 25
34 35 36 37 38 39 40 41
48 49 50 51 52 53 54
42 43 44 45 46 47
26 27 28 29 30 3132 33
1 2 3 4
5 6 7 8
1 2 7
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16 17
27 28
18 22 23 24 25
26
1 2
8 9
5 6 3 4
10 11 12
19 20 21
29 30 31
13 14 15 16
17 27
28
18 22 23 24 25 26
7
32 33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6
B20 E57
B137 D:
B21 B122
B136 C:
B362
B134 A:
3
6
5
2
3
4
3
5
3
7
E
E2
B21
E
A
5
C
2
1
C
1
A
2
9
1
9
E1
B20
A
1
8
C
6
A
2
8
6 4
1
5
*
*
B122
1
6
E
3
8
3
9
2
0
D
5
D
4
A
1
9
D
7
D
1
A
3
D
2
D
3
3
E57
2 1 5
B134
B362
5
7
6
A: B137 B136 D: C:
ECM
*
E
SBF-7
8
6 4
B47
B47
3 4
1 2
5 6
EN-05658
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
BATTERY
ELECTRONIC THROTTLE
CONTROL
ARRANGEMENT
EN(H6DO)(diag)-345
Step Check Yes No
chassis ground.
(B134) No. 18 (B136) No. 6:
more?
ness between
ECM and elec-
trol connector.
throttle control connectorelectronic throttle con-
trol connector and engine ground.
more?
ness between
ECM and elec-
trol connector.
Replace the ECM if
defective. <Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
circuit of harness
between ECM and
electronic throttle
control connector.
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground
Poor contact in
ECM connector
Poor contact of
coupling connector
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Go to step 6.
EN(H6DO)(diag)-346
nectors.
(B134) No. 19 (B134) No. 18:
(B134) No. 19 (B134) No. 28:
more?
Repair poor con-
tact of the elec-
tronic throttle
control connector.
Replace the elec-
trol if if defective.
<Ref. to
FU(H6DO)-12,
Throttle Body.>
Repair the short
circuit to power in
the harness
between ECM and
electronic throttle
control connector.
Step Check Yes No
EN(H6DO)(diag)-347
EK:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E
VOLTAGE CORRELATION
SOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Inspection Mode.>.
TROUBLE SYMPTOM:
Improper idling
WIRING DIAGRAM:
B315
E
C: B136
B137 D:
B83
B315
*
*
465132
B
2
1
B
2
3
B
2
9
B
2
2
B
3
1
B
3
0
A
3
D
2
B21
E2
D
1
1 2 3 4
5 6 7 8
B21
1 2 3 4
12 13 14 15
5 6 7 8
16 17 18 19
9 10 11
20 21 22
23 24 25 26 27 28 29 30 31 32 33
35 34 37 36 39 38 41 40
43 42 44 45 47 46
49 48 51 50 53 52 54
B137
5 6 7
8
2 1
9
4 3
10
22 23
11 12 13 14 15
24 25
26
16 17
18 19 20 21
27 28 29 30 31
B136
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B135
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B:
C:
D:
B122
B83
D
3
A
5
C
6
B: B135
A: B134
D
7
3
7
3
5
3
4
5
2
3
6
B122
1 2 3 4 5 6
*
*
*
E
B134
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17
18 19 20 21
33 34 29 32 30 31
A:
EN-05663
ACCELERATOR
PEDAL POSITION
SENSOR
ECM
ARRANGEMENT
EN(H6DO)(diag)-348
Step Check Yes No
SENSOR OUTPUT.
chassis ground.
SENSOR OUTPUT.
ground.
Replace the accel-
erator pedal. <Ref.
to SP(H6DO)-3,
Accelerator
Pedal.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and ac-
celerator pedal po-
sition sensor
connector.
Ground short cir-
cuit of harness be-
tween the ECM
and accelerator
pedal position sen-
sor connectors.
Poor contact of
coupling connector
CONNECTOR.
and chassis ground.
contact of the ECM
connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
the ECM and ac-
celerator pedal po-
sition sensor
connector.
Open circuit of
harness between
ECM and engine
ground
Poor contact of
coupling connector
EN(H6DO)(diag)-349
EL:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H6DO)-242, DTC P2227 BAROMETRIC PRESSURE CIRCUIT
CAUTION:
Inspection Mode.>.
EM:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW
CAUTION:
Inspection Mode.>.
Step Check Yes No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
NOTE:
The barometric
pressure sensor is
built into the ECM.
Step Check Yes No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
NOTE:
The barometric
pressure sensor is
built into the ECM.
EN(H6DO)(diag)-350
EN:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH
CAUTION:
Inspection Mode.>.
Step Check Yes No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Replace the ECM.
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
NOTE:
The barometric
pressure sensor is
built into the ECM.
EN(H6DO)(diag)-351
A: CHECK SI-DRIVE (SUBARU Intelligent Drive) SYSTEM
DIAGNOSIS:
SI-DRIVE mode will not change.
CAUTION:
Note that the SI-DRIVE system performs the following control when changing modes.
1. When the engine is cold, the low coolant temperature display will light in the multi-information dis-
play meter. In this case, it will not be possible to change to the S# (sports sharp) mode.
2. If the engine is stopped in the S# (sports sharp) mode, it will be in the S (sports) mode when the
engine is restarted.
3. If the engine is stopped in the S (sports) or I (intelligent) mode, then restarted, it will enter the mode
it was on before stopping the engine.
4. If the malfunction indicator light becomes lit while the engine is running, it will enter the S (sports)
mode. In this case, it will not be possible to change to the S# (sports sharp) or I (intelligent) mode.
5. If there is a possible engine coolant or engine oil temperature overheat condition, it will not be
possible to switch to the S# (sports sharp) mode. When driving in the S# (sports sharp) mode, it will
enter the S (sports) mode.
1. EVEN WHEN THE SI-DRIVE MODE IS CHANGED, THE MULTI-INFORMATION DISPLAY
DOES NOT CHANGE, AND THE MODE DOES NOT SWITCH.
EN(H6DO)(diag)-352
WIRING DIAGRAM:
Step Check Yes No
1 CHECK SI-DRIVE SELECTOR.
1) Disconnect the connector from the multi-
information display meter.
2) Measure the resistance between connec-
tors when the SI-DRIVE selector is operated.
(i11) No. 9 (i11) No. 12:
Does the resistance change as
shown below?
S#: 2.14 3.2 k
I: 0.8 1.2 k
S: less than 10
2 CHECK SI-DRIVE S# SWITCH.
1) Hold down the SI-DRIVE S# switch.
the multi-information display meter connector
and chassis ground.
Is the resistance less than 10 ? Go to step 3. Go to step 6.
EN-05720
i1
5 6 7 8
2 1
9
4 3
10
24
22
23 25 27 26 28
11 12 13 14 15 16
17 18 19 20 21
C7
1 2 3 4 5
B68
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
B: i11
A: i10
3 4 5 6 7 8 9
19 20 21 14 15 16 17 18
1 2 10
12 11 13 22
i54
1
9
2 3 8
10
4
11 12 13 14 15 16
5 6 7
17 18
R43
2 3 4 5 6 7 8 9
11 12 13 14 17 18 19 20
1
10 15 16
ST4
2 3 4 5 1 6
i10 A: i11 B:
A
1
1
A
1
2
B
9
B
1
2
i1
B36
9
2
4
i54
R99
21
R43
C1
1
5
1
6
B
8
3 2
ST1
ST4
B68
1
2
5
4 3
C7
I
S#
S
E
4 5ST5
ST5
2 3 4 5 1
COMBINATION
METER
ROLL
CONNECTOR
SI-DRIVE
SELECTOR
SI-DRIVE S#
SWITCH
EN(H6DO)(diag)-353
Cracked or improperly connected connector
Broken connector pin
Disconnection of connector terminal
tion?
Correct the cause
of trouble.
Go to step 4.
4 RECHECK FAULT.
tion?
Replace the multi-
information dis-
play meter. <Ref.
to IDI-19, Combi-
nation Meter.>
The circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the failure,
and then perform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector
may be the cause.
5 CHECK SI-DRIVE SELECTOR HARNESS
AND CONNECTOR.
Improperly connected or loose terminal in the
SI-DRIVE selector connector
coupling connector
tion?
Correct the cause
of trouble.
Go to step 7.
6 CHECK SI-DRIVE S# SWITCH HARNESS
AND CONNECTOR.
steering roll connector
coupling connector
tion?
Correct the cause
of trouble.
Go to step 7.
7 RECHECK FAULT.
tion?
Replace the SI-
DRIVE selector or
SI-DRIVE S#
switch. <Ref. to
FU(H6DO)-35, SI-
DRIVE (SUBARU
Intelligent Drive)
Selector.> or <Ref.
to FU(H6DO)-36,
SI-DRIVE (SUB-
ARU Intelligent
Drive) S# Switch.>
The circuit has
returned to a nor-
mal condition at
this time. Repro-
duce the failure,
and then perform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector
may be the cause.
Step Check Yes No
EN(H6DO)(diag)-354
2. WHEN THE SI-DRIVE MODE IS CHANGED, MODE CHANGE ERROR APPEARS IN THE
MULTI INFORMATION DISPLAY APPROXIMATELY 5 SECONDS LATER.
Step Check Yes No
1 CHECK DTC. Is DTC displayed? Check for the cor-
responding DTC
using the List of
Diagnostic Trouble
Code (DTC) for
each unit.
Go to step 2.
2 CHECK DISPLAY OF MULTI-INFORMATION
DISPLAY METER.
Check whether there are other errors displayed
other than the Mode Change Error.
Example:
Err is displayed in the external temperature
or fuel consumption displays.
FUEL gauge, TEMP gauge or ECO gauge
does not move.
Is there other errors displayed
other than the Mode Change
Error?
For the diagnostic
procedure, refer to
LAN section. <Ref.
to LAN(diag)-2,
Basic Diagnostic
Procedure.>
Go to step 3.
3 CHECK MULTI-INFORMATION DISPLAY
METER AND ECM.
Is the multi-information display
meter and ECM part numbers
correct?
Replace the multi-
information dis-
play meter. <Ref.
to IDI-19, Combi-
nation Meter.>
Replace the multi-
information dis-
play meter and/or
ECM to that of the
correct part num-
ber. <Ref. to IDI-
19, Combination
Meter.> or <Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-355
3. WHEN THE SI-DRIVE MODE IS CHANGED, MODE CHANGE ERROR IS NOT DISPLAYED
IN MULTI-INFORMATION DISPLAY, AND S#, I, S FLASHES.
NOTE:
In this case, there may be a problem outside the SI-DRIVE system.
Step Check Yes No
1 CHECK MALFUNCTION INDICATOR LIGHT.
2) Check whether the malfunction indicator
light is lit or not.
light illuminate?
Check the appro-
priate DTC using
the List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(H6DO)(diag)-
tic Trouble Code
(DTC).>
Go to step 2.
GAUGE.
2) Check the engine coolant temperature
gauge.
Is it overheating? Investigate and
repair the cause of
the overheating.
Go to step 3.
3 CHECK ENGINE OIL TEMPERATURE.
2) Check the engine oil temperature using
NOTE:
tor.>
Is the engine oil temperature
Inspect and repair
the cause of
engine oil tempera-
ture rise.
NOTE:
Ask the customer
whether the vehi-
cle has experi-
enced a long drive
in low gear or tow-
ing of heavy load. If
not, drive the vehi-
cle again after the
engine oil temper-
ature lowers, and
check if the oil tem-
perature rises.
Go to step 4.
4 CHECK DISPLAY OF MULTI-INFORMATION
DISPLAY.
3) Check the display of the multi-information
display.
Do the displays S#, I, S of
the multi-information display
flash?
Replace the multi-
information dis-
play meter. <Ref.
to IDI-19, Combi-
nation Meter.>
Perform test opera-
tion, and check the
malfunction indica-
tor, the engine
coolant tempera-
ture gauge and the
engine oil tempera-
ture. If they are
operating normally,
end the diagnosis.
EN(H6DO)(diag)-356
A: INSPECTION
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H6DO)-86, Engine Trouble in Gen-
eral.>
2. Rough idling
10) Oxygen sensor
5) Accelerator pedal position sensor
6) Oil temperature sensor
12) Accelerator pedal position sensor
13) Oil temperature sensor
5. Engine stalls, engine sags or hesitates at accel-
eration.
EN(H6DO)(diag)-357
*1: Check ignition coil and spark plug.
*4: Check the fuel injector and fuel pressure regulator.
6. Surging
7. Spark knock
4) Knock sensor
EN(H6DO)(diag)-358
GD(H6DO)-2
GENERAL DESCRIPTION
A: LIST
DTC Item Index
mance (Bank 1)
<Ref. to GD(H6DO)-10, DTC P0011 INTAKE CAMSHAFT POSITION - TIM-
ING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnos-
<Ref. to GD(H6DO)-12, DTC P0016 CRANKSHAFT POSITION - CAM-
<Ref. to GD(H6DO)-13, DTC P0018 CRANKSHAFT POSITION - CAM-
mance (Bank 2)
<Ref. to GD(H6DO)-14, DTC P0021 INTAKE CAMSHAFT POSITION - TIM-
ING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Diagnos-
<Ref. to GD(H6DO)-14, DTC P0026 INTAKE VALVE CONTROL SOLENOID
(Bank 1 Sensor 1)
<Ref. to GD(H6DO)-17, DTC P0030 HO2S HEATER CONTROL CIRCUIT
(Bank 1 Sensor 1)
ria.>
(Bank 1 Sensor 1)
ria.>
(Bank 1 Sensor 2)
ria.>
(Bank 1 Sensor 2)
ria.>
(Bank 2 Sensor 1)
(Bank 2 Sensor 1)
ria.>
(Bank 2 Sensor 1)
ria.>
(Bank 2 Sensor 2)
ria.>
(Bank 2 Sensor 2)
ria.>
tion
<Ref. to GD(H6DO)-28, DTC P0068 MAP/MAF - THROTTLE POSITION
Low (Bank 1)
CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
GD(H6DO)-3
GENERAL DESCRIPTION
High (Bank 1)
CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
Low (Bank 2)
CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
High (Bank 2)
CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
Range/Performance
<Ref. to GD(H6DO)-34, DTC P0101 MASS OR VOLUME AIR FLOW CIR-
Criteria.>
Input
Input
<Ref. to GD(H6DO)-41, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/
BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code
<Ref. to GD(H6DO)-43, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/
BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble
<Ref. to GD(H6DO)-45, DTC P0111 INTAKE AIR TEMPERATURE SENSOR
1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC)
cuit Low
cuit High
Low
<Ref. to GD(H6DO)-51, DTC P0117 ENGINE COOLANT TEMPERATURE
High
<Ref. to GD(H6DO)-53, DTC P0118 ENGINE COOLANT TEMPERATURE
<Ref. to GD(H6DO)-55, DTC P0122 THROTTLE/PEDAL POSITION SEN-
SOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
SOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
<Ref. to GD(H6DO)-59, DTC P0125 INSUFFICIENT COOLANT TEMPERA-
TURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code
<Ref. to GD(H6DO)-62, DTC P0126 INSUFFICIENT ENGINE COOLANT
TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code
<Ref. to GD(H6DO)-64, DTC P0128 COOLANT THERMOSTAT (ENGINE
(Bank 1 Sensor 1)
<Ref. to GD(H6DO)-66, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE
(Bank 1 Sensor 1)
<Ref. to GD(H6DO)-68, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE
(Bank 1 Sensor 1)
<Ref. to GD(H6DO)-70, DTC P0133 O2 SENSOR CIRCUIT SLOW
ing Criteria.>
DTC Item Index
GD(H6DO)-4
GENERAL DESCRIPTION
<Ref. to GD(H6DO)-73, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY
DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
(Bank 1 Sensor 2)
(Bank 1 Sensor 2)
(Bank 1 Sensor 2)
ing Criteria.>
ing Criteria.>
(Bank 2 Sensor 1)
(Bank 2 Sensor 1)
(Bank 2 Sensor 1)
ing Criteria.>
ing Criteria.>
(Bank 2 Sensor 2)
(Bank 2 Sensor 2)
(Bank 2 Sensor 2)
ing Criteria.>
ing Criteria.>
P0171 System Too Lean (Bank 1) <Ref. to GD(H6DO)-89, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diag-
P0172 System Too Rich (Bank 1) <Ref. to GD(H6DO)-91, DTC P0172 SYSTEM TOO RICH (BANK 1), Diag-
P0174 System Too Lean (Bank 2) <Ref. to GD(H6DO)-92, DTC P0174 SYSTEM TOO LEAN (BANK 2), Diag-
P0175 System Too Rich (Bank 2) <Ref. to GD(H6DO)-92, DTC P0175 SYSTEM TOO RICH (BANK 2), Diag-
Range/Performance
<Ref. to GD(H6DO)-93, DTC P0181 FUEL TEMPERATURE SENSOR A
ing Criteria.>
Low Input
High Input
<Ref. to GD(H6DO)-100, DTC P0196 ENGINE OIL TEMPERATURE SEN-
SOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC)
P0197 Engine Oil Temperature Sensor Low <Ref. to GD(H6DO)-102, DTC P0197 ENGINE OIL TEMPERATURE SEN-
SOR LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0198 Engine Oil Temperature Sensor High <Ref. to GD(H6DO)-103, DTC P0198 ENGINE OIL TEMPERATURE SEN-
SOR HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
DTC Item Index
GD(H6DO)-5
GENERAL DESCRIPTION
SOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
SOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
P0230 Fuel Pump Primary Circuit <Ref. to GD(H6DO)-108, DTC P0230 FUEL PUMP PRIMARY CIRCUIT,
P0301 Cylinder 1 Misfire Detected <Ref. to GD(H6DO)-110, DTC P0301 CYLINDER 1 MISFIRE DETECTED,
<Ref. to GD(H6DO)-116, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW
Criteria.>
<Ref. to GD(H6DO)-118, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH
Criteria.>
P0332 Knock Sensor 2 Circuit Low (Bank 2) <Ref. to GD(H6DO)-119, DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW
P0333 Knock Sensor 2 Circuit High (Bank 2) <Ref. to GD(H6DO)-119, DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH
cuit
<Ref. to GD(H6DO)-120, DTC P0335 CRANKSHAFT POSITION SENSOR
<Ref. to GD(H6DO)-122, DTC P0336 CRANKSHAFT POSITION SENSOR
A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC)
<Ref. to GD(H6DO)-124, DTC P0340 CAMSHAFT POSITION SENSOR A
CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC)
(Bank 2)
<Ref. to GD(H6DO)-126, DTC P0345 CAMSHAFT POSITION SENSOR A
CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0400 Exhaust Gas Recirculation Flow <Ref. to GD(H6DO)-127, DTC P0400 EXHAUST GAS RECIRCULATION
Threshold (Bank 1)
<Ref. to GD(H6DO)-131, DTC P0420 CATALYST SYSTEM EFFICIENCY
Criteria.>
<Ref. to GD(H6DO)-134, DTC P0442 EVAPORATIVE EMISSION CON-
TROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble
TROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble
TROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble
DTC Item Index
GD(H6DO)-6
GENERAL DESCRIPTION
tem Pressure Sensor
TROL SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC)
TROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble
TROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble
Leak)
TROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trou-
Off)
<Ref. to GD(H6DO)-160, DTC P0458 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC)
<Ref. to GD(H6DO)-162, DTC P0459 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC)
Performance
<Ref. to GD(H6DO)-164, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT
ria.>
P0462 Fuel Level Sensor A Circuit Low <Ref. to GD(H6DO)-166, DTC P0462 FUEL LEVEL SENSOR A CIRCUIT
P0463 Fuel Level Sensor A Circuit High <Ref. to GD(H6DO)-168, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT
P0464 Fuel Level Sensor Circuit Intermittent <Ref. to GD(H6DO)-170, DTC P0464 FUEL LEVEL SENSOR CIRCUIT
P0500 Vehicle Speed Sensor A <Ref. to GD(H6DO)-173, DTC P0500 VEHICLE SPEED SENSOR A, Diag-
Than Expected
<Ref. to GD(H6DO)-175, DTC P0506 IDLE AIR CONTROL SYSTEM RPM
LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
Than Expected
<Ref. to GD(H6DO)-177, DTC P0507 IDLE AIR CONTROL SYSTEM RPM
HIGHER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
P0512 Starter Request Circuit <Ref. to GD(H6DO)-179, DTC P0512 STARTER REQUEST CIRCUIT, Diag-
P0513 Incorrect Immobilizer Key <Ref. to GD(H6DO)-180, DTC P0513 INCORRECT IMMOBILIZER KEY,
P0600 Serial Communication Link <Ref. to GD(H6DO)-181, DTC P0600 SERIAL COMMUNICATION LINK,
<Ref. to GD(H6DO)-183, DTC P0604 INTERNAL CONTROL MODULE
RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code
Memory (ROM) Error
<Ref. to GD(H6DO)-184, DTC P0605 INTERNAL CONTROL MODULE
READ ONLY MEMORY (ROM) ERROR, Diagnostic Trouble Code (DTC)
P0607 Control Module Performance <Ref. to GD(H6DO)-185, DTC P0607 CONTROL MODULE PERFOR-
P0638 Throttle Actuator Control Range/ Per-
formance (Bank 1)
<Ref. to GD(H6DO)-188, DTC P0638 THROTTLE ACTUATOR CONTROL
RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC)
DTC Item Index
GD(H6DO)-7
GENERAL DESCRIPTION
(MIL Request)
<Ref. to GD(H6DO)-190, DTC P0700 TRANSMISSION CONTROL SYSTEM
(MIL REQUEST), Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H6DO)-191, DTC P1152 O2 SENSOR CIRCUIT RANGE/PER-
FORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC)
FORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC)
FORMANCE (LOW) (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC)
FORMANCE (HIGH) (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC)
P1160 Return Spring Failure <Ref. to GD(H6DO)-197, DTC P1160 RETURN SPRING FAILURE, Diag-
Valve Circuit Low
<Ref. to GD(H6DO)-199, DTC P1400 FUEL TANK PRESSURE CONTROL
SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
Valve Circuit High
<Ref. to GD(H6DO)-201, DTC P1420 FUEL TANK PRESSURE CONTROL
SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
Problem
<Ref. to GD(H6DO)-203, DTC P1443 VENT CONTROL SOLENOID VALVE
<Ref. to GD(H6DO)-205, DTC P1492 EGR SOLENOID VALVE SIGNAL #1
P1560 Back-up voltage circuit malfunction <Ref. to GD(H6DO)-210, DTC P1560 BACK-UP VOLTAGE CIRCUIT MAL-
P1570 Antenna <Ref. to GD(H6DO)-211, DTC P1570 ANTENNA, Diagnostic Trouble Code
P1571 Reference Code Incompatibility <Ref. to GD(H6DO)-211, DTC P1571 REFERENCE CODE INCOMPATIBIL-
ITY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
(Except Antenna Circuit)
<Ref. to GD(H6DO)-211, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
DTC Item Index
GD(H6DO)-8
GENERAL DESCRIPTION
P1574 Key Communication Failure <Ref. to GD(H6DO)-211, DTC P1574 KEY COMMUNICATION FAILURE,
P1576 EGI Control Module EEPROM <Ref. to GD(H6DO)-211, DTC P1576 EGI CONTROL MODULE EEPROM,
P1577 IMM Control Module EEPROM <Ref. to GD(H6DO)-211, DTC P1577 IMM CONTROL MODULE EEPROM,
P1578 Meter Failure <Ref. to GD(H6DO)-211, DTC P1578 METER FAILURE, Diagnostic Trouble
P1602 Control Module Programming Error <Ref. to GD(H6DO)-212, DTC P1602 CONTROL MODULE PROGRAM-
<Ref. to GD(H6DO)-214, DTC P2088 INTAKE CAMSHAFT POSITION
Lean Bank 1
<Ref. to GD(H6DO)-218, DTC P2096 POST CATALYST FUEL TRIM SYS-
TEM TOO LEAN BANK 1, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
Rich Bank 1
TEM TOO RICH BANK 1, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
Lean Bank 2
TEM TOO LEAN BANK 2, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
Rich Bank 2
TEM TOO RICH BANK 2, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code
cuit Low
cuit High
MOTOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
SOR A MINIMUM STOP PERFORMANCE, Diagnostic Trouble Code
SOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC)
SOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC)
SOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC)
DTC Item Index
GD(H6DO)-9
GENERAL DESCRIPTION
SOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC)
SOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code
SOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code
Performance
<Ref. to GD(H6DO)-242, DTC P2227 BAROMETRIC PRESSURE CIRCUIT
ria.>
P2228 Barometric Pressure Circuit Low <Ref. to GD(H6DO)-243, DTC P2228 BAROMETRIC PRESSURE CIRCUIT
P2229 Barometric Pressure Circuit High <Ref. to GD(H6DO)-244, DTC P2229 BAROMETRIC PRESSURE CIRCUIT
DTC Item Index
GD(H6DO)-10
GENERAL DESCRIPTION
Judge NG when the amount of AVCS actual timing advance does not approach to the amount of AVCS target
timing advance.
3. ENABLE CONDITION
Perform the diagnosis continuously after warming up when the engine speed increases and AVCS operates.
Time of establishing all secondary
parameter conditions
> 3000 ms
AVCS control Operation
Target advance angle > 0 CA
Target timing advance change amount
(per 64 ms)
< 1.07 CA
EN-01852
(3)
(4)
(1)
(5)
(2)
GD(H6DO)-11
GENERAL DESCRIPTION
1) When the conditions during which the differences of AVCS target timing advance amount and AVCS ac-
tual timing advance amount is large continues for certain amount of time.
2) When the differences of target timing advance amount and actual timing advance amount is calculated
during AVCS control, and the difference per predetermined time is the specified value or larger.
Judge as NG when the following conditions are established within the predetermined time.
cles.
Normality Judgment
Judge as OK and clear the NG if the following conditions are established within the predetermined time.
8. FAIL SAFE
Fix valve lift amount to High
Judgment Value
Malfunction criteria Threshold value
E(Target position Actual position) > 8000 CA (Bank 1)
> 8000 CA (Bank 2)
or
E(Target position Actual position) < 2500 CA (Bank 1)
< 2500 CA (Bank 2)
Judgment Value
Malfunction riteria Threshold value
E(Target position Actual position) s 8000 CA (Bank 1)
s 8000 CA (Bank 2)
and
> 2500 CA (Bank 1)
> 2500 CA (Bank 2)
GD(H6DO)-12
GENERAL DESCRIPTION
B: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION
(BANK1)
Judge as NG when the timing advance is outside the normal range.
3. ENABLE CONDITION
Perform the diagnosis continuously after starting engine and while AVCS is not operating.
AVCS control Not in operation
Target timing advance 0CA
EN-01852
(3)
(4)
(1)
(5)
(2)
GD(H6DO)-13
GENERAL DESCRIPTION
Judge as NG when the camshaft sensor input position is not within the normal range.
cles.
Normality Judgment
8. FAIL SAFE
Fix valve lift amount to High
C: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELA-
TION (BANK2)
NOTE:
For the detection standard, refer to DTC P0016. <Ref. to GD(H6DO)-12, DTC P0016 CRANKSHAFT POSI-
TION - CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
Judgment Value
Camshaft input position < BTDC 22 CA (Bank 1)
< BTDC 22 CA (Bank 2)
or
> BTDC 58 CA (Bank 1)
Judgment Value
Camshaft input position > BTDC 22 CA (Bank 1)
and
s BTDC 58 CA (Bank 1)
s BTDC 58 CA (Bank 2)
GD(H6DO)-14
GENERAL DESCRIPTION
NOTE:
For the detection standard, refer to DTC P0011. <Ref. to GD(H6DO)-10, DTC P0011 INTAKE CAMSHAFT
POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Trouble
E: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PER-
FORMANCE (BANK 1)
Judge as NG with 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
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.
Oil switching solenoid valve duty Intake valve
Variable valve lift diag-
nosis oil pressure
switch
Large High mode ON
Minimum Low mode OFF
GD(H6DO)-15
GENERAL 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
Perform the diagnosis continuously 6 seconds after engine start while variable valve lift is being controlled
(1) Oil switching solenoid valve (A) When at low speed
(B) When at high speed
After engine starting > 6000 ms
Engine oil temperature > 0 C (32 F)
Variable valve lift control Operation
EN-03119
(1)
(B)
(A)
GD(H6DO)-16
GENERAL DESCRIPTION
Low side: 784 ms
High side: 3000 ms
Normality Judgment
Low side: 208 ms
High side: 3000 ms
8. FAIL SAFE
None
Judgment Value
Low
Duty ratio > 62 %
switch
OFF
High
Duty ratio < 33 %
switch
ON
Judgment Value
Low
Duty ratio > 62 %
switch
ON
High
Duty ratio < 33 %
switch
OFF
GD(H6DO)-17
GENERAL DESCRIPTION
F: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/
NOTE:
For the detection standard, refer to DTC P0026. <Ref. to GD(H6DO)-14, DTC P0026 INTAKE VALVE CON-
TROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
G: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
3. ENABLE CONDITION
(2) Ceramic heater
Condition established time > 30000 ms
Control duty > 35 % Experienced
EN-02181
( 1 ) ( 2 )
( 3 ) ( 4 )
GD(H6DO)-18
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Rear oxygen sensor sub learning compensation: Not allowed to calculate.
Judgment Value
Front oxygen (A/F) sensor impedance > 50 O
Judgment Value
Front oxygen (A/F) sensor impedance s 50 O
GD(H6DO)-19
GENERAL DESCRIPTION
3. ENABLE CONDITION
output voltage

EN-01792
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H6DO)-20
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
duty
< 87.5 %
Judgment Value
GD(H6DO)-21
GENERAL DESCRIPTION
3. ENABLE CONDITION
output voltage

EN-01793
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H6DO)-22
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
duty
> 12.5 %
Judgment Value
GD(H6DO)-23
GENERAL DESCRIPTION
J: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)
3. ENABLE CONDITION
sensor heater

EN-01792
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H6DO)-24
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H6DO)-25
GENERAL DESCRIPTION
K: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
3. ENABLE CONDITION
sensor heater

EN-01793
(C)
(A)
(B)
ON
OFF
0V
(D)
GD(H6DO)-26
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
Rear oxygen sensor heater control duty > 15 %
Judgment Value
GD(H6DO)-27
GENERAL DESCRIPTION
L: DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1)
NOTE:
For the detection standard, refer to DTC P0030. <Ref. to GD(H6DO)-17, DTC P0030 HO2S HEATER CON-
TROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
M: DTC P0051 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1)
NOTE:
TROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
N: DTC P0052 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1)
NOTE:
TROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
O: DTC P0057 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2)
NOTE:
TROL CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P: DTC P0058 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2)
NOTE:
TROL CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-28
GENERAL DESCRIPTION
Q: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
3. ENABLE CONDITION
EN-01765
(B)
(A)
(2)
(3)
(1)
GD(H6DO)-29
GENERAL DESCRIPTION
Low side: 3000 msec
cles.
Normality Judgment
Judgment Value
Low
Engine load > 0.87 g/rev
(0.031 oz/rev)
High
Engine load < 0.6 g/rev
(0.021 oz/rev)
Judgment Value
Low
Engine load > 0.87 g/rev
(0.031 oz/rev)
High
Engine load < 0.6 g/rev
(0.021 oz/rev)
GD(H6DO)-30
GENERAL DESCRIPTION
8. FAIL SAFE
Intake manifold pressure sensor process: Estimate the pressure from the engine speed and size of the
throttle opening. When the throttle opening is also NG, fix at 66.7 kPa (500 mmHg, 19.69 inHg).
Fuel cut control: Fuel cut will operate at engine high speed.
Knocking compensation
When normal: Learning ignition advance angle value = knock F/B advance angle + entire learning advance
angle value + portional learning advance angle value
Failure: learned ignition advance value = 6CA. (6CA retard)
Knock F/B advance angle value = 0CA
Whole learning prohibited
Portional learning prohibited
ISC control: ISC feedback amount calculation prohibited
Amount of ISC open-loop compensation = Fixed at 6.82%
GD(H6DO)-31
GENERAL DESCRIPTION
R: 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
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Duty ratio > 30 %
Control current < 0.026 A
Judgment Value
current value|
< 0.08 A
Target current > 0.11 A
GD(H6DO)-32
GENERAL DESCRIPTION
S: 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
Normality Judgment
7. FAIL SAFE
None
T: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)
NOTE:
TROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
Judgment Value
Duty ratio < 7 %
Control current > 0.465 A
Judgment Value
current value|
< 0.08 A
GD(H6DO)-33
GENERAL DESCRIPTION
U: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)
NOTE:
TROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-34
GENERAL DESCRIPTION
V: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE
3. ENABLE CONDITION
EN-01766
(3)
(4)
(2)
(1)
(A)
GD(H6DO)-35
GENERAL DESCRIPTION
Low: 5000 ms
High: 10000 ms
cles.
Normality Judgment
Judgment Value
Low
Intake manifold pressure > 73.32 kPa (550 mmHg, 21.654 inHg)
High (1)
High (2)
Judgment Value
Low
High
Intake manifold pressure < 46.66 kPa (350 mmHg, 13.78 inHg)
GD(H6DO)-36
GENERAL DESCRIPTION
8. FAIL SAFE
None
GD(H6DO)-37
GENERAL DESCRIPTION
W: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-01766
(3)
(4)
(2)
(1)
(A)
GD(H6DO)-38
GENERAL DESCRIPTION
8. FAIL SAFE
Knock compensation:
GD(H6DO)-39
GENERAL DESCRIPTION
X: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-01766
(3)
(4)
(2)
(1)
(A)
GD(H6DO)-40
GENERAL DESCRIPTION
8. FAIL SAFE
Knock compensation:
GD(H6DO)-41
GENERAL DESCRIPTION
Y: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT LOW INPUT
3. ENABLE CONDITION
None
EN-01765
(B)
(A)
(2)
(3)
(1)
GD(H6DO)-42
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Amount of ISC open-loop compensation = Fixed at 6.82 %
Judgment Value
Judgment Value
GD(H6DO)-43
GENERAL DESCRIPTION
Z: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE
CIRCUIT HIGH INPUT
3. ENABLE CONDITION
None
EN-01765
(B)
(A)
(2)
(3)
(1)
GD(H6DO)-44
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Amount of ISC open-loop compensation = Fixed at 6.82%
Judgment Value
Judgment Value
GD(H6DO)-45
GENERAL DESCRIPTION
AA:DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/
PERFORMANCE
3. ENABLE CONDITION
starting
< 30 C (86 F)
is less than 60 km/h (37.3 MPH)
> 600 sec
EN-01767
(3)
(4)
(2)
(1)
(A)
GD(H6DO)-46
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
and Min.
approximately 0.5C
(0.9F) near 25C)
Judgment Value
and Min.
> 0.02 V
GD(H6DO)-47
GENERAL DESCRIPTION
AB:DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-01767
(3)
(4)
(2)
(1)
(A)
GD(H6DO)-48
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H6DO)-49
GENERAL DESCRIPTION
AC:DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-01767
(3)
(4)
(2)
(1)
(A)
GD(H6DO)-50
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H6DO)-51
GENERAL DESCRIPTION
AD:DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-02917
(A)
(2)
(1)
(B)
GD(H6DO)-52
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H6DO)-53
GENERAL DESCRIPTION
AE:DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
3. ENABLE CONDITION
Normality Judgment
None
Judgment Value
Judgment Value
EN-02917
(A)
(2)
(1)
(B)
GD(H6DO)-54
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H6DO)-55
GENERAL DESCRIPTION
AF:DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT
LOW
3. ENABLE CONDITION
Ignition switch ON
EN-01859
(1)
(2)
(3)
(4)
GD(H6DO)-56
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H6DO)-57
GENERAL DESCRIPTION
AG:DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT
HIGH
3. ENABLE CONDITION
Ignition switch ON
EN-01859
(1)
(2)
(3)
(4)
GD(H6DO)-58
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H6DO)-59
GENERAL DESCRIPTION
AH:DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP
FUEL CONTROL
3. ENABLE CONDITION
Engine speed > Value from Map
Map
C (F)
40 (40) 110 (230)
Engine speed
rpm
500 500
EN-02917
(A)
(2)
(1)
(B)
GD(H6DO)-60
GENERAL DESCRIPTION
t = 429523 ms 28605 ms/C Ti
cles.
Normality Judgment
Judgment Value
Timer for diagnosis after engine start > Judgment value of
0 (0) 8 (5) 16 (9.9) 24 (14.9) 32 (19.9) 40 (24.9) 48 (29.8) 56 (34.8)
Tempera-
ture
C (F)
Judgment Value
GD(H6DO)-61
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H6DO)-62
GENERAL DESCRIPTION
AI: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE
OPERATION
3. ENABLE CONDITION
(A) Resistance value (kO) (B) Temperature C (F)

None
3.3 Imp gal)
engine stop
> 75 C (167 F)
EN-02917
(A)
(2)
(1)
(B)
GD(H6DO)-63
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
< 2.5 C (36.5 F)
fuel temperature
> 5 C (41 F)
ture
< 2.5 C (36.5 F)
Judgment Value
> 2.5 C (36.5 F)
GD(H6DO)-64
GENERAL DESCRIPTION
AJ:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE
3. ENABLE CONDITION
None
EN-01692
(9)
(2)
(6)
(8)
(7)
(5)
(4)
(3)
(1)
(2)
GD(H6DO)-65
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
starting
< 55 C (131 F)
Estimated coolant temperature > 75 C (167 F)
Engine coolant temperature s 75 C (167 F)
temperature
> 20 C (68 F)
Judgment Value
starting
< 55 C (131 F)
temperature
s 20 C (68 F)
GD(H6DO)-66
GENERAL DESCRIPTION
AK:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
3. ENABLE CONDITION
(3) ZrO
2
(C) Lean
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H6DO)-67
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Compensation when starting the engine at high temperature: Make the MIN value to be 0.06 0, normal-
ly.
Judgment Value
Input voltage < 1.800 V
or
Input current < 0.005 A
Judgment Value
GD(H6DO)-68
GENERAL DESCRIPTION
AL:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
3. ENABLE CONDITION
(3) ZrO
2
(C) Lean
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H6DO)-69
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Front oxygen (A/F) sensor heater control: Not allowed to turn on heater
Judgment Value
or
Judgment Value
Input voltage s 3.800 V
Input current s 0.005 A
GD(H6DO)-70
GENERAL DESCRIPTION
AM:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
diagnosed.
(3) ZrO
2
(C) Lean
EN-01694
(1)
(2)
(3)
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H6DO)-71
GENERAL DESCRIPTION
3. ENABLE CONDITION
Calculate faf difference and the value difference every 32ms 4 . Calculate the diagnosis value after cal-
culating 820 time.
cles.
> 1024 ms
Barometric pressure > 75.05 kPa (563 mmHg, 22.165
inHg)
Vehicle speed 10 km/h 120 km/h (6.2 MPH
74.6 MPH)
Amount of intake air 10 g/s 40 g/s (0.353 oz/s
1.411 oz/s)
purge
< 0.2
Judgment Value
parafca = td2faf/td2lmd > 0.25
where,
faf (n2))
(n1) lmd (n2))
onds
GD(H6DO)-72
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
parafca = td2faf/td2lmd s 0.25
where,
faf (n2))
(n1) lmd (n2))
onds
GD(H6DO)-73
GENERAL DESCRIPTION
AN:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 1)
3. ENABLE CONDITION
(3) ZrO
2
(C) Lean
None
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H6DO)-74
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Front oxygen (A/F) sensor IC communication: Not allowed to communicate.
Judgment Value
more
> 30000 ms
Front oxygen (A/F) sensor impedance. > 500 O
Judgment Value
Front oxygen (A/F) sensor impedance. s 500 O
GD(H6DO)-75
GENERAL DESCRIPTION
AO:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H6DO)-76
GENERAL DESCRIPTION
3. ENABLE CONDITION
High
Low (1)
Low (2)
Low (3)
GD(H6DO)-77
GENERAL DESCRIPTION
High: 2500 ms
Low (1): 20000 ms
Low (2): 40000 ms
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
Malfunction criteria Threshold value DTC
High P0138
Low P0137
Map
Judgment Value
High P0138
Sensor output voltage s 1.200 V P0158
Low P0137
GD(H6DO)-78
GENERAL DESCRIPTION
AP:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
NOTE:
For the detection standard, refer to DTC P0137. <Ref. to GD(H6DO)-75, DTC P0137 O2 SENSOR CIRCUIT
GD(H6DO)-79
GENERAL DESCRIPTION
AQ:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
cut.
Diagnostic method
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H6DO)-80
GENERAL DESCRIPTION
3. ENABLE CONDITION
more.
Experienced
gen sensor heater
> 40000 ms
gen sensor heater
> 20000 ms
GD(H6DO)-81
GENERAL DESCRIPTION
(D) 0.15 V
(A)
(B)
(C)
(D)
(E)
(G)
(F)
(H)
EN-05566
GD(H6DO)-82
GENERAL DESCRIPTION
NOTE:
cles.
Normality Judgment
condition.
8. FAIL SAFE
Judgment Value
2
> 491 ms
or
Longest time over 0.55 V > 2000 ms
Judgment Value
2
s 491 ms
GD(H6DO)-83
GENERAL DESCRIPTION
10.ENABLE CONDITION
more.
Experienced
gen sensor heater
> 0 ms
gen sensor heater
> 0 ms
GD(H6DO)-84
GENERAL DESCRIPTION
(A) 0.55 V (G) More than 120000 ms (J) Judge NG when the voltage of
tion.
(B) 0.5 V (H) Measure the response time (diag-
nostic value).
(C) 0.3 V
(D) 0.25 V (I) Execute the malfunction judg-
(E) 0 V
(I)
(E)
(F)
(G)
(D)
(C)
(B)
(A)
(H)
(J)
EN-05567
GD(H6DO)-85
GENERAL DESCRIPTION
judge as NG.
cles.
Normality Judgment
condition.
15.FAIL SAFE
Judgment Value
O
2
> 2000 ms
or
Longest time under 0.25 V > 120000 ms
Judgment Value
O
2
s 2000 ms
GD(H6DO)-86
GENERAL DESCRIPTION
AR:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 2)

sensor
In operation
sor
> 0.55 V + 0.05 V
coefficient
Not in limit value
more.
Experienced
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H6DO)-87
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
AS:DTC P0151 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1)
NOTE:
AT:DTC P0152 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1)
NOTE:
HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
Judgment Value
or
Judgment Value
age low side
Incomplete
Minimum output voltage s 0.15 V
Maximum output voltage > 0.55 V
GD(H6DO)-88
GENERAL DESCRIPTION
AU:DTC P0153 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 1)
NOTE:
SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
AV:DTC P0154 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 2 SENSOR 1)
NOTE:
NO ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
AW:DTC P0157 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 2)
NOTE:
AX:DTC P0158 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2)
NOTE:
AY:DTC P0159 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 2)
NOTE:
SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
AZ:DTC P0160 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED
(BANK 2 SENSOR 2)
NOTE:
NO ACTIVITY DETECTED (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-89
GENERAL DESCRIPTION
BA:DTC P0171 SYSTEM TOO LEAN (BANK 1)
Diagnostic method
measured by sensor.
2. ENABLE CONDITION
cles.
Normality Judgment
Map1
Measured value
(g(oz)/rev)
Non-turbo
0.357
(0.013)
0.25
(0.009)
0.25
(0.009)
0.317
(0.011)
0.326
(0.011)
0.337
(0.012)
0.397
(0.014)
0.439
(0.015)
0.454
(0.016)
0.454
(0.016)
Judgment Value
fsobd = (sglmd tglmda) + faf + flaf > Value of Map 2
faf = main feedback compensation coefficient every 64
milliseconds
flaf = main feedback learning compensation coefficient
Map2
3.2
(0.113)
6.4
(0.226)
9.6
(0.339)
12.8
(0.451)
16
(0.564)
19.2
(0.677)
fsobdL1 (%) 1.4 1.4 1.332 1.265 1.265 1.265 1.265
Judgment Value
GD(H6DO)-90
GENERAL DESCRIPTION
7. FAIL SAFE
None
GD(H6DO)-91
GENERAL DESCRIPTION
BB:DTC P0172 SYSTEM TOO RICH (BANK 1)
Diagnostic method
measured by sensor.
2. ENABLE CONDITION
cles.
Engine load change s 0.02 g/rev (0.001 oz/rev)
Cumulative time of canister purge after
engine start
> 20 sec
Continuous period after canister purge
starting
> 29884 ms
Map1
Measured value
(g(oz)/rev)
Non-turbo
0.357
(0.013)
0.25
(0.009)
0.25
(0.009)
0.317
(0.011)
0.326
(0.011)
0.337
(0.012)
0.397
(0.014)
0.439
(0.015)
0.454
(0.016)
0.454
(0.016)
Judgment Value
tion coefficient
Map2
3.2
(0.113)
6.4
(0.226)
9.6
(0.339)
12.8
(0.451)
16
(0.564)
19.2
(0.677)
fsobdL1 (%) 0.6 0.6 0.688 0.735 0.735 0.735 0.735
GD(H6DO)-92
GENERAL DESCRIPTION
Normality Judgment
7. FAIL SAFE
BC:DTC P0174 SYSTEM TOO LEAN (BANK 2)
NOTE:
For the detection standard, refer to DTC P0171. <Ref. to GD(H6DO)-89, DTC P0171 SYSTEM TOO LEAN
BD:DTC P0175 SYSTEM TOO RICH (BANK 2)
NOTE:
For the detection standard, refer to DTC P0172. <Ref. to GD(H6DO)-91, DTC P0172 SYSTEM TOO RICH
Judgment Value
fsobd = (sglmd tglmda) + faf + flaf > 0.8
GD(H6DO)-93
GENERAL DESCRIPTION
BE:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/
PERFORMANCE
Diagnosis is performed in two methods (drift diagnosis and stack diagnosis). If either is NG, judge as NG. If
Drift Diagnosis
Stuck Diagnosis
3. ENABLE CONDITION
DRIFT DIAGNOSIS
None
EN-01700
(A)
(B)
GD(H6DO)-94
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
10.ENABLE CONDITION
Stuck Diagnosis
Judgment Value
2.112 Imp gal)
> 10 C (50 F)
perature
> 10 C (50 F)
Judgment Value
2.112 Imp gal)
> 10 C (50 F)
perature
< 10 C (50 F)
GD(H6DO)-95
GENERAL DESCRIPTION
cles.
Normality Judgment
15.FAIL SAFE
None
Judgment Value
(19435.287 oz)
Max. and Min.
< 2 C (35.6 F)
Judgment Value
Max. and Min.
> 2 C (35.6 F)
GD(H6DO)-96
GENERAL DESCRIPTION
BF:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT
3. ENABLE CONDITION
None
EN-01700
(A)
(B)
GD(H6DO)-97
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H6DO)-98
GENERAL DESCRIPTION
BG:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT
3. ENABLE CONDITION
None
EN-01700
(A)
(B)
GD(H6DO)-99
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H6DO)-100
GENERAL DESCRIPTION
BH: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
Engine speed > Value from Map
Map
C (F)
40 (40) 110 (230)
Engine speed
rpm
500 500
GD(H6DO)-101
GENERAL DESCRIPTION
After engine start oil temperature sensor characteristic diagnosis timer (timer for diagnosis).
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.
After engine start oil temperature characteristic diagnosis timer judgment value (t).
t = 2400000 ms 60000 ms/C Ti (t > 2400000)
Ti = The lowest coolant temperature after starting the engine.
cles.
Normality Judgment
7. FAIL SAFE
Judgment Value
Engine oil temperature < 15 C (59 F)
After engine start oil temperature sensor
characteristic diagnosis timer.
> Judgment value for after engine
start oil temperature sensor char-
acteristic diagnosis timer
0 (0) 8 (5) 16 (9.9) 24 (14.9) 32 (19.9) 40 (24.9) 48 (29.8) 56 (34.8)
Tempera-
ture
C (F)
40 (40) 0 ms 32 ms 76 ms 130 ms 149 ms 171 ms 176 ms 181 ms
Judgment Value
Engine oil temperature > 15 C (59 F)
GD(H6DO)-102
GENERAL DESCRIPTION
BI: DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H6DO)-103
GENERAL DESCRIPTION
BJ:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H6DO)-104
GENERAL DESCRIPTION
BK:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
LOW
3. ENABLE CONDITION
Ignition switch ON
EN-01859
(1)
(2)
(3)
(4)
GD(H6DO)-105
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H6DO)-106
GENERAL DESCRIPTION
BL:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT
HIGH
3. ENABLE CONDITION
Ignition switch ON
EN-01859
(1)
(2)
(3)
(4)
GD(H6DO)-107
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H6DO)-108
GENERAL DESCRIPTION
BM: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.
3. ENABLE CONDITION
(1) Engine control module (ECM) (3) Fuel pump (4) Battery
(2) Fuel pump control unit
None
EN-01771
E
E
(3)
(4)
(2)
FPC
DI
FP+
FP-
+B
(1)
GD(H6DO)-109
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
OFF setting may be needed depending on the NG portion.
Judgment Value
signal
Low
2.112 Imp gal)
Judgment Value
signal
High
2.112 Imp gal)
GD(H6DO)-110
GENERAL DESCRIPTION
BN:DTC P0301 CYLINDER 1 MISFIRE DETECTED
1.5 times misfire
fire
2. ENABLE CONDITION
Map1
Map2
All secondary parameters enable condi-
tions
> 1024 ms
Intake manifold pressure change
at 120 CA
< Value of Map 1
Throttle position change during 16 milli-
seconds
< 20 deg
2.112 Imp gal)
Vehicle dynamic control or AT torque
control
Not in operation
Intake manifold pressure > Value of Map 2
Fuel parameter determination Not extremely low vol-
atility
Engine speed change during 32 millisec-
onds
< 500 rpm
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000
kPa
(mmHg,
inHg)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
20
(150,
5.906)
rpm 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000
kPa
(mmHg,
inHg)
26.66
(200.0 ,
7.874)
23.33
(175.0
, 6.89)
23.33
(175.0
, 6.89)
23.33
(175.0
, 6.89)
23.59
(177.0 ,
6.968)
24.39
(183.0 ,
7.205)
28.33
(212.5 ,
8.366)
32.29
(242.2 ,
9.535)
36.26
(272.0 ,
10.709)
36.26
(272.0 ,
10.709)
37.19
(279.0 ,
10.984)
38.12
(286.0 ,
11.26)
41.86
(314.0 ,
12.362)
48.92
(367.0 ,
14.449)
GD(H6DO)-111
GENERAL DESCRIPTION
culation
speed)
ignition
Method
Method
Method
EN-02184
#1 #6 #3 #2 #5 #4 #1 #6 #3 #2 (A)
GD(H6DO)-112
GENERAL DESCRIPTION
Diagnostic value domg 120 = (omg 1 omg 0) (omg 7 omg 1)/6
domg 121 s judgment value of negative side
EN-02185
Judged as misfire
Threshold value (positive number)
Threshold value (negative number)
domg120
domg120
EN-02279
Judged as misfire
Threshold value
domg360
domg360
GD(H6DO)-113
GENERAL DESCRIPTION
cles.
Normality Judgment
FTP emission judgment value > 27 100/3000% in
1000 revs.
Judgment Value
1000 revs.
EN-02280
Judged as misfire
Threshold value
domg720
domg720
GD(H6DO)-114
GENERAL DESCRIPTION
Map 3
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Catalyst damage misfire judgment value > Value of Map 3
0.2
(0.007)
0.4
(0.014)
0.6
(0.021)
0.8
(0.028)
1
(0.035)
1.2
(0.042)
1.4
(0.049)
1.6
(0.056)
1.8
(0.063)
2
(0.071)
Engine
speed
(rpm)
700 90 90 88 76 68 68 68 68 68 68
1000 90 90 88 76 68 68 68 68 68 68
1500 89 88 80 64 56 56 56 56 56 56
2000 88 84 64 40 36 35 35 35 35 35
2500 88 80 56 36 30 30 30 30 30 30
3000 64 56 30 30 30 30 30 30 30 30
3500 50 40 30 30 30 30 30 30 30 30
4000 40 38 30 30 30 30 30 30 30 30
4500 50 30 30 30 30 30 30 30 30 30
5000 40 30 30 30 30 30 30 30 30 30
5500 40 30 30 30 30 30 30 30 30 30
6000 36 36 30 30 30 30 30 30 30 30
6500 32 32 30 30 30 30 30 30 30 30
7000 32 32 30 30 30 30 30 30 30 30
Judgment Value
Catalyst damage misfire judgment value < Value of Map 2
GD(H6DO)-115
GENERAL DESCRIPTION
BO:DTC P0302 CYLINDER 2 MISFIRE DETECTED
NOTE:
For the detection standard, refer to DTC P0301. <Ref. to GD(H6DO)-110, DTC P0301 CYLINDER 1 MIS-
BP:DTC P0303 CYLINDER 3 MISFIRE DETECTED
NOTE:
BQ:DTC P0304 CYLINDER 4 MISFIRE DETECTED
NOTE:
BR:DTC P0305 CYLINDER 5 MISFIRE DETECTED
NOTE:
BS:DTC P0306 CYLINDER 6 MISFIRE DETECTED
NOTE:
GD(H6DO)-116
GENERAL DESCRIPTION
BT:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE
SENSOR)
3. ENABLE CONDITION
None
EN-01707
(1)
(2)
(3)
(4) (5)
(A)
GD(H6DO)-117
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H6DO)-118
GENERAL DESCRIPTION
BU:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE
SENSOR)
3. ENABLE CONDITION
None
EN-01707
(1)
(2)
(3)
(4) (5)
(A)
GD(H6DO)-119
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
BV:DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW (BANK 2)
NOTE:
For the detection standard, refer to DTC P0327. <Ref. to GD(H6DO)-116, DTC P0327 KNOCK SENSOR 1
CIRCUIT LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.>
BW:DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH (BANK 2)
NOTE:
For the detection standard, refer to DTC P0328. <Ref. to GD(H6DO)-118, DTC P0328 KNOCK SENSOR 1
CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.>
Judgment Value
Judgment Value
GD(H6DO)-120
GENERAL DESCRIPTION
BX:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT
3. ENABLE CONDITION
None
(A)
(C)
10 CA 30 CA 30 CA
EN-03092
(B)
Number of camshaft signal - 3 is normal at two engine revolution in a range of 0 CA - 0 CA.
EN-02188
(1)
(2)
(3)
GD(H6DO)-121
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Starter switch ON
Judgment Value
GD(H6DO)-122
GENERAL DESCRIPTION
BY:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/
PERFORMANCE
3. ENABLE CONDITION
(A)
(C)
10 CA 30 CA 30 CA
EN-03092
(B)
EN-02188
(1)
(2)
(3)
GD(H6DO)-123
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Amount of crank sensor signal during 1 rev. Not = 30
Judgment Value
Amount of crank sensor signal during 1 rev. = 30
GD(H6DO)-124
GENERAL DESCRIPTION
BZ:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT
3. ENABLE CONDITION
(1) Throttle (3) Detecting point (4) Camshaft one revolution (engine
two revolutions)
(2) Camshaft plate
(A)
(C)
10 CA 30 CA 30 CA
EN-03092
(B)
(1)
(2)
(3)
(4)
EN-02190
GD(H6DO)-125
GENERAL DESCRIPTION
Judge as NG when the condition where the number of camshaft position sensor signals are less than 3 times
during 2 engine speed. continues.
Judgment Value
2 revs.
< 3.000 time
Judgment Value
Camshaft position sensor signal > 3.000 time
Judgment Value
Starter ON
Camshaft position sensor signal No input
Judgment Value
Camshaft position sensor signal Input exists
GD(H6DO)-126
GENERAL DESCRIPTION
8. FAIL SAFE
ISC feedback compensation: Do not perform the AVCS actual timing advance compensation. Make the
OCV driving Duty to be the given value (9.36%).
CA:DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)
NOTE:
For the detection standard, refer to DTC P0340. <Ref. to GD(H6DO)-124, DTC P0340 CAMSHAFT POSI-
TION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
GD(H6DO)-127
GENERAL DESCRIPTION
CB: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 de-
celeration 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.
(1) ECM (4) CPU (6) Main relay
(2) Detecting circuit (5) EGR valve (7) Battery power supply
(3) Switching circuit
(1)
(2)
(3)
(4)
(5)
(6)
(7)
EN-02192
GD(H6DO)-128
GENERAL DESCRIPTION
3. ENABLE CONDITION
During deceleration fuel cut from 53 km/h (approx. 33 MPH) or more, perform diagnosis once.
Be careful of vehicle speed and engine speed. (Diagnosis will not be completed if the vehicle speed and en-
gine speed conditions become out of specification due to deceleration.)
Measure the pressure values when the enable conditions are established, and perform diagnosis by calcu-
lating those results.
1. Label the intake manifold pressure value as PMOF1, which is observed when enable conditions are es-
tablished, 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 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).
Engine coolant temperature > 75 C(167 F)
Intake manifold pressure (absolute pressure) < 36.66 kPa (275 mmHg, 10.827 inHg)
Ambient air temperature > 5 C(41 F)
Vehicle speed >53 km/h (32.9 MPH)
Fuel shut-off function In operation
Neutral switch OFF
After neutral switch ON/OFF change > Value from Map
No load change (A/C, power steering, lighting,
rear defogger, heater fan and radiator fan)
> 5000 ms
Map
C (F)
40
(40)
30
(22)
20
(4)
10
(14)
0
(32)
10
(50)
20
(68)
30
(86)
msec
0 0 0 0 0 0 0 0
C (F)
40
(104)
50
(122)
60
(140)
70
(158)
80
(176)
90
(194)
100
(212)
110
(230)
msec
0 0 0 0 0 0 0 0
GD(H6DO)-129
GENERAL DESCRIPTION
cles.
Judgment Value
PMON (PMOF1 + PMOF2)/2 < 1.57 kPa (11.8 mmHg, 0.465 inHg)
(A) 2000 ms (C) 1500 ms (D) 50 STEP
(B) 1500 ms
EN-05568
ON
OFF
(Open)
(Close)
(Open)
(Close)
PMOF1
PMON
PMOF2
Deceleration fuel cut
Diagnosis enable condition
EGR target step
EGR actual step
DIagnostic mode timer
Start dignosis
(D)
(A) (B) (C)
Intake manifold pressure
(During normal condition)
GD(H6DO)-130
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
A/F main learning = Not allowed.
Knock learning = Not allowed.
Judgment Value
PMON (PMOF1 + PMOF2)/2 > 1.57 kPa (11.8 mmHg, 0.465 inHg)
GD(H6DO)-131
GENERAL DESCRIPTION
CC:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)
(1) Front oxygen (A/F) sensor (2) Front oxygen sensor (3) Catalytic converter
(A) Normal (C) Output waveform from the front
oxygen (A/F) sensor
(D) Output waveform from the rear
oxygen Sensor
(B) Deterioration
EN-01713
(A)
(B)
(C) (D)
(1) (2)
(3)
(3)
GD(H6DO)-132
GENERAL DESCRIPTION
3. ENABLE CONDITION
lative value (E |(sglmd
n
sglmd
n1
)|)and rear oxygen sensor output voltage deviation cumulative value (E |
(ro2sad
n
ro2sad
n1
cumulative value (E |(sglmd
n
sglmd
n1
nostic value.
cles.
Normality Judgment
> 1000 ms
and
< 40 g/s (1.411 oz/s)
Engine load change every 0.5 engine speed. < 0.02 g/rev (0.001 oz/rev)
Purge execution calculated time > 5 sec
Judgment Value
E |(ro2sad
n
ro2sad
n1
)| / E |(sglmd
n
sglmd
n1
)| > 25
Judgment Value
E |(ro2sad
n
ro2sad
n1
)| / E |(sglmd
n
sglmd
n1
)| s 25
GD(H6DO)-133
GENERAL DESCRIPTION
8. FAIL SAFE
None
GD(H6DO)-134
GENERAL DESCRIPTION
CD:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED
(SMALL LEAK)
(1) Fuel gauge (7) Pressure control valve (12) Fuel level sensor
(2) Intake manifold (8) Drain valve (13) Fuel tank
(3) Throttle body (9) Drain filter (14) Fuel cut valve
(4) Purge control solenoid valve (10) Shut-off valve (15) Fuel tank pressure sensor
(5) Engine control module (ECM) (11) Fuel temperature sensor (16) Vent valve
(6) Canister
(1)
(2)
(3)
(4)
(5)
(7)
(8)
(9)
(6)
(11)
(10)
(12)
(13)
(16)
(14)
(15)
EN-04151
GD(H6DO)-135
GENERAL DESCRIPTION
0.04-inch Diagnosis
Mode Z
(Purge control solenoid valve open-
ing failure diagnosis)
Perform purge control solenoid valve opening failure diagnosis
from the size of tank pressure variation from diagnosis start.
0 ms + 3000 ms
0 ms + 3000 ms +
13000 ms
Mode A
10000 ms
Mode B
(Sealed negative pressure, large
leakage judgment)
If the tank pressure cannot be reduced, it is diagnosed as large
leak.
0 10000 ms +
25000 ms
Mode C
calculation). If the tank pressure does not become the value,
make advanced OK judgment.
0 17000 ms
Mode D
(Negative pressure variation mea-
surement, evaporation leakage
diagnosis)
Calculate the tank pressure variation (P2), and obtain the diag-
nostic value using P1 found in Mode A.
Perform the evaporation diagnosis using the diagnostic value.
0 ms + 10000 ms
Mode Behavior of tank internal pressure under normal conditions Diagnostic item DTC
Mode Z
Roughly the same as barometric pressure
(Same as 0 kPa (0 mmHg, 0 inHg))
Purge control solenoid valve is judged
to be open.
P0457
Mode A Pressure is in proportion to amount of evaporative emission. None
Mode B
Negative pressure is formed due to intake manifold negative
pressure
Large leak
P0457
[1.0 mm (0.04 in)]
P0442
Mode
Z
Mode
A
Mode
B
Mode
C
Mode
D
OK OK OK OK OK
NG
Early OK
Cancel
Mode
Z
Extend
NG
NG
OK
END
EN-02872
GD(H6DO)-136
GENERAL DESCRIPTION
0.02-inch Diagnosis
Mode A
When the pressure in the tank is not near 0 mmHg, wait until it
returns to 0 point (near 0 mmHg).
0 Value of Map 1
Mode B
0 Value of Map 2
Mode C
calculation).
0 20000 ms + 0 +
Value of Map 2
Mode D
(Negative pressure change calcu-
lated)
Calculate the time it takes for the tank pressure to change to the
Mode E shifting pressure. If the tank pressure does not change to
the Mode E shifting pressure, make advanced OK judgment.
0 0 ms + 200000 ms
Mode E
calculation)
0 0 ms + 200000 ms
+ Value of Map 3
Map1
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Map2
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Map 3
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
EN-02871
Cancel
Early OK 2
Early OK 1
OK OK OK OK
Cancel
Cancel
Cancel
Cancel
END
GD(H6DO)-137
GENERAL DESCRIPTION
(c) Canister
EN-01715
(a)
(b) (c)
(4)
(1)
(2)
(3)
GD(H6DO)-138
GENERAL DESCRIPTION
Solenoid ON B C
EN-01716
A
B C
X X Y
(a)
(b) (c)
EN-01717
A
B C
(a)
(b) (c)
GD(H6DO)-139
GENERAL DESCRIPTION
When Solenoid is ON
(b) Fuel tank
(c) Canister
EN-01718
A
B C
(a)
(b) (c)
(1)
EN-01719
A
B C
(a)
(b) (c)
GD(H6DO)-140
GENERAL DESCRIPTION
Drain valve
3. ENABLE CONDITION
0.04-inch Diagnosis
Intake manifold relative vacuum (relative pressure) > 26.66 kPa ( 200 mmHg, 7.874 inHg)
11.968 Imp gal)
Intake air temperature > 10 C (14 F)
< 1.7 mmHg (Mode D)
Minimum pressure change value every one second Maximum
pressure change value every one second
< 1.7 mmHg (Mode A)
< 1.7 mmHg (Mode D)
EN-02293
GD(H6DO)-141
GENERAL DESCRIPTION
0.02-inch Diagnosis
0.04-inch Diagnosis
0.02-inch Diagnosis
Perform the diagnosis when 125 seconds or more have passed at a constant engine speed of 50 km/h (31
MPH) or higher to judge as NG or OK.
Time since last incomplete 0.02-inch leakage diagnosis
11.968 Imp gal)
Intake manifold relative vacuum (relative pressure) > 8 kPa ( 60 mmHg, 2.362 inHg)
Fuel tank pressure 0.67 kPa (5 mmHg, 0.197 inHg) 1.43 kPa (10.7 mmHg,
0.421 inHg)
Vehicle speed 50 km/h (31.1 MPH) 510 km/h (316.9 MPH) continues for
125000 ms
During diagnosis
Change of fuel level s Value of Map 4
Pressure change every one second < 0.06 kPa (0.44 mmHg, 0.017 inHg)
Minimum pressure change value every one second Maximum
pressure change value every one second
< 0.07 kPa (0.51 mmHg, 0.02 inHg) (Mode D)
| Pressure change in tank every second | s 0.1 kPa (0.75 mmHg, 0.03 inHg)
Barometric pressure change 0.48 kPa (3.6 mmhg, 0.142 inHg) 0.32 kPa (2.4 mmhg,
0.094 inHg) (Mode D)
0.32 kPa (2.4 mmhg, 0.094 inHg) 0.32 kPa (2.4 mmhg,
0.094 inHg) (Mode E)
Map4
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
5, 1.321,
1.1
GD(H6DO)-142
GENERAL DESCRIPTION
DTC
Purpose of Mode Z
celled.
DIAGNOSTIC METHOD
If OK judgment cannot be made, extend Mode Z, and Judge as NG when the following conditions are estab-
lished after predetermined amount of time.
cles.
Judgment Value
evptez evptezha > 0.6 kPa (4.5 mmHg, 0.177 inHg) P0457
Time of 2 L (0.528 US gal, 0.44 Imp gal) or more fuel no sloshing > 40000 ms
GD(H6DO)-143
GENERAL DESCRIPTION
Normality Judgment
Normal
evptez evptezha s 0.4 kPa (3 mmHg, 0.118 inHg) Normal when above is established
Judgment Value
evptez evptezha s 0.4 kPa (3 mmHg, 0.118 inHg) P0457
(2) 3000 ms (4) 0.4 kPa (3 mmHg, 0.118 inHg)
EN-02869
(1)
(2)
(4)
evptez
evptezini
evptezha
0
(3)
(5)
GD(H6DO)-144
GENERAL DESCRIPTION
(1) Mode Z (4) Fuel tank pressure (7) 40000 ms no fuel sloshing
(2) Extended mode Z (5) 0.6 kPa (4.5 mmHg, 0.177 inHg) (8) NG judgment
(3) 3000 ms + 13000 ms (6) 1.43 kPa (10.7 mmHg, 0.421 inHg)
EN-02870
(8)
(7)
(6)
(4)
(5)
evptez
evptezini
evptezha
0
(3)
(2) (1)
GD(H6DO)-145
GENERAL DESCRIPTION
Leak Diagnosis
DTC
culation.)
Judgment Value
Time to reach target negative pressure > 10000 ms + 25000 ms P0457
or
Mode B time > 10000 ms
started)
> 0.33 kPa (2.5 mmHg,
0.098 inHg)
Tank pressure when starting calcula-
tion of P2
judgment
1.3 kPa (9.75 mmHg, 0.384 inHg) 17000 ms
GD(H6DO)-146
GENERAL DESCRIPTION
cles.
Leak Diagnosis
DTC
culation.)
Judgment Value
P2 1.5 - P1 > Value of Map 5 P0442
10000 ms in mode D
10000 ms in mode A
0.28 kPa
(2.1 mmHg,
0.083 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.35 mmHg,
0.093 inHg)
0.32 kPa
(2.4 mmHg,
0.094 inHg)
10 L (2.642 US gal, 2.2 Imp gal)
0.28 kPa
(2.1 mmHg,
0.083 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.35 mmHg,
0.093 inHg)
0.32 kPa
(2.4 mmHg,
0.094 inHg)
20 L (5.284 US gal, 4.4 Imp gal)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.32 kPa
(2.4 mmHg,
0.094 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
0.35 kPa
(2.6 mmHg,
0.102 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
30 L (7.926 US gal, 6.6 Imp gal)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.41 kPa
(3.05 mmHg,
0.12 inHg)
0.42 kPa
(3.15 mmHg,
0.124 inHg)
0.43 kPa
(3.25 mmHg,
0.128 inHg)
0.45 kPa
(3.35 mmHg,
0.132 inHg)
40 L (10.568 US gal, 8.8 Imp gal)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.42 kPa
(3.15 mmHg,
0.124 inHg)
0.44 kPa
(3.3 mmHg, 0.13
inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
50 L (13.21 US gal, 11 Imp gal)
0.43 kPa
(3.2 mmHg,
0.126 inHg)
0.44 kPa
(3.3 mmHg, 0.13
inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.48 kPa
(3.6 mmHg,
0.142 inHg)
0.49 kPa
(3.7 mmHg,
0.146 inHg)
60 L (15.852 US gal, 13.2 Imp gal)
0.43 kPa
(3.2 mmHg,
0.126 inHg)
0.44 kPa
(3.3 mmHg, 0.13
inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.48 kPa
(3.6 mmHg,
0.142 inHg)
0.49 kPa
(3.7 mmHg,
0.146 inHg)
GD(H6DO)-147
GENERAL DESCRIPTION
Normality Judgment
Judgment Value
Tank internal pressure s Value of Map 6
P2 s Value of Map 7
Map6
Fuel level
(2, US gal, Imp gal)
0, 0, 0
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21, 11
60, 15.852,
13.2
Tank pressure
(kPa, mmHg, inHgl)
1.85, 13.9,
0.547
1.85, 13.9,
0.547
1.84, 13.8,
0.543
1.83, 13.7,
0.539
1.81, 13.6,
0.535
1.8, 13.5,
0.531
1.8, 13.5,
0.531
Map7
Fuel level
(2, US gal, Imp gal)
0, 0, 0
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21, 11
60, 15.852,
13.2
Tank pressure
(kPa, mmHg, inHgl)
0.93, 7,
0.276
0.93, 7,
0.276
0.94, 7.05,
0.278
0.95, 7.1,
0.28
1.09, 8.2,
0.323
1.28, 9.6,
0.378
1.28, 9.6,
0.378
GD(H6DO)-148
GENERAL DESCRIPTION
cles.
Judgment Value
P1 < Value of Map 8
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa
(1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
10 L (2.642 US gal, 2.2 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa (
1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
20 L (5.284 US gal, 4.4 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa
(1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
30 L (7.926 US gal, 6.6 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.23 kPa
(1.7 mmHg,
0.067 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
0.36 kPa
(2.7 mmHg,
0.106 inHg)
40 L (10.568 US gal, 8.8 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.25 kPa
(1.85 mmHg,
0.073 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
0.33 kPa
(2.5 mmHg,
0.098 inHg)
50 L (13.21 US gal, 11 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.27 kPa
(2 mmHg,
0.079 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0 kPa
(0 mmHg,
0 inHg)
60 L (15.852 US gal, 13.2 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.07 kPa
(0.5 mmHg,
0.02 inHg)
0.27 kPa
(2 mmHg,
0.079 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0.31 kPa
(2.3 mmHg,
0.091 inHg)
0 kPa
(0 mmHg,
0 inHg)
GD(H6DO)-149
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
P1 > Value of Map 9
0.13 kPa
(1 mmHg,
0.039 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
10 L (2.642 US gal, 2.2 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.47 kPa
(3.5 mmHg,
0.138 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
0.56 kPa
(4.2 mmHg,
0.165 inHg)
20 L (5.284 US gal, 4.4 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.43 kPa
(3.25 mmHg,
0.128 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
0.55 kPa
(4.1 mmHg,
0.161 inHg)
30 L (7.926 US gal, 6.6 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.4 kPa
(3 mmHg,
0.118 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
40 L (10.568 US gal, 8.8 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.3 kPa
(2.25 mmHg,
0.089 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 L (13.21 US gal, 11 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.2 kPa
(1.5 mmHg,
0.059 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
60 L (15.852 US gal, 13.2 Imp gal)
0.13 kPa
(1 mmHg,
0.039 inHg)
0.2 kPa
(1.5 mmHg,
0.059 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
0.39 kPa
(2.9 mmHg,
0.114 inHg)
GD(H6DO)-150
GENERAL DESCRIPTION
CE:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL
CIRCUIT OPEN
3. ENABLE CONDITION
(7) Yoke
None
(1) (2) (3)
(4) (5) (6) (7) (8)
(9) (10) (11) (12) (13) (17)
(14) (15) (16) (18) (19) (19)
EN-02294
GD(H6DO)-151
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
puts OFF signal
Low
Judgment Value
puts OFF signal
High
GD(H6DO)-152
GENERAL DESCRIPTION
CF:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL
CIRCUIT SHORTED
3. ENABLE CONDITION
(7) Yoke
None
(1) (2) (3)
(4) (5) (6) (7) (8)
(9) (10) (11) (12) (13) (17)
(14) (15) (16) (18) (19) (19)
EN-02294
GD(H6DO)-153
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
puts ON signal
High
Judgment Value
puts ON signal
Low
GD(H6DO)-154
GENERAL DESCRIPTION
CG:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR
tus.
3. ENABLE CONDITION
2.112 Imp gal)
mmHg, 22.165 inHg)
EN-04462
(A)
(B)
(2) (1)
(C)
GD(H6DO)-155
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
> 16 time
< 0.05 kPa (0.375 mmHg,
0.015 inHg)
> 7 C (44.6 F)
Judgment Value
Maximum Minimum tank pressure > 0.05 kPa (0.375 mmHg,
0.015 inHg)
GD(H6DO)-156
GENERAL DESCRIPTION
CH:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR LOW INPUT
3. ENABLE CONDITION
None
Judgment Value
2.199 inHg)
EN-04462
(A)
(B)
(2) (1)
(C)
GD(H6DO)-157
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
2.199 inHg)
GD(H6DO)-158
GENERAL DESCRIPTION
CI: DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR HIGH INPUT
3. ENABLE CONDITION
> 5000 ms
< 0.08
(left and right)
> 0.9
EN-04462
(A)
(B)
(2) (1)
(C)
GD(H6DO)-159
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
CJ:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECT-
ED (VERY SMALL LEAK)
NOTE:
For the detection standard, refer to DTC P0442. <Ref. to GD(H6DO)-134, DTC P0442 EVAPORATIVE
tecting Criteria.>
CK:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECT-
ED (FUEL CAP LOOSE/OFF)
For the detection standard, refer to DTC P0442. <Ref. to GD(H6DO)-134, DTC P0442 EVAPORATIVE
tecting Criteria.>
Judgment Value
Fuel tank pressure > 7.98 kPa (59.85 mmHg, 2.356 inHg)
Judgment Value
Fuel tank pressure < 7.98 kPa (59.85 mmHg, 2.356 inHg)
GD(H6DO)-160
GENERAL DESCRIPTION
CL:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT LOW
3. ENABLE CONDITION
(A) (B)
EN-02197
GD(H6DO)-161
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H6DO)-162
GENERAL DESCRIPTION
CM:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE
CIRCUIT HIGH
3. ENABLE CONDITION
(A) (B)
EN-02197
GD(H6DO)-163
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Duty ratio of ON > 0.25
Judgment Value
GD(H6DO)-164
GENERAL DESCRIPTION
CN:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE
3. ENABLE CONDITION
None
EN-01734
0
(B)
(A)
GD(H6DO)-165
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
(11672.853 oz)
0.572 Imp gal)
Judgment Value
(11672.853 oz)
Max. min. values of fuel level output > 2.6 L (0.687 US gal,
0.572 Imp gal)
GD(H6DO)-166
GENERAL DESCRIPTION
CO:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW
3. ENABLE CONDITION
(1) Engine control module (ECM) (3) Fuel sub level sensor (5) Body integrated unit
(2) Fuel level sensor (4) Detecting circuit
None
(5)
(4)
(1)
(2) (3)
EN-05371
GD(H6DO)-167
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H6DO)-168
GENERAL DESCRIPTION
CP:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH
3. ENABLE CONDITION
(1) Engine control module (ECM) (3) Fuel sub level sensor (5) Body integrated unit
(2) Fuel level sensor (4) Detecting circuit
None
(5)
(4)
(1)
(2) (3)
EN-05371
GD(H6DO)-169
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Judgment Value
GD(H6DO)-170
GENERAL DESCRIPTION
CQ:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
2. ENABLE CONDITION
Idle switch ON
Fuel level > 9.6 L (2.536 US gal, 2.112 Imp gal)
and
< 54.4 L (14.372 US gal, 11.968 Imp gal)
Vehicle speed = 0 km/h (0 MPH) > 10000 ms
GD(H6DO)-171
GENERAL DESCRIPTION
(B) NG at 4 time
Diagnosis condition
Diagnosis timer
(A)
Fuel level sensor
A/D value
Diagnosis counter
(B)
1
2
3
4
5
6
0
(C)
(D)
EN-05569
GD(H6DO)-172
GENERAL DESCRIPTION
cles.
Normality Judgment
7. FAIL SAFE
None
Judgment Value
Integrated times of the condition reaching follows, > 4 time
DELFLMAX > Value from Map
or
SUMFL > 25.92 V
At this time,
Map
10, 2.642,
2.2
20, 5.284,
4.4
30, 7.926,
6.6
40, 10.568,
8.8
50, 13.21,
11
60, 15.852,
13.2
Maximum value Minimum value of
change of tank pressure for 12288 ms
> 0.05 kPa (0.375031 mmHg,
0.015 inHg)
Maximum value Minimum value of bat-
tery voltage for12288 ms
> 0.609 V
Judgment Value
SUMFL < 25.92 V
At this time,
GD(H6DO)-173
GENERAL DESCRIPTION
CR:DTC P0500 VEHICLE SPEED SENSOR A
is impossible.
3. ENABLE CONDITION
Normality Judgment
Elapsed time after engine starting > 2000 ms
Judgment Value
Front left wheel speed > 300 km/h (186.4 MPH)
Front right wheel speed > 300 km/h (186.4 MPH)
Judgment Value
and
< 300 km/h (186.4 MPH)
and
< 300 km/h (186.4 MPH)
GD(H6DO)-174
GENERAL DESCRIPTION
8. FAIL SAFE
Accelerator sensor signal process: Not allowed full closed point learning (hold the previous value)
ABS wheel speed sensor signal process: Vehicle speed = 10 km/h (6 MPH)
condition (4400 rpm or more).
ISC control: Open loop compensation is set to (1 g (0.04 oz) oz/s) Not allowed ISC feedback volume cal-
culation.
Radiator fan control: Both main and sub fan ON drive
Gear ratio judgment: Gear = Control as fixed in sixth gear
GD(H6DO)-175
GENERAL DESCRIPTION
CS:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
2. ENABLE CONDITION
cles.
Normality Judgment
22.165 inHg)
2.112 Imp gal)
and
< 1.1
OFF
> 5.1 sec
more.
> 5.1 sec
> 5.1 sec
Judgment Value
speed
< 100 rpm
Judgment Value
speed
> 100 rpm
GD(H6DO)-176
GENERAL DESCRIPTION
7. FAIL SAFE
Judgment of heavy fuel: Not allowed to make the judgment of heavy fuel
GD(H6DO)-177
GENERAL DESCRIPTION
CT:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
2. ENABLE CONDITION
cles.
Normality Judgment
22.165 inHg)
2.112 Imp gal)
and
< 1.1
OFF
> 5.1 sec
more.
> 5.1 sec
> 5.1 sec
Judgment Value
Actual Target engine speed > 200 rpm
Judgment Value
GD(H6DO)-178
GENERAL DESCRIPTION
7. FAIL SAFE
Judgment of heavy fuel: Not allowed to make the judgment of heavy fuel
GD(H6DO)-179
GENERAL DESCRIPTION
CU:DTC P0512 STARTER REQUEST CIRCUIT
2. ENABLE CONDITION
cles.
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Judgment Value
GD(H6DO)-180
GENERAL DESCRIPTION
CV:DTC P0513 INCORRECT IMMOBILIZER KEY
2. ENABLE CONDITION
DTC Item Outline of diagnosis
Incorrect immobilizer key (Use of unregistered key in body inte-
grated unit)
ECM
P1572
Antenna Circuit)
P1578 Meter Failure
combination meter
GD(H6DO)-181
GENERAL DESCRIPTION
CW:DTC P0600 SERIAL COMMUNICATION LINK
(High speed CAN)
3. ENABLE CONDITION
None
Judgment Value
Starter switch OFF
Engine run
or
TCM, ABSCM or VDCCM
or
TCM, ABSCM or VDCCM
GD(H6DO)-182
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Starter switch OFF
Engine run
Yes
Yes
GD(H6DO)-183
GENERAL DESCRIPTION
CX:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY
(RAM) ERROR
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
then read.
The written value can-
not be read.
Judgment Value
then read.
The written value can
be read.
GD(H6DO)-184
GENERAL DESCRIPTION
CY:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)
ERROR
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
Ignition switch ON
Judgment Value
Judgment Value
GD(H6DO)-185
GENERAL DESCRIPTION
CZ:DTC P0607 CONTROL MODULE PERFORMANCE
(1) When the read value of throttle position sensor 1 signal is mismatched between main CPU and sub CPU.
(2) When the read value of accelerator pedal position sensor 1 signal is mismatched between main CPU and
sub CPU.
(3) When the sub CPU operates abnormally.
(4) When the communication between main CPU sub CPU is abnormal.
(5) When the input amplifier circuit of throttle position sensor 1 is abnormal.
(6) When the cruise control cannot be canceled correctly.
(7) When the signal of brake SW1 and 2 is mismatched.
EN-01862
(1)
(4)
(2)
(3)
(5)
(6)
(7)
(8)
(9)
(12)
(11) (10)
(10)
(10)
(10)
(13)
(14)
GD(H6DO)-186
GENERAL DESCRIPTION
3. ENABLE CONDITION
(1): 600 msec
(2): 830 msec
(3): 200 msec
(4): 200 msec
(5): 24 msec
(6): 250 msec
(7): 200 ms
Judgment Value
> 0.4058 V
> 0.127542424 V
(3) WD pulse from sub CPU No WD pulse occur
(4) Communication between CPU Not possible to communicate
(5) |Throttle position sensor 1 opening angle
(Throttle position sensor 1 opening angle
after passing amplifier) 1/4|
> 3 deg
(6) Cruise control cancel signal at brake ON Cruise control cancel signal OFF
(7) Brake switch 1, 2 signal SW 1 and 2 are not matched
GD(H6DO)-187
GENERAL DESCRIPTION
Normality Judgment
(1): 2000 msec
(2): 2000 msec
(3): 2000 msec
(4): 2000 msec
(5): 24 msec
(6): 2000 msec
(7): 2000 ms
8. FAIL SAFE
Judgment Value
< 0.4058 V
< 0.127542424 V
(4) Communication between CPU Possible to communicate
(5) |Throttle position sensor 1 opening angle
(Throttle position sensor 1 opening angle
after passing amplifier) 1/4|
< 3 deg
(6) Cruise control cancel signal at brake ON Cruise control cancel signal ON
(7) Brake switch 1, 2 signal SW 1 and 2 are matched
GD(H6DO)-188
GENERAL DESCRIPTION
DA:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE
(BANK 1)
3. ENABLE CONDITION
Always perform the diagnosis continuously when the electric throttle control is operating.
Normal operation of electric throttle control ON
EN-01863
(3)
(4)
(1)
(2)
GD(H6DO)-189
GENERAL DESCRIPTION
Difference between target opening angle and actual opening angle: 1000 milliseconds (when target open-
ing angle > actual opening angle) or value of Map 2 (when target opening angle s actual opening angle)
Output duty to drive circuit: value of Map 3
Normality Judgment
Difference between target opening angle and actual opening angle: 2000 msec
Output duty to drive circuit: 2000 msec
8. FAIL SAFE
Judgment Value
> Value of Map 1
Output duty to drive circuit > 95%
Map1
angle () = d
0 s d < 6.15 6.15 s d < 9.65 9.65 s d < 14.65 14.65 s d < 26.65 26.65 s d
Difference between target
opening angle and actual
opening angle ()
3.5 5 12 25 25
Map2
Throttle position sensor 1 opening angle () = d 0 s d < 5.5 5.5 s d < 9 9 s d < 13 13 s d < 22 22 s d
Judgment time (milliseconds) 1000 400 300 250 250
Map 3
Voltage to drive circuit (V) 6 8 10 12 14 16
Judgment time (milliseconds) 2000 2000 2000 2000 2000 2000
Judgment Value
< Value of Map 1
Output duty to drive circuit < 95%
GD(H6DO)-190
GENERAL DESCRIPTION
DB:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Judgment Value
GD(H6DO)-191
GENERAL DESCRIPTION
DC:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW)
(BANK1 SENSOR1)
control, etc.
air fuel ratio
> 1: Lean
< 1: Rich
(3) ZrO
2
(C) Lean
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H6DO)-192
GENERAL DESCRIPTION
3. ENABLE CONDITION
cles.
Normality Judgment
conditions
> 4096 ms
Load change at 120CA < 0.02 g/rev (0.001 oz/rev)
Judgment Value
value < 0.85
Judgment Value
value > 0.85
GD(H6DO)-193
GENERAL DESCRIPTION
8. FAIL SAFE
GD(H6DO)-194
GENERAL DESCRIPTION
DD:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH)
(BANK1 SENSOR1)
control, etc.
air fuel ratio
> 1: Lean
< 1: Rich
(3) ZrO
2
(C) Lean
(1)
(2)
(4)
(2)
(3)
EN-01693
(C) (B) (D)
(A)
GD(H6DO)-195
GENERAL DESCRIPTION
3. ENABLE CONDITION
cles.
Normality Judgment
conditions
> 4096 ms
Load change at 120CA < 0.02 g/rev (0.001 oz/rev)
Judgment Value
value > 1.15
Judgment Value
value s 1.15
GD(H6DO)-196
GENERAL DESCRIPTION
8. FAIL SAFE
DE:DTC P1154 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW)
(BANK 2 SENSOR 1)
NOTE:
For the detection standard, refer to DTC P1152. <Ref. to GD(H6DO)-191, DTC P1152 O2 SENSOR CIR-
CUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
DF:DTC P1155 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH)
(BANK 2 SENSOR 1)
NOTE:
For the detection standard, refer to DTC P1153. <Ref. to GD(H6DO)-194, DTC P1153 O2 SENSOR CIR-
CUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
GD(H6DO)-197
GENERAL DESCRIPTION
DG:DTC P1160 RETURN SPRING FAILURE
3. ENABLE CONDITION
(2) Return spring (5) Throttle valve (8) Main and sub throttle position sen-
sor
Throttle position sensor Normal
EN-04463
S S
(8)
(6)
(7)
(5)
(1)
(3)
(2)
(4)
GD(H6DO)-198
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
to OFF
< 2 deg
Judgment Value
to OFF
> 2 deg
GD(H6DO)-199
GENERAL DESCRIPTION
DH:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT
LOW
3. ENABLE CONDITION
None
EN-01759
(1)
(2)
(3)
(4)
(5)
(A)
(B) (C)
GD(H6DO)-200
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
puts OFF signal
Low
Judgment Value
puts OFF signal
High
GD(H6DO)-201
GENERAL DESCRIPTION
DI: DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
3. ENABLE CONDITION
None
EN-01759
(1)
(2)
(3)
(4)
(5)
(A)
(B) (C)
GD(H6DO)-202
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
puts ON signal
High
Judgment Value
puts ON signal
Low
GD(H6DO)-203
GENERAL DESCRIPTION
DJ:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM
3. ENABLE CONDITION
(7) Yoke
Drain valve Open
Tank pressure when starter is OFF ON 0.43 kPa (3.2 mmHg, 0.126 inHg)
and
1.43 kPa (10.7 mmHg, 0.421 inHg)
(1) (2) (3)
(4) (5) (6) (7) (8)
(9) (10) (11) (12) (13) (17)
(14) (15) (16) (18) (19) (19)
EN-02294
GD(H6DO)-204
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Fuel tank pressure s 4 kPa (30 mmHg, 1.181 inHg)
Judgment Value
> 30000 ms
Intake manifold relative pressure > 26.66 kPa (200 mmHg, 7.874 inHg)
GD(H6DO)-205
GENERAL DESCRIPTION
DK:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION
(LOW INPUT)
3. ENABLE CONDITION
Perform diagnosis continuously during EGR operation.
EN-02051
(1)
(2)
(3)
(4)
(5)
(6)
GD(H6DO)-206
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
puts OFF signal
Low level
Judgment Value
puts OFF signal
High level
GD(H6DO)-207
GENERAL DESCRIPTION
DL:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION
(HIGH INPUT)
3. ENABLE CONDITION
EN-02051
(1)
(2)
(3)
(4)
(5)
(6)
GD(H6DO)-208
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
puts ON signal
High level
Judgment Value
puts ON signal
Low level
GD(H6DO)-209
GENERAL DESCRIPTION
DM:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
For the detection standard, refer to DTC P1492. <Ref. to GD(H6DO)-205, DTC P1492 EGR SOLENOID
teria.>
DN:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
Criteria.>
DO:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
teria.>
DP:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
Criteria.>
DQ:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION
(LOW INPUT)
NOTE:
teria.>
DR:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION
(HIGH INPUT)
NOTE:
Criteria.>
GD(H6DO)-210
GENERAL DESCRIPTION
DS:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
2. ENABLE CONDITION
Normality Judgment
7. FAIL SAFE
None
None
Judgment Value
Judgment Value
GD(H6DO)-211
GENERAL DESCRIPTION
DT:DTC P1570 ANTENNA
NOTE:
For the detection standard, refer to DTC P0513. <Ref. to GD(H6DO)-180, DTC P0513 INCORRECT IMMO-
DU:DTC P1571 REFERENCE CODE INCOMPATIBILITY
NOTE:
DV:DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)
NOTE:
DW:DTC P1574 KEY COMMUNICATION FAILURE
NOTE:
DX:DTC P1576 EGI CONTROL MODULE EEPROM
NOTE:
DY:DTC P1577 IMM CONTROL MODULE EEPROM
NOTE:
DZ:DTC P1578 METER FAILURE
NOTE:
GD(H6DO)-212
GENERAL DESCRIPTION
EA:DTC P1602 CONTROL MODULE PROGRAMMING ERROR
control.
NG.
specified value.
control.
2. ENABLE CONDITION
cles.
Normality Judgment
Judgment Value
Map
Coolant tempera-
ture after starting
the engine
40 C
(40 F)
30 C
(22 F)
20 C
(4 F)
10 C
(14 F)
0 C
(32 F)
10 C
(50 F)
20 C
(68 F)
30 C
(86 F)
40 C
(104 F)
50 C
(122 F)
Threshold Value
0 C
(32 F)
0 C
(32 F)
0 C
(32 F)
0 C
(32 F)
155 C
(311 F)
150 C
(302 F)
155 C
(311 F)
140 C
(284 F)
133 C
(271.4 F)
130 C
(266 F)
Judgment Value
Estimated exhaust gas temperature > Value from Map
GD(H6DO)-213
GENERAL DESCRIPTION
cles.
Normality Judgment
7. FAIL SAFE
None
Judgment Value
> 6000 ms
> 20 CA)
> 0 ms
Judgment Value
< 6000 ms
> 20 CA)
< 0 ms
GD(H6DO)-214
GENERAL DESCRIPTION
EB:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
LOW (BANK 1)
Detect open or short circuit of the oil flow control solenoid valve.
Judge as NG when the current is small even though the duty signal is large.
2. ENABLE CONDITION
Normality Judgment
None
Judgment Value
duty
> 99.61 %
current
< 0.306 A
Judgment Value
Target current value of the oil flow control
solenoid valve
> 0.14 A
< 0.08 A
GD(H6DO)-215
GENERAL DESCRIPTION
7. FAIL SAFE
AVCS control:
perienced.
GD(H6DO)-216
GENERAL DESCRIPTION
EC:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
HIGH (BANK 1)
Detect open or short circuit of oil flow control solenoid valve.
Judge as NG when the current is large even though the duty signal is small.
2. ENABLE CONDITION
Normality Judgment
None
Judgment Value
duty
< 0.39 %
current
> 0.306 A
Judgment Value
< 0.08 A
GD(H6DO)-217
GENERAL DESCRIPTION
7. FAIL SAFE
AVCS control:
perienced.
ED:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
LOW (BANK 2)
NOTE:
POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
EE:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT
HIGH (BANK 2)
NOTE:
POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
GD(H6DO)-218
GENERAL DESCRIPTION
EF:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1
3. ENABLE CONDITION
MPH) or more.
back learning
Completed
established.
> 1 sec
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H6DO)-219
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
Judgment Value
Sub feedback learning value < 0.03
Judgment Value
Sub feedback learning value > 0.03 + 0
GD(H6DO)-220
GENERAL DESCRIPTION
EG:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1
3. ENABLE CONDITION
MPH) or more.
back learning
Completed
established.
> 1 sec
EN-01696
(3)
V
(1)
(2) (2)
(E)
(F)
(C) (B) (D)
(A)
GD(H6DO)-221
GENERAL DESCRIPTION
cles.
Normality Judgment
8. FAIL SAFE
None
EH:DTC P2098 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 2
NOTE:
For the detection standard, refer to DTC P2096. <Ref. to GD(H6DO)-218, DTC P2096 POST CATALYST
FUEL TRIM SYSTEM TOO LEAN BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
EI: DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2
NOTE:
For the detection standard, refer to DTC P2097. <Ref. to GD(H6DO)-220, DTC P2097 POST CATALYST
FUEL TRIM SYSTEM TOO RICH BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
Judgment Value
Sub feedback learning value > 0.04
Judgment Value
Sub feedback learning value < 0.04 + 0
GD(H6DO)-222
GENERAL DESCRIPTION
EJ:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/
PERFORMANCE
3. ENABLE CONDITION
Under control of electronic throttle control ON
CPU communication line sub main normal
judgment
Normal
EN-01867
(3) (2)
(5) (2)
(4)
(1)
(6)
(7)
12V 12V
GD(H6DO)-223
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Motor current > 8 A
or
Drive circuit inner temperature > 175C (347F)
Judgment Value
Motor current s 8 A
Drive circuit inner temperature s 175C (347F)
GD(H6DO)-224
GENERAL DESCRIPTION
EK:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW
3. ENABLE CONDITION
EN-01868
(2)
(3)
(1)
(4)
(5)
12V 12V
GD(H6DO)-225
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Motor power voltage s 5 V
Judgment Value
GD(H6DO)-226
GENERAL DESCRIPTION
EL:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
3. ENABLE CONDITION
EN-01868
(2)
(3)
(1)
(4)
(5)
12V 12V
GD(H6DO)-227
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
Motor power voltage < 5 V
GD(H6DO)-228
GENERAL DESCRIPTION
EM:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP
PERFORMANCE
3. ENABLE CONDITION
(2) Drive circuit
EN-01869
(1)
(2)
(3)
(4)
GD(H6DO)-229
GENERAL DESCRIPTION
Time Needed for Diagnosis: 8 msec 80 msec
Normality Judgment
8. FAIL SAFE
Judgment Value
< 10.127 deg
or
> 19.872 deg
or
position
< 1.683 deg
Judgment Value
> 10.127 deg
and
s 19.872 deg
position
> 1.683 deg
GD(H6DO)-230
GENERAL DESCRIPTION
EN:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT
LOW INPUT
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
EN-01861
(2)
(3)
(4)
(1)
GD(H6DO)-231
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H6DO)-232
GENERAL DESCRIPTION
EO:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT
HIGH INPUT
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
EN-01861
(2)
(3)
(4)
(1)
GD(H6DO)-233
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H6DO)-234
GENERAL DESCRIPTION
EP:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT
LOW INPUT
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
EN-01861
(2)
(3)
(4)
(1)
GD(H6DO)-235
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H6DO)-236
GENERAL DESCRIPTION
EQ:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT
HIGH INPUT
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
EN-01861
(2)
(3)
(4)
(1)
GD(H6DO)-237
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Judgment Value
GD(H6DO)-238
GENERAL DESCRIPTION
ER:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B
VOLTAGE CORRELATION
3. ENABLE CONDITION
Ignition switch ON
EN-01859
(1)
(2)
(3)
(4)
GD(H6DO)-239
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Map
0 s d < 2.125 deg
2.125 deg s d <
4.25 deg
4.25 deg s d <
9 deg
9 deg s d <
31.625 deg
31.625 deg s d
Judgment Value
Signal difference between two sensors s Value from Map
GD(H6DO)-240
GENERAL DESCRIPTION
ES:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E
VOLTAGE CORRELATION
3. ENABLE CONDITION
2 signal
1 signal
Ignition switch ON
EN-01861
(2)
(3)
(4)
(1)
GD(H6DO)-241
GENERAL DESCRIPTION
Normality Judgment
8. FAIL SAFE
Judgment Value
Map
0 s d < 0.6 deg
0.6 deg s d <
1.2 deg
1.2 deg s d <
2 deg
2 deg s d < 4 deg 4 deg s d
Judgment Value
Signal difference between two sensors s Map
GD(H6DO)-242
GENERAL DESCRIPTION
ET:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE
Detect the malfunction of barometric pressure sensor output property.
Judge as NG when the barometric pressure sensor output is largely different from the intake manifold pres-
sure at engine start.
3. ENABLE CONDITION
Perform the diagnosis once at ignition switch ON.
cles.
Normality Judgment
8. FAIL SAFE
Judgment Value
pressure|
> 26.66 kPa (200 mmHg,
7.874 inHg)
< 1.33 kPa (9.99 mmHg,
0.393 inHg)
Judgment Value
pressure|
< 26.66 kPa (200 mmHg,
7.874 inHg)
GD(H6DO)-243
GENERAL DESCRIPTION
EU:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW
3. ENABLE CONDITION
Normality Judgment
8. FAIL SAFE
Barometric pressure sensor process: Fix the barometric pressure to 101.3 kPa (760 mmHg, 29.9 inHg).
None
Judgment Value
Judgment Value
GD(H6DO)-244
GENERAL DESCRIPTION
EV:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH
3. ENABLE CONDITION
Normality Judgment
8. FAIL SAFE
Barometric pressure sensor process: Fix the barometric pressure to 101.3 kPa (760 mmHg, 29.9 inHg).
None
Judgment Value
Judgment Value
CS-2
General Description
CONTROL SYSTEMS
A: SPECIFICATION
B: COMPONENT
1. AT SELECT LEVER
Item Specification
Swing torque of rod against lever N (kgf, lb) 3.7 (0.38, 0.84) or less
CS-00685
(36)
(35)
(39)
(37)
(38)
(30)
(3)
(4)
(5)
(8)
(34)
(17)
(16)
(14)
(15)
(13)
(10)
(9)
(11)
(12)
(18)
(6)
(7)
(1)
(2)
T1
T4
T3
T1
T2
T5
P
R
N
D
(23)
(22)
(21)
(19)
(20)
(28)
(29)
(32)
(40)
(33)
(24)
(27)
(31)
(24)
(25)
(26)
CS-3
General Description
CONTROL SYSTEMS
(1) Ring indicator (17) Shift lock solenoid ASSY (33) Cable bracket
(2) Front cover (18) Check plate (34) Seat
(3) Grip (19) Lever ASSY (35) Washer
(4) Release cover (20) Check ball (36) Snap pin
(5) Indicator ASSY (21) Return spring (37) Select cable
(6) Indicator bulb (22) Shaft (38) Clamp
(7) Valve harness (23) Washer (39) Nut A
(8) Blind (24) Bushing A (40) Bushing
(9) Detent spring (25) Arm ASSY
(10) Spring washer (26) Bushing plate Tightening torque:Nm (kgf-m, ft-lb)
(11) Washer (27) Bushing B T1: 5.1 (0.52, 3.8)
(12) Guide plate upper (28) Shaft T2: 6.9 (0.70, 5.1)
(13) Up switch (29) Plate lower T3: 7.5 (0.76, 5.5)
(14) Down switch (30) Clamp T4: 12.7 (1.3, 9.4)
(15) SPORT mode switch (31) Collar T5: 18 (1.8, 13.3)
(16) Switch cover (32) Gasket
CS-4
General Description
CONTROL SYSTEMS
2. 5MT GEAR SHIFT LEVER
(1) Gear shift knob (11) O-ring (21) Washer
(2) Front cover ASSY (12) Spring pin (22) Stay
(3) Clamp (13) Bushing B (23) Cushion rubber
(4) Boot and insulator ASSY (14) O-ring (24) Boss
(5) Plate ASSY (15) Boot (25) Bushing
(6) Lever (16) Spring pin (26) Self-locking nut
(7) Bushing (17) Joint
(8) Lock wire (18) Rod Tightening torque:Nm (kgf-m, ft-lb)
(9) Snap ring (19) Spacer T1: 12 (1.2, 8.9)
(10) Bushing (20) Bracket T2: 18 (1.8, 13.3)
CS-00267
T2
T1
T2
T2
T1
T2
T2
(23) (22)
(21)
(20)
(8)
(25)
(7)
(6)
(9)
(10)
(5)
(12)
(7)
(19)
(18)
(17)
(7)
(7)
(7) (19)
(26)
(24)
(19)
(7)
(11)
(13)
(14)
(15)
(26)
(26)
(26)
(16)
(3)
(3)
(4)
(2)
(1)
CS-5
General Description
CONTROL SYSTEMS
3. 6MT GEAR SHIFT LEVER
T4
T5
T3
(7)
(6)
(8)
(25)
(26)
(27)
(21)
(22)
(23)
(24)
(20)
(19)
(18)
T1
(15)
(17)
(16)
(14)
(13)
(12)
(30)
(31)
(12)
(11)
(10)
(9)
(29)
(28)
(13)
(13)
(33)
(12)
(12)
(12)
(12)
T3
T3
(34)
(36)
(37)
(36)
(35)
CS-00561
T4
(5)
(3)
(3)
(4)
(2)
(1)
(32)
CS-6
General Description
CONTROL SYSTEMS
C: PREPARATION TOOL
1. SPECIAL TOOL
D: CAUTION
any work.
Use SUBARU genuine fluid, grease etc. or equivalent. Do not mix fluid, grease, etc. of different grades or
manufacturers.
Apply grease onto sliding or revolving surfaces before installation.
Before installing O-rings or snap rings, apply sufficient amount of fluid to avoid damage and deformation.
Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth
between the part and the vise.
Before disconnecting electrical connectors, be sure to disconnect the negative terminal from battery.
(1) Gear shift knob (16) Bushing (31) Reverse check lever
(2) Front cover ASSY (17) Spring pin (32) Band clip
(3) Clamp (18) Bushing (33) Boss
(4) Boot and insulator ASSY (19) Boot (34) O-ring
(5) Plate ASSY (20) Stay (35) O-ring
(6) Slider (21) Cushion rubber (36) Screw
(7) Spring pin (22) Bushing (37) Spring seat
(8) Spring (23) Reverse check cable
(9) Holder (24) Washer Tightening torque:Nm (kgf-m, ft-lb)
(10) Seat cushion (25) Snap pin T1: 1.3 (0.13, 0.96)
(11) Lever (26) Bracket T2: 7.5 (0.76, 5.5)
(12) Bushing (27) Cable plate T3: 12 (1.2, 8.9)
(13) Spacer (28) Joint T4: 18 (1.8, 13.3)
(14) Lock wire (29) Spring pin T5: 32 (3.3, 23.6)
(15) Snap ring (30) Rod
MONITOR III KIT
ST1B021XU0
CS-7
AT Shift Lock Control System
CONTROL SYSTEMS
2. AT Shift Lock Control System
A: LOCATION
(1) TCM (P range) (4) Key cylinder
(with built-in key warning switch)
(6) P range switch
(2) Body integrated unit (7) Key lock solenoid
(3) Stop light switch (5) Shift lock solenoid ASSY
CS-00513
(1)
(3)
(2)
(5)
(6)
(7)
(4)
CS-8
CONTROL SYSTEMS
CS-00835
(1)
CS-00743
(2)
(3)
CS-00270 CS-00359
(7)
(4)
CS-00543
(6)
(5)
CS-9
CONTROL SYSTEMS
B: ELECTRICAL SPECIFICATION
Item Connector No. Terminal No.
Input/Output signal
Measured value and measuring conditions
Backup power supply B281
1
9 16 V
2
Ignition power supply
i84 1 10 15 V when ignition switch is at ON or START.
i84 24 10 15 V when ignition switch is at ACC.
TCM (P range)
B280 20
Pulse signal
B280 30
Stop light switch B281 23
9 16 V when stop light switch is ON.
0 V when stop light switch is OFF.
P range switch B281 13
0 V when select lever is in P range.
9 16 V when select lever is in other positions than P
range.
Shift lock solenoid signal B280 6
8.5 16 V when shift lock is released.
0 V when shift lock is operating.
Key warning switch signal B281 7
9 16 V when key is inserted.
0 V when key is removed.
Key lock solenoid signal B280 5
7.5 16 V when ignition switch is turned ON, with select
lever in P range and brake switch ON.
0 V at other conditions than above.
Ground
B280 22

i84 21
B281
8
9
SL-00692
7
19
28
6
18
27
5
17
4
16
26
15
25
14
24
1312
23
11
22
3
10
2
9
21
1
8
20
7
20
30
6
19
29
18
28
5
17
4
16
27
15
26
1413
25
12
24
11
23
3
10
2
9
22
1
8
21
B280 B281
8
23
35
7
22
34
21
6
20
33
5
19
32
18
31
17
30
1615
29
14
28
4
13
27
3
12
26
11
2
10
25
1
9
24
i84 A: B: C: TO TO TO
CS-10
CONTROL SYSTEMS
C: WIRING DIAGRAM
(1) Ignition switch (4) Body integrated unit (7) Shift lock solenoid
(2) Stop light switch (5) TCM (P range) (8) P range switch
(3) Key warning switch (6) Key lock solenoid (9) Battery
CS-00363
OFFACCON
(1)
(2)
(3)
(4)
(9)
(6)
(7)
(8)
(5)
CS-11
CONTROL SYSTEMS
D: INSPECTION
1. SHIFT LOCK OPERATION
Step Check Yes No
1 CHECK COMMUNICATION OF SUBARU SE-
LECT MONITOR.
2) Using the Subaru Select Monitor, check
whether communication to all systems can be
executed normally.
Is the system name displayed? Go to step 2. Perform the
inspection follow-
ing the diagnostic
procedure in the
LAN section. <Ref.
to LAN(diag)-2,
Basic Diagnostic
Procedure.>
2 CHECK SHIFT LOCK.
2) Shift the select lever to the P range.
While brake pedal is not
depressed, is it possible to
move the select lever from the
P range to other ranges?
Inspect SELECT
LEVER CANNOT
BE LOCKED.
<Ref. to CS-13,
SELECT LEVER
CANNOT BE
LOCKED,
INSPECTION, AT
Shift Lock Control
System.>
Go to step 3.
3 CHECK SHIFT LOCK. While brake pedal is
depressed, is it possible to
move the select lever from the
P range to other ranges?
Go to step 4. Inspect SELECT
LEVER SHIFT
LOCK CANNOT
BE RELEASED.
<Ref. to CS-16,
SHIFT LOCK OF
SELECT LEVER
CANNOT BE
RELEASED.,
INSPECTION, AT
Shift Lock Control
System.>
4 CHECK KEY INTERLOCK.
2) Shift the select lever to other than P range.
Can the ignition key be
removed?
Perform the
inspection of KEY
INTERLOCK CAN-
NOT BE LOCKED
OR RELEASED.
<Ref. to CS-19,
KEY INTERLOCK
CANNOT BE
LOCKED OR
RELEASED,
INSPECTION, AT
Shift Lock Control
System.>
Go to step 5.
5 CHECK KEY INTERLOCK.
Shift the select lever to the P range.
Can the ignition key be
removed?
AT shift lock sys-
tem is normal.
Perform the
inspection of KEY
INTERLOCK CAN-
NOT BE LOCKED
OR RELEASED.
<Ref. to CS-19,
KEY INTERLOCK
CANNOT BE
LOCKED OR
RELEASED,
INSPECTION, AT
Shift Lock Control
System.>
CS-12
CONTROL SYSTEMS
2. BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT
Step Check Yes No
1 CHECK DTC OF BODY INTEGRATED UNIT.
Check DTC of body integrated unit.
<Ref. to LAN(diag)-12, OPERATION, Subaru
Select Monitor.>
Is the DTC of power line dis-
played on body integrated unit?
Repair or replace it
according to the
DTC.
Go to step 2.
BODY INTEGRATED UNIT AND CHASSIS
GROUND.
2) Measure the harness resistance between
the body integrated unit and chassis ground.
circuit of harness
between the body
integrated unit and
chassis ground.
3 CHECK POOR CONTACT. Is there poor contact in connec-
tor?
Repair the poor
contact.
Check the body
integrated unit.
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27 28
16 17 18 19
20 21
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 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 35
B281 C: B280 B: i84 A:
OFF ACC
ACC
ON
B
IG
MAIN SBF SBF-6
IGNITION SWITCH
SBF-8
N
o
.
1
2
N
o
.
7
BATTERY
B281 C:
B280 B:
i84 A:
A
1
C
2
C
8
C
9
A
2
1
B
2
2
E E
CS-00836
CS-13
CONTROL SYSTEMS
3. SELECT LEVER CANNOT BE LOCKED
B281 C: i84 A:
MAIN SBF
SBF-2 No.8
E
B281 C:
B280 B:
i84 A:
C
2
3
B
6
B159
5
9
B116
4
3
3
2
B65
BATTERY
STOP LIGHT
SWITCH
FUSE &
RELAY BOX
SHIFT LOCK SOLENOID
B116
1 2
3 4
B65
1 2 3 4
5 6 7 8 9 10
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27 28
16 17 18 19
20 21
1 2 3 4 5 6 7 8
9 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
B159
C
1
N
o
.
1
4
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
B280 B:
7.5A
3
FUSE
(RELAY BLOCK)
B225
B225
4
C
7
B350
KEY WARNING SWITCH
4
3
5
A
T
B
3
0
B
2
0
TCM
B54
B
2
0
B
2
1
:
:
4AT
5AT
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B54
4 SPEED AT
5 SPEED AT
4
A
T
A
1
7
A
1
8
B: A: B55
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B55 A: B:
E
C
1
3
B116
1
2
P RANGE SWITCH
CS-00837
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
CS-14
CONTROL SYSTEMS
Step Check Yes No
1 CHECK IGNITION POWER. Is the voltage 9 V or more? Go to step 2. Check the ignition
switch harness.
2) Read the DTC of body integrated unit using
Is B1106 current malfunction? Repair or replace it
according to the
DTC.
Go to step 3.
3 CHECK INPUT SIGNAL OF BODY INTE-
GRATED UNIT USING SUBARU SELECT
MONITOR.
Read the input signal of shift position from Sub-
aru Select Monitor.
Select Monitor.>
Is 7 displayed in the P range
and displayed other than 7
except in the P range?
Inspect the inhibi-
tor switch and
TCM.
Go to step 4.
MONITOR.
Read the input signal of P range switch from
Select Monitor.>
Is ON displayed in the P
range and displayed OFF
5 CHECK HARNESS BETWEEN BODY INTE-
GRATED UNIT AND P RANGE SWITCH.
1) Disconnect the connector of the P range
switch.
the body integrated unit and the P range
switch.
(B116) No. 1 (B281) No. 13:
more?
Repair the open
circuit of harness
between the body
integrated unit and
the P range
switch.
Go to step 6.
6 CHECK HARNESS BETWEEN P RANGE
SWITCH AND CHASSIS GROUND.
Measure the resistance of harness between P
range switch and chassis ground.
more?
Repair the open
circuit of harness
between P range
switch and chassis
ground.
Go to step 7.
7 CHECK P RANGE SWITCH.
2) Measure the resistance between P range
Terminals
No. 2 No. 1:
Is the resistance less than 1 ? Go to step 8. Replace the P
range switch.
Terminals
No. 2 No. 1:
more?
Replace the body
integrated unit.
Replace the P
range switch.
MONITOR.
Read the input signal of stop light switch from
Subaru Select Monitor. <Ref. to LAN(diag)-12,
Is ON displayed when the
brake pedal is depressed and
displayed OFF when not
depressed?
CS-15
CONTROL SYSTEMS
10 CHECK STOP LIGHT SWITCH INPUT SIG-
NAL.
2) Disconnect the connector from body inte-
grated unit.
3) Measure the voltage between the body inte-
grated unit connector terminal and chassis
ground.
Is the voltage 9 V or more when
the brake pedal is depressed,
and approx. 0 V when not
depressed?
Replace the body
integrated unit.
Check the stop
light system.
11 CHECK SHIFT LOCK SOLENOID.
1) Disconnect the connector from the shift lock
solenoid.
2) Measure the resistance of shift lock sole-
noid terminals.
Terminals
No. 3 No. 4:
Is the resistance between 19.5
25.5 ?
Go to step 12. Replace the shift
lock solenoid.
Connect the battery to the shift lock solenoid
connector terminal, and then operate the sole-
noid.
Terminals
No. 3 (+) No. 4 ():
Does the shift lock solenoid
operate normally?
lock solenoid unit.
MONITOR.
2) Depress the brake pedal.
3) Read the input signal of shift lock solenoid
from Subaru Select Monitor. <Ref. to
LAN(diag)-12, OPERATION, Subaru Select
Monitor.>
Is ON displayed? Go to step 14. Replace the body
integrated unit.
AND BODY INTEGRATED UNIT.
1) Disconnect the connector of body inte-
grated unit.
2) Measure the voltage between body inte-
grated unit and chassis ground.
Is the voltage 9 V or more? Replace the body
integrated unit.
Check the harness
for open between
the body integrated
unit and battery or
the fuse (No. 14).
Step Check Yes No
CS-16
CONTROL SYSTEMS
4. SHIFT LOCK OF SELECT LEVER CANNOT BE RELEASED
B281 C: i84 A:
MAIN SBF
SBF-2 No.8
E
B281 C:
B280 B:
i84 A:
C
2
3
B
6
B159
5
9
B116
4
3
3
2
B65
BATTERY
STOP LIGHT
SWITCH
FUSE &
RELAY BOX
SHIFT LOCK SOLENOID
B116
1 2
3 4
B65
1 2 3 4
5 6 7 8 9 10
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27 28
16 17 18 19
20 21
1 2 3 4 5 6 7 8
9 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
B159
C
1
N
o
.
1
4
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
B280 B:
7.5A
3
FUSE
(RELAY BLOCK)
B225
B225
4
C
7
B350
KEY WARNING SWITCH
4
3
5
A
T
B
3
0
B
2
0
TCM
B54
B
2
0
B
2
1
:
:
4AT
5AT
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B54
4 SPEED AT
5 SPEED AT
4
A
T
A
1
7
A
1
8
B: A: B55
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B55 A: B:
E
C
1
3
B116
1
2
P RANGE SWITCH
CS-00837
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
CS-17
CONTROL SYSTEMS
Step Check Yes No
switch harness.
according to the
DTC.
Go to step 3.
3 CHECK DTC OF BODY INTEGRATED UNIT. Are U1213 and U1223 current
malfunction?
Check the CAN
communication
system.
Go to step 4.
4 CHECK DTC OF BODY INTEGRATED UNIT. Are U1212 and U1222 current
malfunction?
Check the CAN
communication
system.
Go to step 5.
MONITOR.
Read the input signal of front wheel speed from
Is the front wheel speed 10 km/
h or more?
Check the VDC/
ABS CM.
Go to step 6.
MONITOR.
Read the input signal of shift position from Sub-
aru Select Monitor. <Ref. to LAN(diag)-12,
Is 7 displayed in the P range
and displayed other than 7
Inspect the inhibi-
tor switch and
TCM.
Go to step 7.
MONITOR.
the Subaru Select Monitor. <Ref. to LAN(diag)-
12, OPERATION, Subaru Select Monitor.>
switch.
switch.
(B116) No. 1 (+) (B281) No. 13 ():
more?
Repair the open
circuit of harness
between the body
integrated unit and
the P range
switch.
Go to step 9.
more?
Repair the open
circuit of harness
between P range
switch and chassis
ground.
Go to step 10.
Terminals
No. 2 No. 1:
range switch.
Terminals
No. 2 No. 1:
more?
Replace the body
integrated unit.
Replace the P
range switch.
CS-18
CONTROL SYSTEMS
MONITOR.
Read the input signal of stop light switch from
Is ON displayed when the
brake pedal is depressed and
displayed OFF when not
depressed?
13 CHECK STOP LIGHT SWITCH INPUT SIG-
NAL.
grated unit.
3) Measure the voltage between the body inte-
grated unit connector terminal and chassis
ground.
Is the voltage 9 V or more when
the brake pedal is depressed,
and approx. 0 V when not
depressed?
Replace the body
integrated unit.
Check the stop
light system.
1) Disconnect the connector from the shift lock
solenoid.
2) Measure the resistance of shift lock sole-
noid terminals.
Terminals
No. 3 No. 4:
25.5 ?
lock solenoid.
Connect the battery to the shift lock solenoid
connector terminal, and then operate the sole-
noid.
Terminals
No. 3 (+) No. 4 ():
operate normally?
lock solenoid unit.
MONITOR.
4) Read the output signal of shift lock solenoid
from the Subaru Select Monitor. <Ref. to
Monitor.>
Is ON displayed? Go to step 17. Replace the body
integrated unit.
grated unit.
integrated unit.
Check the harness
for open between
the body integrated
unit and battery or
the fuse (No. 14).
Step Check Yes No
CS-19
CONTROL SYSTEMS
5. KEY INTERLOCK CANNOT BE LOCKED OR RELEASED
1 2 3 4
B350
B116
1 2 3 4
5 6 7 8 9 10
B281
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27 28
16 17 18 19
20 21
C:
B280
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
B:
CS-00792
B38
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B75
1
2
B76
1
2
i84 A:
1 2 3 4 5 6 7 8
9 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
N
o
.
1
4
E E E
B281 C:
B280 B:
i84 A:
C
7
B
5
12
C
1
3
A
3
C
2
B116
1
2
B350
B350
3
4
N
o
.
7
2
2
B76
7
B75
B38
i3
SBF-8
P RANGE SWITCH
KEY WARNING SWITCH
BATTERY
TEST MODE
CONNECTOR
KEY LOCK SOLENOID
CS-20
CONTROL SYSTEMS
Step Check Yes No
MONITOR.
2) Connect the Subaru Select Monitor to the
data link connector.
3) Run the Subaru Select Monitor.
4) Read the input signal of the key warning
switch from the Subaru Select Monitor.
Select Monitor.>
Is ON displayed when the key
is inserted and displayed OFF
when removed?
AND KEY WARNING SWITCH.
1) Disconnect the connector of key warning
switch.
2) Measure the voltage of harness between
key warning switch and chassis ground.
ness between bat-
tery and key
warning switch.
3 CHECK HARNESS BETWEEN KEY WARN-
ING SWITCH AND BODY INTEGRATED
UNIT.
Measure the resistance between key warning
switch and body integrated unit.
(B281) No. 7 (B350) No. 4:
circuit of harness
between key warn-
ing switch connec-
tor and body
integrated unit.
4 CHECK HARNESS BETWEEN KEY WARN-
ING SWITCH AND BODY INTEGRATED
UNIT.
key warning switch and chassis ground.
more?
circuit of harness
between key warn-
ing switch and
chassis ground.
5 CHECK KEY WARNING SWITCH.
Measure the resistance between connector ter-
minals of key warning switch.
Terminals
No. 3 No. 4:
more?
Replace the key
warning switch.
Go to step 6.
6 CHECK KEY WARNING SWITCH.
1) Remove the key.
terminals of key warning switch.
Terminals
No. 3 No. 4:
more?
Replace the body
integrated unit.
Replace the key
warning switch.
switch harness.
1) Shift the select lever to N range.
2) Check DTC indicated by body integrated
unit using Subaru Select Monitor.
according to the
DTC.
Go to step 9.
MONITOR.
CS-21
CONTROL SYSTEMS
switch.
switch.
(B116) No. 1 (B281) No. 13:
more?
Repair the open
circuit of harness
between the body
integrated unit and
the P range
switch.
Go to step 11.
more?
Repair the open
circuit of harness
between P range
switch and chassis
ground.
Go to step 12.
Terminals
No. 2 No. 1:
range switch.
Terminals
No. 2 No. 1:
more?
Replace the body
integrated unit.
Replace the P
range switch.
14 CHECK TEST MODE CONNECTOR.
1) Check that the test mode connector is dis-
connected.
2) Measure the resistance between the body
integrated unit and chassis ground.
more?
circuit of the har-
ness between the
body integrated
unit and test mode
connector.
15 CHECK HARNESS BETWEEN KEY LOCK
SOLENOID AND BODY INTEGRATED UNIT.
Measure the resistance between key lock sole-
noid and body integrated unit.
Terminals
(B280) No. 5 (B350) No. 2:
circuit of harness
between key lock
solenoid connector
and body inte-
grated unit.
16 CHECK HARNESS BETWEEN KEY LOCK
SOLENOID AND CHASSIS GROUND.
key lock solenoid and chassis ground.
Terminals
more?
Go to step 17. Repair short cir-
cuit of harness
between key lock
solenoid and chas-
sis ground.
17 CHECK KEY LOCK SOLENOID.
1) Disconnect the connector from the key lock
solenoid.
2) Measure the resistance of key lock solenoid
connector terminals.
Terminals
No. 2 No. 1:
14.5 ?
Go to step 18. Replace the key
lock solenoid.
18 CHECK KEY LOCK SOLENOID.
2) Operate the key lock solenoid.
Does the key lock solenoid
operate normally?
Go to step 19. Replace the key
lock solenoid.
Step Check Yes No
CS-22
CONTROL SYSTEMS
MONITOR.
2) Read the output signal of key interlock from
Is OFF displayed in the P
range and displayed ON
Go to step 20. Replace the body
integrated unit.
grated unit.
integrated unit.
Check the harness
for open between
the body integrated
unit and battery or
the fuse (No. 14).
Step Check Yes No
CS-23
Select Lever
CONTROL SYSTEMS
3. Select Lever
A: REMOVAL
SOHC model
fler.>
DOHC turbo model
AL, Muffler.>
DOHC 3.0 L model
7) Remove the cable from arm assembly.
8) Raise the claw of clamp to remove the cable.
11) Remove the center console. <Ref. to EI-55,
REMOVAL, Center Console.>
12) Remove the harness clips from the bracket.
13) Disconnect the connectors, and then remove
the four bolts to take out the select lever assembly
from vehicle body.
(A) Adjusting nut
(B) Arm ASSY
AT-01331
(B)
CS-00278
(A)
(A) Claw
CS-00279
(A)
CS-00518
CS-00519
CS-24
Select Lever
CONTROL SYSTEMS
B: INSTALLATION
1) Set the select lever to vehicle body.
2) Tighten the four bolts to install the select lever to
vehicle body, and then connect the connector.
(1) Temporarily tighten the bolt A.
(2) Tighten the bolt B.
(3) Tighten the bolt A.
(4) Tighten the bolts C and D.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
3) Install the harness clips to the bracket.
4) Install the center console. <Ref. to EI-56, IN-
STALLATION, Center Console.>
5) Install the console box. <Ref. to EI-54, INSTAL-
LATION, Console Box.>
8) Shift the range select lever to the N range.
9) Secure the cable to the bracket. <Ref. to CS-28,
INSTALLATION, Select Cable.>
10) Adjust the select cable position. <Ref. to CS-
31, ADJUSTMENT, Select Cable.>
11) After the completion of adjustment, confirm that
the select lever operates properly at all range posi-
tions.
13) Install the rear exhaust pipe and muffler.
SOHC model
<Ref. to EX(H4SO)-8, INSTALLATION, Rear Ex-
haust Pipe.> <Ref. to EX(H4SO)-10, INSTALLA-
TION, Muffler.>
DOHC turbo model
<Ref. to EX(H4DOTC)-13, INSTALLATION, Rear
Exhaust Pipe.> <Ref. to EX(H4DOTC)-15, IN-
STALLATION, Muffler.>
DOHC 3.0 L model
<Ref. to EX(H6DO)-8, INSTALLATION, Rear Ex-
haust Pipe.> <Ref. to EX(H6DO)-10, INSTALLA-
TION, Muffler.>
14) Inspect the following items. When a malfunc-
tion is found in the inspection, adjust the select ca-
ble and inhibitor switch.
NOTE:
Inhibitor switch for 5AT model is not adjustable.
<Ref. to CS-31, 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 ranges.
(2) Back-up light illuminates when the select le-
ver is in the R range, but not in other ranges.
(3) Select lever and indicator positions are
matched.
C: DISASSEMBLY
2) Remove the indicator light.
3) Remove the grip.
4) Remove the indicator assembly.
CS-00520
A
B
D
C
CS-00518
CS-00521
CS-00522
CS-25
Select Lever
CONTROL SYSTEMS
5) Remove the blind.
6) Shift the select lever to the N range, and then re-
move the detent spring.
7) Remove the bolt, and separate the guide plate
upper from plate lower.
8) Remove the connector from the guide plate up-
per.
9) Remove the sheet, and remove the shift lock so-
lenoid assembly.
10) Remove the switch assembly.
11) Remove the check plate.
12) Raise the claw of connector.
(A) Guide plate upper
(B) Plate lower
CS-00523
CS-00538
CS-00524
(A)
(B)
CS-00525
CS-00526
CS-00527
CS-00528
CS-00292
CS-26
Select Lever
CONTROL SYSTEMS
13) Disconnect the terminals of the SPORT mode
switch and shift lock solenoid assembly from the
connector, using a flat-tip screwdriver with a thin
tip.
14) Remove the cable bracket.
15) Remove the cover.
16) Remove the select lever assembly.
17) Remove the clamp, and remove the arm as-
sembly and bushing plate.
D: ASSEMBLY
1) Clean all the parts before assembly.
2) Apply NIGTIGHT LYW No. 2 grease or equiva-
lent to each part. <Ref. to CS-2, AT SELECT LE-
VER, COMPONENT, General Description.>
3) Assemble in the reverse order of disassembly.
NOTE:
Refer to COMPONENT for each tightening
torque. <Ref. to CS-2, AT SELECT LEVER, COM-
Connect the switch terminal to the connector.
4) After completing installation, shift the select le-
ver from P range to D range, then check wheth-
er the indicator and select lever matches, whether
the pointer and position mark matches and what
the operating force is.
E: INSPECTION
1) Inspect the removed parts by comparing with
new parts for deformation, damage and wear. Re-
pair or replace if defective.
2) Confirm the select lever operating condition be-
fore assembly. Normal if it operates smoothly.
(A) P range switch
CS-00529
4
10
3
9 8 7
2 1
6 5
(A)
CS-00530
CS-00531
CS-00532
(A) Arm ASSY
(B) Bushing plate
(C) Bushing A
(D) Bushing B
(A) P range switch
CS-00686
(C)
(D)
(C)
(B)
(A)
CS-00529
4
10
3
9 8 7
2 1
6 5
(A)
CS-27
Select Cable
CONTROL SYSTEMS
4. Select Cable
A: REMOVAL
5) Remove the front, center and rear exhaust pipes
and the muffler. (SOHC and DOHC non-turbo mod-
el)
SOHC MODEL
Pipe.> <Ref. to EX(H4SO)-8, REMOVAL, Rear Ex-
haust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL,
Muffler.>
DOHC 3.0 L model
Pipe.> <Ref. to EX(H6DO)-7, REMOVAL, Rear Ex-
haust Pipe.> <Ref. to EX(H6DO)-9, REMOVAL,
Muffler.>
6) Remove the center and rear exhaust pipes and
the muffler. (DOHC turbo model)
AL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-
15, REMOVAL, Muffler.>
8) Remove the snap pin and washer from range se-
lect lever.
4AT
5AT
AT-01331
(A) Range select lever
(B) Snap pin
(C) Select cable
(D) Bracket
(E) Washer
(B) Snap pin
(C) Select cable
(D) Bracket
(E) Washer
CS-00036
(C)
(B)
(A)
(E)
(D)
CS-00327
(B)
(D)
(C)
(E)
(A)
CS-28
Select Cable
CONTROL SYSTEMS
9) Remove the plate assembly from the transmis-
sion case.
4AT
5AT
10) Disconnect the cable from arm assembly.
11) Raise the claw of clamp to remove the cable
from bracket.
12) Remove the select cable from plate assembly.
B: INSTALLATION
1) Install the select cable to plate assembly.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
2) Install the select cable to range select lever.
(A) Select cable
(B) Plate ASSY
(C) Bracket
(A) Select cable
(B) Plate ASSY
(A) Adjusting nut
(B) Arm ASSY
CS-00037
(A)
(C)
(B)
(A)
(B)
CS-00328
(B)
CS-00278
(A)
(A) Claw
CS-00279
(A)
CS-00607
T
T
CS-29
Select Cable
CONTROL SYSTEMS
3) Install the plate assembly to transmission.
Tightening torque:
T: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
4AT
5AT
4) Install the washer and snap pin to range select
lever.
4AT
5AT
5) Install new clamp paying attention to the install-
ing direction.
(A) Select cable
(B) Plate ASSY
(A) Select cable
(B) Plate ASSY
CS-00039
(A)
(B)
T
(A)
(B)
CS-00328
(B) Snap pin
(C) Select cable
(D) Bracket
(E) Washer
(B) Snap pin
(C) Select cable
(D) Bracket
(E) Washer
(A) Clamp
(B) Forward
CS-00036
(C)
(B)
(A)
(E)
(D)
CS-00327
(B)
(D)
(C)
(E)
(A)
(A)
(B)
C
C
CS-00534
CS-30
Select Cable
CONTROL SYSTEMS
6) Insert the tip of inner cable into connector hole of
select lever, and fix the cable to bracket.
7) Shift the select lever to the N range, and then
adjust the select cable position. <Ref. to CS-31,
ADJUSTMENT, Select Cable.>
9) Install the front, center and rear exhaust pipes,
and the muffler. (SOHC and DOHC non-turbo mod-
el)
SOHC MODEL
TION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10,
INSTALLATION, Muffler.>
DOHC 3.0 L model
<Ref. to EX(H6DO)-5, INSTALLATION, Front Ex-
TION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10,
10) Install the center, rear exhaust pipes and the
muffler. (DOHC turbo model)
STALLATION, Rear Exhaust Pipe.> <Ref. to
EX(H4DOTC)-15, INSTALLATION, Muffler.>
C: INSPECTION
Check the removed cable and replace or adjust if
damaged, rusty or malfunctioning.
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 deterio-
ration.
5) Move the select lever from P to D range.
Check the existence of feel to contact the detents in
each range. If the detents cannot be felt or the po-
sition pointer is improperly aligned, adjust the ca-
ble.
6) Check if the starter motor rotates when the se-
lect lever is set to P range.
7) Check the back-up light illumination when the
select lever is in R range.
8) Check the parking lock operation when the se-
lect lever is in P range.
CS-00535
AT-01331
CS-31
Select Cable
CONTROL SYSTEMS
D: ADJUSTMENT
SOHC MODEL
fler.>
DOHC turbo model
AL, Muffler.>
DOHC 3.0 L model
4) Loosen the adjusting nuts on both sides.
5) With the select lever pushed towards the rear of
the vehicle, turn the adjustment nut B until it just
contacts the connector. Then loosen the nut for 1/2
turn.
6) Set a spanner wrench to adjusting nut B so that
it does not rotate, and then tighten the adjusting nut
A.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
7) After the completion of adjustment, confirm that
the select lever operates normally at all ranges.
(A) Adjusting nut A
(B) Adjusting nut B
AT-01331
CS-00040
(A) (B)
(A) Forward side
(B) Select lever
(C) Connector
(D) Adjusting nut B
(E) Contact point
(F) Adjusting nut A
(A) Adjusting nut A
(B) Adjusting nut B
CS-00041
(A)
(B)
(C)
(D)
(E)
(F)
CS-00042
(A)
(B)
CS-32
Paddle Shift Assembly
CONTROL SYSTEMS
5. Paddle Shift Assembly
A: REMOVAL
2) Set the tire to the straight-ahead position.
WARNING:
If there are airbag modules mounted, always re-
fer to Airbag System when performing airbag
module service. <Ref. to AB-4, CAUTION, Gen-
eral Description.>
4) Remove the steering wheel. <Ref. to PS-14, RE-
MOVAL, Steering Wheel.>
5) Remove the column cover.
6) Disconnect the connector of paddle shift assem-
bly.
7) Remove the paddle shift assembly.
B: INSTALLATION
1) Clean all parts before installation.
3) After completing installation, shift the select le-
ver to the manual mode.
4) Operate the paddle shift assembly and confirm
that 2 illuminates on the combination meter.
CS-00728
CS-00838
CS-33
Paddle Shift Assembly
CONTROL SYSTEMS
C: INSPECTION
1 2 3
CS-00730
Step Check Yes No
1 SHIFT-UP SWITCH CONTINUITY CHECK.
1) Operate the + side of paddle shift assembly
and hold it.
2) Measure the resistance between the termi-
nals of the paddle shift assembly connector.
Terminals
No. 1 No. 2:
?
Go to step 2. Replace the pad-
dle shift assembly.
2 SHIFT-DOWN SWITCH CONTINUITY
CHECK.
1) Operate the side of paddle shift assembly
and hold it.
Terminals
No. 3 No. 2:
?
Go to step 3. Replace the pad-
dle shift assembly.
3 CHECK SHIFT SWITCH INSULATION.
1) Do not operate the paddle shift assembly.
Terminals
No. 2 No. 1:
No. 2 No. 3:
Is the resistance 1 ? Paddle shift
assembly is nor-
mal.
Replace the pad-
dle shift assembly.
CS-34
AT Shift Lock Solenoid and P Range Switch
CONTROL SYSTEMS
6. AT Shift Lock Solenoid and
P Range Switch
A: REMOVAL
3) Remove the indicator bulb.
4) Remove the grip.
5) Remove the indicator cover.
6) Disconnect the connector from the guide plate
upper.
7) Shift the select lever to the N range, and then
remove the detent spring.
8) Remove the switch assembly and shift lock sole-
noid assembly.
9) Remove the bolt to remove the guide plate upper
(A) from the plate lower (B).
10) Raise the claw of the connector.
CS-00521
CS-00522
CS-00525
CS-00538
CS-00536
CS-00524
(A)
(B)
CS-00292
CS-35
CONTROL SYSTEMS
11) Disconnect the terminal of the P range switch
from connector, using a flat-tip screwdriver with a
thin tip.
B: INSTALLATION
NOTE:
Refer to COMPONENT for each tightening
torque. <Ref. to CS-2, AT SELECT LEVER, COM-
Connect the P range switch terminal to connec-
tor.
(A) P range switch
(A) P range switch
CS-00529
4
10
3
9 8 7
2 1
6 5
(A)
CS-00529
4
10
3
9 8 7
2 1
6 5
(A)
CS-36
CONTROL SYSTEMS
C: INSPECTION
Step Check Yes No
Measure the resistance of shift lock solenoid
Terminals
No. 4 No. 3:
18 ?
lock solenoid.
Connect the battery to shift lock solenoid con-
nector terminal, and then operate the solenoid.
Terminals
No. 3 (+) No. 4 ():
operate normally?
lock solenoid.
1) Move the select lever to P range.
Terminals
No. 1 No. 2:
range switch.
1) Set the select lever to other than P range.
Terminals
No. 1 No. 2:
more?
Normal operation Replace the P
range switch.
CS-37
Body Integrated Unit
CONTROL SYSTEMS
7. Body Integrated Unit
A: NOTE
Refer to Body Integrated Unit for removal and in-
stallation procedure. <Ref. to SL-55, Body Integrat-
ed Unit.>
CS-38
MT Gear Shift Lever
CONTROL SYSTEMS
8. MT Gear Shift Lever
A: REMOVAL
1. 5MT MODEL
3) Remove the gear shift knob.
5) Remove the front cover assembly.
6) Remove the clamp.
7) Remove the bushing and insulator assembly.
8) Remove the harness clamp from the plate as-
sembly.
9) Remove the plate assembly from the vehicle
body.
SOHC MODEL
fler.>
DOHC turbo model
AL, Muffler.>
13) Remove the stay from transmission bracket.
CS-00311
CS-00312
CS-00313
(A) Stay
(B) Transmission bracket
CS-00563
AT-01331
CS-00050
(A)
(B)
CS-39
MT Gear Shift Lever
CONTROL SYSTEMS
14) Remove the rod from joint.
15) Remove the cushion rubber from the vehicle
body.
16) Extract the spring pin and remove the joint.
18) Remove the gear shift lever.
2. 6MT MODEL
4) Remove the console box front. <Ref. to EI-54,
REMOVAL, Console Box.>
6) Remove the clamp.
7) Remove the bushing and insulator assembly.
8) Remove the harness clamp from the plate as-
sembly.
(A) Stay
(B) Rod
(A) Stay
(B) Cushion rubber
(A) Joint
(B) Spring pin
CS-00051
(A)
(B)
CS-00052
(A)
(B)
CS-00053
(A)
(B)
CS-00315
CS-00311
CS-00312
CS-00581
CS-40
MT Gear Shift Lever
CONTROL SYSTEMS
9) Remove the plate assembly from the vehicle
body.
AL, Muffler.>
14) Remove the crossmember. <Ref. to 6MT-30,
REMOVAL, Transmission Mounting System.>
15) Remove the snap pin and washer, and remove
the reverse check cable from the reverse check le-
ver.
16) Move the transmission to the right side, and re-
move the joint COMPL, stay bolts and reverse
check cable.
NOTE:
If the transmission is not moved aside, the joint
COMPL and stay bolts may contact the body and
cause damage.
17) Remove the cushion rubber from the vehicle
body.
19) Remove the gear shift lever.
(A) Snap pin
(B) Washer
(C) Reverse check cable
CS-00584
AT-01331
CS-00220
(B)
(A)
(C)
(A) Joint COMPL bolt
(B) Stay bolt
CS-00221
(C)
(A)
(B)
CS-00222
CS-41
MT Gear Shift Lever
CONTROL SYSTEMS
B: INSTALLATION
1. 5MT MODEL
1) Install the joint to the transmission and secure
with a spring pin.
2) Insert the gear shift lever from the room side.
NOTE:
Insert the rod and the stay, and then temporarily set
them onto the transmission mount.
4) Mount the cushion rubber on the vehicle body.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
5) Using new self-locking nuts, connect the rod to
the joint.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
6) Using new self-locking nuts, connect the stay to
the transmission bracket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A) Stay
(B) Cushion rubber
CS-00315
CS-00052
(A)
(B)
(A) Stay
(B) Rod
(A) Stay
(B) Transmission bracket
CS-00051
(A)
(B)
CS-00050
(A)
(B)
AT-01331
CS-42
MT Gear Shift Lever
CONTROL SYSTEMS
SOHC MODEL
TION, Muffler.>
DOHC turbo model
9) Install the plate assembly to the vehicle body.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(1) Set the plate assembly to the vehicle.
(2) Temporarily tighten the bolt (A).
(3) Tighten the bolt (B).
(4) Tighten the bolt (A).
(5) Tighten the bolts (C) and (D).
10) Install the harness clamp to the plate.
11) Install the boot and insulator assembly, and se-
cure with a clamp.
12) Install the front cover assembly.
2. 6MT MODEL
1) Insert the gear shift lever from the room side.
NOTE:
After inserting the rod and stay, temporarily put
them onto transmission mount.
2) Mount the cushion rubber on the vehicle body.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
3) Move the transmission to the right side of the ve-
hicle, and attach the joint COMPL and stay.
Tightening torque:
T1: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
T2: 32 Nm (3.3 kgf-m, 23.6 ft-lb)
4) Install the cross member. <Ref. to 6MT-30, IN-
STALLATION, Transmission Mounting System.>
CS-00314
(B)
(A)
(C)
(D)
CS-00312
(A) Reverse check cable
CS-00222
CS-00223
(A)
T1
T2
CS-43
MT Gear Shift Lever
CONTROL SYSTEMS
5) Install the reverse cable end, washer and snap
pin to the reverse check lever.
NOTE:
Take care to install the snap pin in proper direc-
tion.
Before installing, adjust the reverse check cable.
<Ref. to CS-56, ADJUSTMENT, Reverse Check
Cable.>
7) Install the rear exhaust pipe and muffler. <Ref. to
Pipe.> <Ref. to EX(H4DOTC)-15, INSTALLATION,
Muffler.>
9) Install the plate assembly to the vehicle body.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(1) Set the plate assembly to the vehicle.
(2) Temporarily tighten the bolt (A).
(3) Tighten the bolt (B).
(4) Tighten the bolt (A).
(5) Tighten the bolts (C) and (D).
10) Install the harness clamp to the plate assembly.
11) Install the boot and insulator assembly, and se-
cure with a clamp.
14) Check that the gear shift can be shifted to each
gear properly.
C: DISASSEMBLY
1. 5MT MODEL
1) Remove the lock wires.
(B) Washer
(C) Snap pin
(D) Front side
CS-00224
(B)
(D)
(C)
(A)
AT-01331
(A) Lock wire
CS-00582
(B)
(A)
(C)
(D)
CS-00312
(A)
CS-00316
CS-44
MT Gear Shift Lever
CONTROL SYSTEMS
2) Remove the rod from lever.
3) Separate the rod and inner boot.
4) Remove the snap ring from the stay.
5) Separate the gear shift lever and the stay.
6) Remove the boot, bushing and snap ring from
gear shift lever.
7) Remove the spring pin, and then remove the
bushing and snap ring.
8) Remove the boss from the joint.
(A) Rod
(B) Lever
(C) Stay
(A) Snap ring
(A)
(B)
(C)
CS-00317
CS-00318
(A)
CS-00319
(A) O-ring
(B) Bushing
(C) Snap ring
(A) Spring pin
(B) Bushing
CS-00320
(B) (A) (C) (A)
CS-00060
(B)
(A)
CS-00322
CS-45
MT Gear Shift Lever
CONTROL SYSTEMS
9) Remove the bushing and spacer from the boss.
10) Remove the bushing and cushion rubber from
the stay.
2. 6MT MODEL
1) Remove the spring pin from the slider.
2) Remove the slider and spring.
3) Cut the band clip.
4) Remove the reverse check cable from the cable
plate.
5) Remove the reverse check cable from the gear
shift assembly.
(A) Bushing
(B) Spacer
(A) Bushing B
(B) Stay
(C) Cushion rubber
(A) Slider
(B) Spring pin
CS-00238
(B)
(A)
(A)
CS-00058
(A)
(B)
(C)
CS-00225
(A)
(B)
(A) Slider
(B) Spring
(A) Cable plate
(B) Reverse check cable
CS-00226
(A)
(B)
CS-00228
(A)
(B)
CS-00229
CS-46
MT Gear Shift Lever
CONTROL SYSTEMS
6) Remove the holder and spring.
7) Disassemble the lock wires.
NOTE:
Do not reuse the lock wire.
8) Remove the boss from the rod.
9) Remove the rod from lever.
10) Separate the rod and inner boot.
11) Remove the snap ring from the stay.
12) Separate the gear shift lever and the stay.
(A) Holder
(A) Lock wire
(A) Rod
(B) Boss
CS-00587
(A)
CS-00231
(A)
CS-00232
(B)
(A)
(A) Rod
(B) Lever
(C) Stay
(A) Snap ring
CS-00233
(C)
(A)
(B)
CS-00234
(A)
CS-00235
CS-47
MT Gear Shift Lever
CONTROL SYSTEMS
13) Remove the boot and bushing from gear shift
lever.
14) Remove the spring pin, and then remove the
bushing and snap ring.
15) Remove the bushing and spacer from the boss.
16) Remove the bushing and cushion rubber from
the stay.
D: ASSEMBLY
1. 5MT MODEL
NOTE:
Clean all the parts before assembly.
Apply NIGTIGHT LYW No. 2 grease or equiva-
lent to each part.
1) Mount the bushing and cushion rubber to the
stay.
2) Install the bushing and spacer to boss.
(A) O-ring
(B) Bushing
(A) Bushing
(B) Snap ring
(A) Bushing
(B) Spacer
CS-00236
(A) (B) (A)
CS-00237
(A)
(B)
CS-00238
(B)
(A)
(A)
(A) Bushing
(B) Stay
(C) Cushion rubber
(A) Bushing
(B) Cushion rubber
(A) Bushing
(B) Spacer
CS-00239
(B)
(C)
(A)
CS-00061
(A)
(B)
CS-00238
(B)
(A)
(A)
CS-48
MT Gear Shift Lever
CONTROL SYSTEMS
3) Using new self-locking nuts, install the boss to
the joint.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
4) Install the snap ring to gear shift lever and install
the bushing.
NOTE:
Apply grease to the bushing.
5) Apply grease to the bushing and O-ring, and
then install to gear shift lever.
6) Apply sufficient grease into boss, and then install
the gear shift lever to the stay.
7) Install the washer and snap ring.
8) Insert the gear shift lever and rod into boot hole.
9) Install the rod.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
(A) Spring pin
(B) Bushing
(A) O-ring
(B) Bushing
(C) Snap ring
CS-00322
CS-00060
(B)
(A)
CS-00320
(B) (A) (C) (A)
(A) Snap ring
(A) Rod
(B) Lever
(C) Stay
CS-00319
CS-00318
(A)
(A)
(B)
(C)
CS-00317
CS-49
MT Gear Shift Lever
CONTROL SYSTEMS
10) Install a new lock wire.
NOTE:
Install the lock wire to the stay groove.
Bend the extra wire to the same direction of lock
wire winding.
2. 6MT MODEL
NOTE:
Clean all the parts before assembly.
Apply NIGTIGHT LYW No. 2 grease or equiva-
lent to each part.
1) Mount the bushing and cushion rubber to the
stay.
2) Install the bushing and spacer to boss.
3) Install the snap ring to gear shift lever and install
the bushing.
NOTE:
Apply grease to the bushing.
(A) Lock wire
(A) Inner boot
(B) Lock wire
(C) Stay
(A)
CS-00316
CS-00240
(A) (A)
(B)
(B)
B B
(B)
B - B
(C)
(A) Bushing
(B) Stay
(C) Cushion rubber
(A) Bushing
(B) Spacer
(A) Bushing
(B) Snap ring
CS-00239
(B)
(C)
(A)
CS-00238
(B)
(A)
(A)
CS-00237
(A)
(B)
CS-50
MT Gear Shift Lever
CONTROL SYSTEMS
4) Apply grease to the bushing and O-ring, and
then install to gear shift lever.
5) Apply sufficient grease into boss, and then install
the gear shift lever to the stay.
7) Insert the gear shift lever and rod into boot hole.
8) Install the rod.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
9) Install the boss to the rod.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
(A) O-ring
(B) Bushing
(A) Snap ring
CS-00236
(A) (B) (A)
CS-00235
CS-00234
(A)
(A) Rod
(B) Lever
(C) Stay
(A) Rod
(B) Boss
CS-00233
(C)
(A)
(B)
CS-00232
(B)
(A)
CS-51
MT Gear Shift Lever
CONTROL SYSTEMS
10) Install a new lock wire.
NOTE:
Install the lock wire to the stay groove.
Bend the extra wire to the same direction of lock
wire winding.
11) Install the holder.
Tightening torque:
1.3 Nm (0.13 kgf-m, 0.96 ft-lb)
12) Insert the reverse check cable into the boot
hole.
13) Insert the reverse check cable to the gear shift
assembly, and affix with a band clip.
NOTE:
Cut the excess band clip.
Make sure that the reverse check cable is insert-
ed into the gear shift lever assembly without inter-
space.
14) Attach the seat cushion and spring.
(A) Lock wire
(A) Inner boot
(B) Lock wire
(C) Stay
CS-00231
(A)
CS-00240
(A) (A)
(B)
(B)
B B
(B)
B - B
(C)
(A) Holder
(A) Spring
(B) Seat cushion
CS-00587
(A)
CS-00241
(A)
(B)
CS-52
MT Gear Shift Lever
CONTROL SYSTEMS
15) Using the spring pin, fix the end of reverse
check cable and slider.
NOTE:
Apply grease to the moving part of slider.
16) With the cable pulled (the slider is lowered), ad-
just the distance between the edge of cable plate
and the reverse check cable to 84 mm (3.31 in),
and tighten the lock nut.
Tightening torque:
6 Nm (0.6 kgf-m, 4.4 ft-lb)
17) Fix the reverse check cable to the stay clip.
NOTE:
Install the reverse check cable on top of the stay.
E: INSPECTION
1. 5MT MODEL
1) Check the parts (bushing, cushion rubber, spac-
er, boot, stay and rod, etc.) for deformation, dam-
age and wear. If necessary, correct or replace
faulty parts. Compare the removed parts with new
parts to judge if there are damages or not.
(A) Slider
(B) Spring pin
(A) 84 mm (3.31 in)
(B) Clip
CS-00225
(A)
(B)
CS-00242
(A)
CS-00243
(A)
(B)
(A) Bushing
(B) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod
CS-00323
(C)
(D)
(A)
(F)
(A)
(E)
(C)
(A)
(B)
(C)
CS-53
MT Gear Shift Lever
CONTROL SYSTEMS
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:
3.7 N (0.38 kgf, 0.83 lbf) or less
2. 6MT MODEL
Check the parts (bushing, cushion rubber, spacer,
boot, stay and rod, etc.) for deformation, damage
and wear. If necessary, correct or replace faulty
parts. Compare the removed parts with new parts
to judge if there are damages or not.
(A) Pivot
(B) Swing torque
CS-00116
(A)
(B)
CS-00586
CS-54
Reverse Check Cable
CONTROL SYSTEMS
9. Reverse Check Cable
A: REMOVAL
3) Remove the console box front. <Ref. to EI-54,
REMOVAL, Console Box.>
5) Remove the spring pin from the slider.
6) Remove the slider and spring.
7) Cut the band clip, and separate the reverse
check cable from the gear shift lever.
AL, Muffler.>
12) Remove the snap pin and washer, and sepa-
rate the reverse check cable from the reverse
check lever.
move the stay bolts and reverse check cable.
NOTE:
If the transmission is not moved aside, the stay
bolts may contact the body and cause damage.
14) Lift the stay clip, and separate the stay and re-
verse check cable.
(A) Slider
(B) Spring pin
(A) Slider
(B) Spring
CS-00225
(A)
(B)
CS-00226
(A)
(B)
(A) Snap pin
(B) Washer
(A) Stay
(B) Stay bolt
(B) Clip
CS-00220
(B)
(A)
(C)
CS-00245
(A)
(B)
CS-00243
(A)
(B)
CS-55
Reverse Check Cable
CONTROL SYSTEMS
15) Pull out the reverse check cable from under-
side of the vehicle to remove it.
NOTE:
Be careful not to damage the inner boot.
16) Loosen the lock nut, and remove the reverse
check cable from the cable plate.
B: INSTALLATION
1) Insert the reverse check cable into the inner boot
hole from underside of the vehicle.
2) Insert the reverse check cable to the gear shift
lever assembly, and affix with a band clip.
NOTE:
Cut the excess band clip.
Make sure that the reverse check cable is insert-
ed into the gear shift lever assembly without inter-
space.
3) Using the spring pin, fix the end of reverse check
cable and slider.
NOTE:
Apply grease to the moving part of slider.
Tightening torque:
6 Nm (0.6 kgf-m, 4.4 ft-lb)
6) Move the transmission to the right side, and at-
tach the stay.
Tightening torque:
T: 32 Nm (3.3 kgf-m, 23.6 ft-lb)
(A) Cable plate
(B) Reverse check cable
(A) Slider
(B) Spring pin
CS-00228
(A)
(B)
CS-00225
(A)
(B)
(A) 84 mm (3.31 in)
(A) Stay
CS-00242
(A)
CS-00246
(A)
T
CS-56
Reverse Check Cable
CONTROL SYSTEMS
7) Attach the reverse check cable, washer and
snap pin to the reverse check lever.
NOTE:
Take care to install the snap pin in proper direction.
8) Fix the reverse check cable to the stay clip.
NOTE:
Install the reverse check cable on top of the stay.
9) Install the rear exhaust pipe and muffler. <Ref. to
Pipe.>, <Ref. to EX(H4DOTC)-15, INSTALLA-
TION, Muffler.>
C: INSPECTION
1) Make sure the slider works smoothly. If it does
not move, adjust the reverse check cable, or check
the slider for damage. <Ref. to CS-56, ADJUST-
MENT, Reverse Check Cable.>
2) Check that the gear is shifted to the reverse
when the slider is lifted. If the gear is not shifted to
the reverse, adjust the reverse check cable. <Ref.
to CS-56, ADJUSTMENT, Reverse Check Cable.>
3) Check that the gear is not shifted to the reverse
when the slider is not lifted. If the gear is shifted to
the reverse, adjust or replace the reverse check ca-
ble. <Ref. to CS-56, ADJUSTMENT, Reverse
Check Cable.>
D: ADJUSTMENT
AL, Muffler.>
5) Remove the snap pin and washer, and separate
the reverse check cable from the reverse check le-
ver.
(B) Washer
(C) Snap pin
(D) Front side
(B) Clip
CS-00224
(B)
(D)
(C)
(A)
CS-00243
(A)
(B)
(A) Snap pin
(B) Washer
CS-00220
(B)
(A)
(C)
CS-57
Reverse Check Cable
CONTROL SYSTEMS
move the stay bolts and reverse check cable.
NOTE:
If the transmission is not moved aside, the stay
bolts may contact the body and cause damage.
Tightening torque:
6 Nm (0.6 kgf-m, 4.4 ft-lb)
8) Move the transmission to the right side, and at-
tach the stay.
Tightening torque:
T: 32 Nm (3.3 kgf-m, 23.6 ft-lb)
9) Install the cross member. <Ref. to 6MT-30, IN-
STALLATION, Transmission Mounting System.>
10) Install the rear exhaust pipe and muffler. <Ref.
to EX(H4DOTC)-13, INSTALLATION, Rear Ex-
haust Pipe.> <Ref. to EX(H4DOTC)-15, INSTAL-
LATION, Muffler.>
11) Attach the reverse check cable, washer and
snap pin to the reverse check lever.
NOTE:
Take care to install the snap pin in proper direction.
(A) Stay
(B) Stay bolt
(A) 84 mm (3.31 in)
(A) Stay
CS-00245
(A)
(B)
CS-00242
(A)
CS-00246
(A)
T
(B) Washer
(C) Snap pin
(D) Front side
CS-00224
(B)
(D)
(C)
(A)
CS-58
CONTROL SYSTEMS
A: INSPECTION
Select lever Starter does not run. Adjust the select cable and inhibitor switch, or
inspect the circuit.
Back-up light does not illuminate. Adjust the select cable and inhibitor switch, or
AT shift lock system does not operate normally. Adjust the select cable and inhibitor switch, or
Manual mode can not be set. Adjust the mode switch and select lever, or inspect
the circuit.
Up-shift is not engaged at manual mode. Check the shift-up switch and circuit.
Down-shift is not engaged at manual mode. Check the shift-down switch and circuit.
4AT-2
General Description
A: SPECIFICATION
1. TORQUE CONVERTER
2. OIL PUMP
3. TRANSMISSION CONTROL ELEMENT
4. TRANSMISSION GEAR RATIO
5. PLANETARY GEAR AND PLATE
6. SELECTOR POSITION
Type
Symmetric, 3 element, single stage,
2 phase torque converter
Stall torque ratio 2.05 2.35
Nominal
diameter
mm (in) 246 (9.69)
Stall speed
(at sea level)
2,200 3,000 rpm
One-way clutch Sprague type one-way clutch
Type
Parachoid constant-displacement
pump
Driving method Driven by engine
Number of teeth
Inner rotor 9
Outer rotor 10
Type
4-forward, 1-reverse,
double-row planetary gears
Multi-plate clutch 3 sets
Multi-plate brake 2 sets
One-way clutch
(sprague type)
1 set
1st 2.785
2nd 1.545
3rd 1.000
4th 0.694
Rev 2.272
Number of front
sun gear teeth
33
Number of front
pinion teeth
21
Number of front
internal gear teeth
75
Number of rear
sun gear teeth
42
Number of rear
pinion teeth
17
Number of rear
internal gear teeth
75
Number of high
clutch drive plates
4
Number of low
clutch drive plates
5
Number of reverse
clutch drive plates
2
Number of drive
plates for the 2-4
brake
3
Number of drive
plates for low &
reverse brake
5
P (Park)
Transmission is in neutral, output mem-
ber is fixed, engine start is possible
R (Reverse) Transmission in reverse for backing up
N (Neutral)
Transmission is in neutral and engine
start is possible
D (Drive)
4-forward automatic gear change
1st 2nd 3rd 4th
SPORT mode
4-forward automatic gear change
1st 2nd 3rd 4th
Manual mode (+)
4-forward manual gear change
(shift up)
1st 2nd 3rd 4th
Manual mode ()
4-forward manual gear change
(shift down)
1st 2nd 3rd 4th
Control method Wire cable type
4AT-3
General Description
7. HYDRAULIC CONTROL AND
LUBRICATION
8. COOLING AND HARNESS
9. TRANSFER
10.FINAL REDUCTION GEAR
11.RECOMMENDED GEAR OIL
Type
Electronic hydraulic control [4
forward gear changes made
by electronic signals of vehi-
cle speed and accelerator
(throttle) opening]
Fluid
Recommended
materials
SUBARU ATF HP
Alternative
IDEMITSU ATF HP,
Castrol Transmax J
Fluid
capacity
2
(US qt, Imp qt)
9.3 9.6
(9.8 10.1, 8.2 8.4)
Lubrication system
Forced feed lubrication with
oil pump
Oil
Automatic transmission fluid
(see above)
Cooling system Liquid-cooler
Inhibitor switch 12 poles
Transmission harness 20 poles
Model
Except for VTD
models
VTD model
Transfer type
Multi-plate
transfer (MPT)
Variable torque
distribution (VTD)
Number of transfer
clutch drives &
driven plates
5 3
Control method Electronic hydraulic type
Lubricant
Same automatic transmission fluid as
used in the automatic transmission
Reduction gear
ratio
1.000 (53/53)
Model Except for OUTBACK OUTBACK
Front final reduction gear ratio 4.111 (37/9) 4.444 (40/9)
Lubrication oil
(1) Item (3) API standard
(2) Front differential gear oil (4) SAE viscosity No. and
applicable temperature
Front differential oil capacity
2 (US qt, Imp qt)
1.1 1.3 (1.2 1.4, 1.0 1.1)
(1)
(4)
GL-5
(3)
(2)
( C)
( F)
-30 -26 -15 15
90
85W
80W
75W -90
25 30 -5 0
-22 -15 23 32 86 59 77 5
MT-00001
4AT-4
General Description
B: COMPONENT
1. TORQUE CONVERTER AND CASE
(1) Pitching stopper bracket (8) Oil drain pipe (15) Converter case
(2) O-ring (9) Input shaft
(3) Differential oil level gauge (10) O-ring Tightening torque:Nm (kgf-m, ft-lb)
(4) Stay (11) Torque converter ASSY T1: 18 (1.8, 13.3)
(5) Seal pipe (12) Differential gear oil drain plug T2: 41 (4.2, 30.2)
(6) Oil pump shaft (13) Gasket T3: 44 (4.5, 32.5) (Aluminum gasket)
(7) Clip (14) Oil seal 70 (7.1, 51.6) (Copper gasket)
AT-03390
T2
T2
T2
T2
T3
T1
(8)
(11)
(1)
(2)
(3)
(4)
(7)
(5)
(6)
(10)
(9)
(14)
(15)
(12)
(13)
4AT-5
General Description
2. OIL PUMP
(1) Oil pump rotor (11) Gasket (21) Lock nut
(2) Oil pump cover (12) O-ring
(3) Seal ring (13) Test plug Tightening torque:Nm (kgf-m, ft-lb)
(4) Thrust needle bearing (14) Stud bolt T1: 7 (0.7, 5.1)
(5) Drive pinion shaft (15) O-ring T2: 13 (1.3, 9.6)
(6) Roller bearing (16) O-ring T3: 18 (1.8, 13.3)
(7) Shim (17) Oil seal retainer T4: 25 (2.5, 18.4)
(8) Oil pump housing (18) Oil seal T5: 40 (4.1, 29.5)
(9) Nipple (19) O-ring T6: 42 (4.3, 31)
(10) Air breather hose (20) Drive pinion collar T7: 116 (11.8, 85)
AT-03358
4AT-6
General Description
3. TRANSMISSION CASE AND CONTROL DEVICE
(1) ATF level gauge (19) Oil pan (36) Air breather hose
(2) Oil charge pipe (20) Magnet (37) Transmission case
(3) O-ring (21) Stud bolt (short) (38) Plate ASSY
T8
T4
T3
T10
T8
T1
T3
T7
T7
T8
T8
T9
T2
T5
T6
(1)
(40)
(2)
(3)
(34)
(39)
(31)
(33)
(26)
(25)
(27)
(28)
(30)
(29)
(36)
(35)
(32)
(38)
(37)
(4)
(9)
(7)
(6)
(5)
(8)
(16)
(13)
(14) (10)
(11)
(12)
(15)
(17)
(18)
(20)
(19)
(21)
(22) (23)
(24)
AT-04380
4AT-7
General Description
(4) Straight pin (22) Stud bolt (long) (39) Washer
(5) Return spring (23) Parking rod (40) O-ring
(6) Shaft (24) Manual plate
(7) Parking pawl (25) Spring pin Tightening torque:Nm (kgf-m, ft-lb)
(8) Parking support (26) Detention spring T1: 3.4 (0.35, 2.5)
(9) Bushing (27) Ball T2: 5 (0.5, 3.6)
(10) Gasket (28) Spring T3: 6 (0.6, 4.4)
(11) ATF inlet pipe (29) Gasket T4: 12 (1.2, 8.7)
(12) Union screw (30) ATF outlet pipe T5: 13 (1.3, 9.6)
(13) O-ring (31) Union screw T6: 14 (1.4, 10.3)
(14) Test plug (32) Oil seal T7: 18 (1.8, 13.3)
(15) Oil filter (33) Range select lever T8: 25 (2.5, 18.4)
(16) Oil filter stud bolt (34) Inhibitor switch ASSY T9: 40 (4.1, 29.5)
(17) Drain plug (ATF) (35) Nipple T10: 45 (4.6, 33.2)
(18) Gasket
4AT-8
General Description
4. CONTROL VALVE AND HARNESS ROUTING
(1) Stay (6) O-ring Tightening torque:Nm (kgf-m, ft-lb)
(2) Transmission harness (7) Front vehicle speed sensor T1: 7 (0.7, 5.1)
(3) O-ring (8) O-ring T2: 8 (0.8, 5.8)
(4) O-ring (9) Rear vehicle speed sensor
(5) Torque converter turbine speed
sensor
(10) Control valve body
AT-01322
T1
T2
T1
T1
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
4AT-9
General Description
5. HIGH CLUTCH AND REVERSE CLUTCH
(1) High clutch drum (8) Spring retainer (15) Dish plate
(2) Lip seal (9) Clutch cover (16) Driven plate (reverse clutch)
(3) D-ring (10) Snap ring (17) Drive plate (reverse clutch)
(4) Reverse clutch piston (11) Driven plate (high clutch) (18) Retaining plate (reverse clutch)
(5) D-ring (12) Drive plate (high clutch) (19) Snap ring
(6) D-ring (13) Retaining plate (high clutch) (20) Thrust needle bearing
(7) High clutch piston (14) Snap ring (21) High clutch hub
AT-00006
4AT-10
General Description
6. PLANETARY GEAR AND 2-4 BRAKE
(1) Thrust needle bearing (10) Washer (19) Snap ring
(2) Front sun gear (11) Thrust needle bearing (20) Spring retainer
(3) Thrust needle bearing (12) Rear internal gear (21) 2-4 brake piston
(4) Snap ring (13) Washer (22) D-ring
(5) Front planetary carrier (14) Snap ring (23) D-ring
(6) Thrust needle bearing (15) Retaining plate (24) 2-4 brake piston retainer
(7) Rear sun gear (16) Drive plate (25) 2-4 brake seal
(8) Thrust needle bearing (17) Driven plate (26) Leaf spring
(9) Rear planetary carrier (18) Pressure rear plate
AT-00007
(1)
(2)
(3)
(4)
(5)
(6)
(14)
(15)
(16)
(16)
(16)
(18)
(17)
(20)
(26)
(17)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(19)
(21)
(22)
(23)
(25)
(24)
4AT-11
General Description
7. LOW CLUTCH AND LOW & REVERSE BRAKE
(1) Snap ring (12) Low clutch drum (23) Return spring
(2) Retaining plate (13) Needle bearing (24) Snap ring
(3) Drive plate (14) Snap ring (25) Retaining plate
(4) Driven plate (15) One-way clutch (26) Leaf spring
(5) Dish plate (16) Snap ring (27) Drive plate
(6) Snap ring (17) Thrust needle bearing (28) Driven plate
(7) Cover (18) Seal ring (29) Dish plate
(8) Spring retainer (19) Needle bearing (30) Low & reverse brake piston
(9) D-ring (20) One-way clutch inner race
(10) Low clutch piston (21) Socket bolt Tightening torque:Nm (kgf-m, ft-lb)
(11) D-ring (22) Spring retainer T: 25 (2.5, 18.4)
AT-01278
(2)
(3)
(4)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10) (11)
(12)
(17)
(24)
(26)
(25)
(27)
(28)
(27)
(28)
(29)
(30)
(18)
(19)
(20)
(23)
(21)
(22)
(13)
(14)
(15)
(16)
T
(1)
4AT-12
General Description
8. REDUCTION GEAR
MP-T model
(1) Seal ring (6) Snap ring (11) Lock nut
(2) Ball bearing (7) Ball bearing (12) Gasket
(3) Reduction drive gear (8) Snap ring
(4) Reduction drive shaft (9) Reduction driven gear Tightening torque:Nm (kgf-m, ft-lb)
(5) Drive pinion shaft (10) Washer T: 100 (10.2, 73.8)
(10)
(1)
(2)
(3)
(4)
(11)
T
(5)
(6)
(7)
(8)
(8)
(8)
(9)
(12)
AT-03119
4AT-13
General Description
VTD model
(1) Ball bearing (13) Rear drive shaft (25) Snap ring
(2) Reduction drive gear (14) Ball bearing (26) Ball bearing
(3) Washer (15) Multi-plate clutch hub (27) Snap ring
(4) Needle bearing (16) Ball bearing (28) Reduction driven gear
(5) Pinion gear (17) Revolution gear (29) Lock washer
(6) Carrier (18) Driven plate (Thick) (30) Lock nut
(7) Planetary pinion shaft (19) Drive plate (31) Gasket
(8) Snap ring (20) Driven plate (Thin) (32) Extension case
(9) Seal ring (21) Driven plate (Thick)
(10) Thrust needle bearing (22) Retaining plate Tightening torque: Nm (kgf-m, ft-lb)
(11) Intermediate shaft (23) Rear drive shaft shim T: 100 (10.2, 73.8)
(12) Thrust washer (24) Drive pinion shaft
AT-02203
T
(3)
(4)
(5)
(4)
(3)
(2)
(1)
(6)
(7)
(8)
(9)
(10)
(11)
(17)
(18)
(19)
(20)
(19)
(21)
(22)
(23)
(32)
(31)
(30)
(12)
(13)
(14)
(15)
(16)
(29)
(28)
(26)
(25)
(24)
(27)
(27)
(27)
4AT-14
General Description
9. DIFFERENTIAL GEAR
(1) Hypoid driven gear (7) Oil seal (13) Differential bevel gear
(2) Pinion shaft (8) O-ring
(3) Differential case (RH) (9) Differential side retainer Tightening torque:Nm (kgf-m, ft-lb)
(4) Straight pin (10) Lock plate T1: 25 (2.5, 18.4)
(5) Differential case (LH) (11) Washer T2: 62 (6.3, 45.7)
(6) Taper roller bearing (12) Differential bevel pinion
AT-00011
T2
T1
T1
(8)
(8)
(9)
(9)
(7)
(7)
(6)
(6)
(10)
(13)
(13)
(1)
(2)
(3)
(4)
(5)
(10)
(11)
(11) (12)
(12)
4AT-15
General Description
10.TRANSFER AND EXTENSION CASE
MP-T model
(1) Thrust needle bearing (10) Return spring (19) Oil seal
(2) Needle bearing (11) Transfer clutch piston (20) Dust cover
(3) Snap ring (12) Rear drive shaft (21) Test plug
(4) Driven plate (Thick) (13) Ball bearing (22) O-ring
(5) Drive plate (14) Seal ring
(6) Driven plate (Thin) (15) Gasket Tightening torque:Nm (kgf-m, ft-lb)
(7) Retaining plate (16) Transfer clutch pipe T1: 13 (1.3, 9.6)
(8) Snap ring (17) Extension case T2: 25 (2.5, 18.4)
(9) Transfer clutch piston seal (18) Transmission hanger
AT-01784
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(16)
(18)
(19)
(22)
(21)
(12)
(13)
(14)
(15)
(5)
(17)
(20)
T2
T2
T1
(6)
4AT-16
General Description
VTD model
(1) Driven plate (Thick) (10) Multi-plate clutch piston ASSY (18) Dust cover
(2) Drive plate (11) D-ring (19) O-ring
(3) Driven plate (Thin) (12) Gasket (20) Rear vehicle speed sensor
(4) Driven plate (Thick) (13) Multi-plate clutch pipe
(5) Retaining plate (14) Extension case Tightening torque: Nm (kgf-m, ft-lb)
(6) Snap ring (15) O-ring T1: 7 (0.7, 5.1)
(7) Spring retainer (16) Test plug T2: 13 (1.3, 9.6)
(8) Plate (17) Oil seal T3: 25 (2.5, 18.4)
(9) O-ring
AT-00013
T3
T2
T1
(10)
(11)
(13)
(14)
(19)
(6)
(7)
(8)
(9)
(12)
(20)
(16)
(1)
(2)
(3)
(2)
(4)
(5)
(15)
(17)
(18)
4AT-17
General Description
11.TRANSMISSION MOUNTING
(1) Pitching stopper (3) Crossmember Tightening torque:Nm (kgf-m, ft-lb)
(2) Rear cushion rubber (4) Stopper T1: 35 (3.6, 25.8)
T2: 40 (4.1, 29.5)
T3: 50 (5.1, 36.9)
T4: 58 (5.9, 42.8)
T5: 75 (7.6, 55.3)
(2)
(3)
(4)
(1)
T4
T3
T5
T5
T2
T2
T1
AT-03876
4AT-18
General Description
C: CAUTION
forming any work.
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 al-
loy 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. of dif-
ferent grades or manufacturers.
Be sure to tighten bolts and nuts to the specified
torque.
Place lifts, shop jacks or rigid racks at the speci-
fied points.
Apply gear oil or ATF onto sliding or revolution
surfaces before installation in view of components
usage.
Replace deformed or damaged snap rings with
new parts.
Before installing O-rings or oil seals, apply suffi-
cient amount of ATF fluid to avoid damage and de-
formation.
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 cushion-
ing material such as wood blocks, aluminum plate,
or cloth between the part and the vise.
Avoid damaging the mating surface of the case.
Before applying liquid gasket, completely re-
move the old seal.
When disassembling the AT, be sure to use ny-
lon gloves and paper towels. Do not use cloth
gloves or waste cloth.
4AT-19
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
498575400 OIL PRESSURE
GAUGE ASSY
Used for measuring oil pressure.
GAUGE ADAPTER
Used at the oil pump housing when measuring
reverse clutch pressure and line pressure.
498897700 ADAPTER SET Used for measuring transfer clutch pressure.
498545400 FILTER WRENCH Used for removing and installing the ATF filter.
ST-498575400
ST-498897200
ST-498897700
ST-498545400
4AT-20
General Description
498277200 STOPPER SET Used for removing and installing automatic
transmission assembly to engine.
398527700 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.
498057300 INSTALLER Used for installing the extension oil seal.
41099AC000 ENGINE SUPPORT
ASSY
Used for supporting the engine.
498077000 REMOVER Used for removing the differential taper roller
bearing.
ST-498277200
ST-398527700
ST-498057300
ST41099AC000
ST-498077000
4AT-21
General Description
499247400 INSTALLER Used for installing the transfer outer snap ring.
Used together with the GUIDE (499257300).
499257300 SNAP RING
OUTER GUIDE
Used for installing the transfer outer snap ring.
Used together with the INSTALLER
(499247400).
18630AA010 WRENCH COMPL
RETAINER
Used for removing and installing the differen-
tial side retainer.
WRENCH ASSEMBLY (499787000) can also
be used.
398437700 DRIFT Used for installing the converter case oil seal.
398487700 INSTALLER Used for installing the front differential taper
roller bearing.
ST-499247400
ST-499257300
ST18630AA010
ST-398437700
ST-398487700
4AT-22
General Description
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.
498247001 MAGNET BASE Used for measuring the gear backlash.
Used together with DIAL GAUGE
(498247100).
498247100 DIAL GAUGE Used for measuring the gear backlash.
Used together with MAGNET BASE
(498247001).
ST-398673600
ST-498255400
ST-399893600
ST-498247001
ST-498247100
4AT-23
General Description
498517000 REPLACER Used for removing the front roller bearing.
398623600 SEAT Used for removing the spring of the transfer
clutch piston.
499267300 STOPPER PIN Used for installing the inhibitor switch.
499787700 WRENCH Used for removing and installing the drive pinion
lock nut.
499787500 ADAPTER Used for removing and installing the drive pinion
lock nut.
ST-498517000
ST-398623600
ST-499267300
ST-499787700
ST-499787500
4AT-24
General Description
398643600 GAUGE Used for measuring the total end play, extension
end play and drive pinion height.
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.
ST-398643600
ST-498627100
ST-499577000
ST-499737000
ST-499737100
4AT-25
General Description
498077600 REMOVER Used for removing the ball bearing.
498937110 HOLDER Used for removing and installing the drive pinion
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.
ST-498077600
ST-498937110
ST-498677100
ST-498437000
ST-498437100
4AT-26
General Description
899580100 INSTALLER Used for press-fitting the ball bearing of the
transfer clutch.
28399SA010 OIL SEAL
PROTECTOR
Used for installing the axle shaft.
18675AA000 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 Use only the bolt.
Used together with the PULLER SET
(499737100).
Used together with the PULLER (499737000).
1. Puller
2. Cap
ST-899580100
ST28399SA010
ST18675AA000
ST-398497701
ST-899524100
(1)
(2)
4AT-27
General Description
2. GENERAL TOOL
499247300 INSTALLER Used for installing the oil pump housing retainer
oil seal.
MONITOR III KIT
TOOL NAME REMARKS
Depth gauge Used for measuring the transmission end play.
Thickness gauge Used for measuring clearance of the clutch, brake and oil pump.
Micrometer Used for measuring thickness of the drive pinion.
Spring scale Used for measuring the starting torque of the drive pinion.
Circuit tester Used for measuring resistance and voltage.
TORX
T70 Used for removing and installing differential gear oil drain plug.
Push/pull gauge Used for measuring the piston stroke of each clutch.
ST-499247300
ST1B021XU0
4AT-28
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.
176F) on Subaru Select Monitor. <Ref. to
3) After selecting all positions (P, R, N, D), set the
select lever in P range. Idle the engine for 1 or 2
4) Make sure that the ATF level is between upper
and lower marks of the HOT side.
If the fluid level is below the lower mark, check the
transmission for leaks. If there are leaks, it is nec-
essary to repair or replace gaskets, oil seals, plugs
or other parts.
5) If the ATF level is below the center point be-
tween upper and lower level marks, add the recom-
mended ATF until the fluid level is above the center
point between the upper and lower level marks.
CAUTION:
Be careful not to exceed the upper level.
If ATF is added to the upper level while the
transmission is cool, there will be too much
ATF and will cause problems. Do not exceed
the upper level.
6) Check ATF level after raising ATF temperature
to 70 80C (158 176F) by running the vehicle
again or by idling the engine.
B: REPLACEMENT
2) Remove the drain plug (ATF) and completely
drain the ATF.
CAUTION:
After running the engine or after idling for a
long time, the ATF is hot. Be careful not to burn
yourself.
3) Check the condition of ATF. <Ref. to 4AT-29,
CONDITION CHECK, Automatic Transmission
Fluid.>
4) Perform replacement with a new gasket, and
tighten the drain plug (ATF).
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
6) Pour ATF from the oil charge pipe.
Recommended fluid:
<Ref. to RM-4, FLUID, RECOMMENDED MA-
TERIALS, Recommended Materials.>
Capacity:
Refill with the same amount of ATF drained
from the drain plug hole.
Capacity when transmission is overhauled:
9.3 9.6 2 (9.8 10.1 US qt, 8.2 8.4 Imp
qt)
7) Bleed the air of control valve.
<Ref. to 4AT-61, Air Bleeding of Control Valve.>
8) Check the level and leaks of ATF.
mission Fluid.>
(A) ATF level gauge
(B) Upper level
(C) Lower level
AT-01323
C
O
L
D
L
F
H
O
T
L
F
(C)
(C)
(B)
(B)
(A)
(A) Oil pan
(B) Drain plug (ATF)
AT-01332
(B)
(A)
4AT-29
C: CONDITION CHECK
NOTE:
When replacing ATF, check the inside condition of transmission body by inspecting the drained ATF.
Fluid condition Trouble and possible cause Corrective action
Large amount of metallic pieces are
found.
Excessive wear of the internal of the transmission
body.
Replace ATF and check if AT operates
correctly.
Thick and varnish-form fluid. Burned clutch, etc.
Replace ATF and check the AT body or
vehicle for faulty.
Clouded fluid or bubbles are found
in fluid.
Water mixed in fluid.
Replace ATF and check the water
entering point.
4AT-30
Differential Gear Oil
3. Differential Gear Oil
A: INSPECTION
3) Reinsert the level gauge all the way. Make sure
the level gauge is inserted correctly and in the
proper orientation.
4) Remove the oil level gauge again, and check the
level of differential gear oil. If the differential gear oil
level is below L line, add oil to bring the level up to
F line.
NOTE:
To prevent overfilling the differential gear oil, do not
fill oil to the F line or more.
B: REPLACEMENT
2) Remove the differential gear oil drain plug using
TORX

bit T70, and drain the differential gear oil
completely.
CAUTION:
Because the differential gear will be very hot
after driving, be very careful not be receive
burns.
Be careful not to spill the differential gear oil
on exhaust pipe to prevent it from emitting
smoke or causing fires. If differential gear oil is
spilled on the exhaust pipe, wipe it off com-
pletely.
3) Replace the gasket with a new part and tighten
the differential gear oil drain plug using the TORX
bit T70.
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)
5) Fill the differential with differential gear oil from
the level gauge hole.
<Ref. to 4AT-3, RECOMMENDED GEAR OIL,
Gear oil capacity:
1.1 1.3 2 (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.>
(A) Oil level gauge
(B) Upper level
(C) Lower level
PI-00183
(B)
(C)
(A)
(A)
(A) Oil pan
(B) Differential gear oil drain plug
AT-02204
(B)
(A)
4AT-31
Road Test
4. Road Test
A: INSPECTION
1. GENERAL PRECAUTION
Road tests should be conducted to properly diag-
nose the condition of automatic transmission.
NOTE:
When performing the test, do not exceed posted
speed limit.
2. D RANGE SHIFT FUNCTION
Check shifting between 1st 2nd 3rd
4th while driving on normal city streets.
3. D RANGE SHIFT SHOCK
Check the shock level when shifting up during nor-
mal driving.
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Check the shock
level during kick-down at the same time.
5. ENGINE BRAKE OPERATION
Check the 3rd gear engine brake when shifting
down from 4th to 3rd range while driving in 4th gear
of manual mode [50 60 km/h (31 37 MPH)].
Check the 2nd gear engine brake when shifting
down from 3rd to 2nd range while driving in 3rd
gear of manual mode [40 50 km/h (25 31
MPH)].
Check the 1st gear engine brake when shifting
down from 2nd to 1st range while driving in 2nd
gear of manual mode [20 30 km/h (12 19
MPH)].
6. LOCK-UP FUNCTION
When the accelerator is lightly depressed while
driving on a flat road in D range, check that rpm
does not change abruptly.
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 ac-
cording 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:
Slip lock-up will not operate when the vehicle is
lifted up off of its wheels, since there is no surface
resistance.
When checking on the free roller, the driving re-
sistance will be slightly inadequate. It will be easier
to judge if the foot brake is lightly applied while per-
forming the check.
2) Connect the Subaru Select Monitor.
3) Check the ATF temperature using the Subaru
Select Monitor.
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, and set so that the lock-up duty
can be read on the data display of the Subaru Se-
lect 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.
Standard
25 45%
NOTE:
The reading may be slightly lower on a free roller.
Slip lock-up control is not operating if the lock-up
duty is 5% or less, 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 re-
place 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 dur-
ing shifting.
9. TRANSFER CLUTCH
Check for tight corner braking phenomenon when
the vehicle is moved forward with the steering fully
turned.
10.OIL LEAKAGE
After the driving test, inspect for oil leaks.
4AT-32
Stall Test
5. Stall Test
A: INSPECTION
NOTE:
The stall test is extremely important in diagnosing
the condition of an automatic transmission and en-
gine. The test is necessary to measure the engine
stall speeds in R and 2nd of manual mode.
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 cor-
rect.
6) Increase the ATF temperature to 70 to 80C
(158 to 176F) by idling the engine for approximate-
ly 30 minutes (with select lever set to N or P).
7) Place the wheel chocks at the front and rear of
all wheels and apply the parking brake.
8) Move the manual linkage to ensure it operates
properly, and then set to the 2nd gear of manual
mode.
9) While pressing hard on the foot brake pedal,
slowly depress the accelerator pedal to full throttle.
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 one minute or more.
12) If the stall speed in 2nd gear of manual mode
is higher than specifications, low clutch slipping
and 2-4 brake slipping may occur. To identify this,
conduct the same test as above in R range.
13) Perform the stall tests with the select lever in
D range.
NOTE:
Do not continue the stall test for 5 seconds or
more 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 de-
teriorate 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 of
1,200 rpm or less.
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):
2,200 3,000 rpm
AT-02205
Stall speed (at sea level) Range Cause
Below specified value 2nd gear on manual mode, R
Throttle valve is not fully open
Engine malfunction
One-way clutch of the torque converter is slipping
Over specified value
D
Line pressure too low
Low clutch slipping
One-way clutch malfunctioning
R
Reverse clutch slipping
Low & reverse brake slipping
2nd gear of manual mode
Low clutch slipping
2-4 brake slipping
4AT-33
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 be-
fore shock is felt. This is used for checking the con-
dition of the low clutch, reverse clutch, low &
reverse brake and one-way clutch.
Perform the test at normal operation fluid tem-
perature of 70 80C (158 176F).
Be sure to allow a one minute or more 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: 1.2 seconds or less
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: 1.5 seconds or less
If N R time lag is longer than specified:
Reverse clutch worn
Low & reverse brake worn
D-ring worn
4AT-34
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 condi-
tions, 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 or 2nd of manual mode with en-
gine 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) Remove the test plug and attach the ST instead.
ST 498897200 OIL PRESSURE GAUGE
ADAPTER
4) Connect the ST1 with ST2.
ST1 498897200 OIL PRESSURE GAUGE
ADAPTER
ASSY
5) Check for duty ratio changes by adjusting the ac-
celeration pedal position using the Subaru Select
Monitor.
6) Remove the ST and install the test plug.
Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)
(A) Test plug
AT-04373
(A)
Standard line pressure
Range
position
Line
pressure
duty ratio
(%)
Throttle
valve angle
Line pressure
kPa (kg/cm
2
, psi)
Manual
mode (2nd)
25 35 Full open
1,000 1,300
(10.2 13.3,
145 189)
R 15 25 Full open
1,500 1,850
(15.3 18.9,
217 268)
D 35 43 Full closed
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 chart in the same manner as line
pressure. <Ref. to 4AT-34, Line Pressure Test.>
ST 498897700 OIL PRESSURE ADAPTER
SET
ASSY
NOTE:
Before setting to FWD mode, install the spare
fuse on the FWD mode switch. (MP-T model only)
If no oil pressure is produced or if it does not
change in AWD mode, there may be a problem in
the transfer duty solenoid or control valve body.
If oil pressure is produced in FWD mode, there is
the same problem as the AWD mode. (MP-T model
only)
(A) Test plug
Range
position
ON
duty
ratio
(%)
Acceleration
opening
angle (%)
Standard transfer clutch
pressure
kPa (kg/cm
2
, psi)
AWD mode
FWD
mode
Manual
mode
(2nd)
95
Fully opened
(100)
1,000 1,200
(10.2 12.2,
145 174)

60
Adjust ON
Duty ratio to
60%.
500 700
(5.1 7.1,
73 102)

Fully closed
(0)

0
(0, 0)
N or P 5
Fully closed
(0)
0
AT-00021
( A)
4AT-36
Automatic Transmission Assembly
Assembly
A: REMOVAL
2) Open the front hood and support with the hood
stay.
ber.>
6) Remove the air intake chamber stay.
7) Disconnect the following connectors.
(1) Transmission harness connectors
(2) Transmission ground terminal
8) Remove the starter.
<Ref. to SC(H4SO)-6, REMOVAL, Starter.>
10) Separate the torque converter assembly from
the drive plate.
CAUTION:
Be careful not to damage the mounting bolts.
Be careful not to drop bolts into the converter
case.
(1) Remove the V-belt covers.
(3) Remove the bolts which hold the torque
converter assembly to the drive plate.
(4) Place the wrench on the crank pulley bolt,
and remove all the bolts while rotating the crank
pulley a little bit at a time.
12) Remove the ATF level gauge.
NOTE:
Plug the opening to prevent entry of foreign parti-
cles into the transmission fluid.
13) Remove the throttle body. <Ref. to FU(H4SO)-
AT-01327
AT-01328
AT-03877
AT-00102
AT-00804
ST
AT-01330
4AT-37
14) Disconnect the engine harness, then remove
the harness connector from the engine harness
bracket.
15) Remove the engine harness bracket.
16) Remove the pitching stopper bracket.
17) Set the ST.
ST 41099AC000 ENGINE SUPPORT ASSY
18) Remove the bolts which hold upper side of
21) Remove the front, center and rear exhaust
pipes and the muffler.
Muffler.>
23) Remove the drain plug (ATF) to drain the ATF.
24) Disconnect the ATF cooler hoses from the
pipes of the transmission side, and remove the oil
charge pipe.
25) Remove the propeller shaft.
<Ref. to DS-10, REMOVAL, Propeller Shaft.>
26) Remove the shift select cable.
<Ref. to CS-27, REMOVAL, Select Cable.>
27) Remove the brackets (two) which hold front
stabilizer.
AT-02815
AT-02167
ST
AT-00106
(A) Oil pan
AT-01331
AT-01332
(B)
(A)
AT-04449
4AT-38
28) Remove the bolt securing the ball joint of the
front arm to housing.
29) Pull out the front drive shaft from the transmis-
sion.
(1) Using a tire lever or a crow bar, etc., pull out
until the front drive shaft transmission side joint
slides move smoothly.
NOTE:
Place cloth between the tire lever or bar and the
transmission in order to avoid damaging the trans-
mission side retainer.
(2) Hold the transmission side joint of the front
drive shaft by hand and extract the housing
from the transmission while pressing the hous-
ing outward, so as not to stretch the boot.
30) Remove the bolts which hold the clutch hous-
ing cover.
32) Place the transmission jack under the transmis-
sion.
NOTE:
Make sure that the support plates of transmission
jack do not touch the oil pan.
33) Remove the transmission rear crossmember
from the vehicle.
34) While lowering the transmission jack gradually,
fully retract the engine support, and then tilt the en-
gine rearward.
NOTE:
Retract the support until the clearance between
front crossmember and converter case becomes
approx. 10 mm (0.39 in).
35) Remove the transmission.
NOTE:
Remove the transmission and torque converter as
a single unit from engine.
36) Remove the rear cushion rubber from the
transmission assembly.
AT-00809
AT-00108
AT-03697
AT-00109
4AT-39
B: INSTALLATION
1) Replace the differential side oil seal with a new
part. <Ref. to 4AT-46, REPLACEMENT, Differen-
tial Side Retainer Oil Seal.>
NOTE:
When a new oil seal has been installed, replace-
ment is not required.
2) Install the rear cushion rubber to the transmis-
sion assembly.
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
4) Install the transmission onto the engine.
(1) Lift up the transmission gradually using
transmission jack.
(2) Insert the engine side stud bolt into the
transmission bolt hole.
(3) While raising the transmission jack gradual-
ly, turn the screw of engine support, then tilt the
engine forward and connect.
5) Install the transmission rear crossmember.
Tightening torque:
T1: 35 Nm (3.6 kgf-m, 25.8 ft-lb)
T2: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
6) Remove the transmission jack.
7) Tighten the bolts and nuts which hold the lower
side of transmission to the engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
8) Install the clutch housing cover bolts.
9) Lower the lift.
AT-00103
ST
AT-00109
T 2
T 2
T 1
AT-03698
AT-00108
4AT-40
10) Connect the engine and transmission.
(1) Remove the ST from converter case.
NOTE:
When removing the ST, be careful not to drop it into
converter case.
(2) Install the starter.
<Ref. to SC(H4SO)-6, INSTALLATION, Start-
er.>
(3) Tighten the bolts which hold the upper side
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
11) Install the torque converter assembly to the
drive plate.
CAUTION:
Be careful not to drop bolts into the converter
case.
(1) Tighten the bolts which hold the torque con-
verter assembly to the drive plate.
(2) Place the wrench on the crank pulley bolt,
and remove all the bolts while rotating the crank
pulley a little bit at a time.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
(3) Fit the plug to service hole.
(4) Install the V-belt cover.
12) Remove the ST.
13) Install the engine harness bracket.
Tightening torque:
T1: 16 Nm (1.6 kgf-m, 11.6 ft-lb)
T2: 36 Nm (3.6 kgf-m, 26.0 ft-lb)
14) Install the harness connector to engine harness
bracket, then connect the harness.
15) Install the pitching stopper bracket.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
16) Install the throttle body. <Ref. to FU(H4SO)-11,
INSTALLATION, Throttle Body.>
AT-00106
AT-00102
AT-02167
ST
AT-02816
T1
T2
AT-02817
4AT-41
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
19) Replace the circlip of the front drive shaft with a
new part.
20) Apply grease to the oil seal lip.
21) Attach the ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
22) Align and insert the spline of the front drive
shaft to the splines of the differential bevel gear,
and remove the ST.
23) Insert the front drive shaft into the transmission
securely by pressing the front housing from the out-
side.
24) Install the ball joint into the housing.
25) Tighten the attachment bolts.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
26) Install the stabilizer to the crossmember.
NOTE:
Install the bushing (on front crossmember side)
while aligning it with the paint mark on the stabilizer.
Make sure the bushing and stabilizer are marked
with the same identification colors (paint mark)
when installing.
27) Always tighten the rubber bushing locations
with wheels in full contact with the ground and the
vehicle at curb weight.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
28) Install the shift select cable onto select lever.
<Ref. to CS-28, INSTALLATION, Select Cable.>
29) Install the oil charge pipe, and connect the ATF
cooler hoses to the pipe.
T2
T1
AT-03878
AT-00110
ST
AT-00111
(1) Identification mark on stabilizer
(2) Bushing identification color
AT-00809
FS-00050
AT-04449
4AT-42
30) Install the propeller shaft.
<Ref. to DS-11, INSTALLATION, Propeller Shaft.>
TION, Muffler.>
haust Pipe.>
35) Lower the lift.
36) Install the ATF level gauge.
(2) Transmission ground terminal
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
Chamber.>
Duct.>
41) From the oil charge pipe, add ATF until the fluid
level is between the upper and lower level on the
COLD side of the level gauge. <Ref. to 4AT-28,
Automatic Transmission Fluid.>
43) Check the differential gear oil level. <Ref. to
4AT-30, Differential Gear Oil.>
44) Check the select lever operation.
<Ref. to 4AT-47, INSPECTION, Inhibitor Switch.>
45) Bleed the air of control valve. <Ref. to 4AT-61,
Air Bleeding of Control Valve.>
46) Check the ATF level. <Ref. to 4AT-28, Auto-
matic Transmission Fluid.>
47) Execute the learning control promotion. <Ref.
to 4AT(diag)-17, FACILITATION OF LEARNING
CONTROL, OPERATION, Subaru Select Moni-
tor.>
48) Perform the road test.
<Ref. to 4AT-31, Road Test.>
AT-01331
AT-01330
4AT-43
Transmission Mounting System
10.Transmission Mounting
System
A: REMOVAL
1. PITCHING STOPPER
ber.>
2. TRANSMISSION REAR CROSSMEMBER
AND REAR CUSHION RUBBER
2) Jack-up the vehicle and support it with rigid
racks.
3) Remove the front, center and rear exhaust pipes
and the muffler.
Muffler.>
5) Set the transmission jack under transmission.
NOTE:
Make sure that the support plate of transmission
jack does not touch the oil pan.
6) Remove the transmission rear crossmember.
7) 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, 42.8 ft-lb)
Chamber.>
1) Install the rear cushion rubber.
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
2) Install the cross member.
Tightening torque:
T1: 35 Nm (3.6 kgf-m, 25.8 ft-lb)
T2: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
and the muffler.
AT-03877
AT-03697
T2
T1
AT-03878
T 2
T 2
T 1
AT-03698
4AT-44
C: INSPECTION
If problems are found in the following inspection,
repair or replace the part.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Check that there are no cracks, harden-
ing or damage on rubber parts.
Make sure that the crossmember is not bent or
damaged. Check that there are no cracks, harden-
ing, or damage on cushion rubbers.
4AT-45
Extension Case Oil Seal
11.Extension Case Oil Seal
A: INSPECTION
Confirm that there is no ATF leakage from the joint
of the transmission and propeller shaft. If a leak is
found, replace the oil seal and inspect the propeller
shaft. <Ref. to 4AT-45, REPLACEMENT, Exten-
sion Case Oil Seal.>
B: REPLACEMENT
2) Clean the transmission exterior.
3) Remove the drain plug (ATF) and completely
drain the ATF.
CAUTION:
yourself.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
fler.>
7) Remove the propeller shaft. <Ref. to DS-10, RE-
MOVAL, Propeller Shaft.>
8) Using the ST, remove the oil seal.
ST 398527700 PULLER ASSY
9) Using the ST, install the oil seal.
ST 498057300 INSTALLER
TION, Muffler.>
13) Fill with ATF. <Ref. to 4AT-28, Automatic
15) Check the level and leaks of the ATF. <Ref. to
4AT-28, Automatic Transmission Fluid.>
(A) Oil pan
AT-01332
(B)
(A)
4AT-46
Differential Side Retainer Oil Seal
12.Differential Side Retainer Oil
Seal
A: INSPECTION
Check for leakage of gear oil from differential side
retainer oil seal part. If there is an oil leak, replace
the oil seal and inspect the drive shaft.
B: REPLACEMENT
2) Remove the front exhaust pipe and center ex-
haust pipe. <Ref. to EX(H4SO)-4, REMOVAL,
Front Exhaust Pipe.>
TORX
BIT T70, and then drain differential gear

oil.
CAUTION:
Because the differential gear will be very hot
after driving, be very careful not be receive
burns.
smoke or causing fires. If differential gear oil is
pletely.
tighten the differential gear oil drain plug.
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)
5) Separate the front drive shaft from the transmis-
sion. <Ref. to DS-23, REMOVAL, Front Drive
Shaft.>
6) Remove the differential side retainer oil seal us-
ing driver wrapped with vinyl tape etc.
7) Using the ST, install the differential side retainer
oil seal by lightly tapping with a hammer.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
8) Apply gear oil to the oil seal lips.
9) Install the front drive shaft. <Ref. to DS-23, IN-
STALLATION, Front Drive Shaft.>
10) Install the front exhaust pipe and the center ex-
haust pipe. <Ref. to EX(H4SO)-5, INSTALLATION,
12) Fill with differential gear oil through the oil level
gauge hole.
Gear oil capacity:
1.1 1.3 2 (1.3 1.4 US qt, 1.0 1.1 Imp qt)
13) Check the level of differential gear oil. <Ref. to
4AT-30, INSPECTION, Differential Gear Oil.>
(A) Oil pan
AT-02204
(B)
(A)
AT-00029
ST
4AT-47
Inhibitor Switch
13.Inhibitor Switch
A: INSPECTION
When the driving condition or starter motor opera-
tion is improper, first check the shift linkage for im-
proper 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.
NOTE:
Also check that there is no continuity in the igni-
tion circuit when the select lever is in the R and
D ranges.
If the inhibitor switch does not operate, check for
poor contact of the connector on transmission side.
3) Check that there is continuity at equal points
when the select lever is turned 1.5 in both direc-
tions 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.>
4) Repeat the above inspection in other gear rang-
es. If there are abnormalities, adjust the select ca-
ble. <Ref. to CS-31, ADJUSTMENT, Select
Cable.>
B: ADJUSTMENT
1) Set the select lever to N range.
2) Loosen the three inhibitor switch securing bolts.
3) Insert the ST as vertical as possible into the
holes in the inhibitor switch lever and switch body.
ST 499267300 STOPPER PIN
4) Tighten the three inhibitor switch securing bolts.
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
5) Repeat the inspection of the inhibitor switch. If
the inhibitor switch is determined to be faulty, re-
place it.
Signal sent to TCM
Range Pin No.
P 4 3
R 4 2
N 4 1
D 4 8
Ignition circuit P/N 12 11
Back-up light circuit R 10 9
(A) Inhibitor switch connector
AT-00030
( 4) ( 3) ( 2) ( 1)
( 5) ( 6) ( 7) ( 8)
( 9) ( 10) ( 11) ( 12)
(A)
(A) Continuity does not exist.
(B) Continuity exists.
(C) 1.5
AT-02206
(A)
(A)
(C)
(B)
ST
AT-00032
4AT-48
Inhibitor Switch
C: REMOVAL
2) Set the select lever to N range.
ber.>
4) Disconnect the inhibitor switch connector.
5) Remove the inhibitor switch connector from the
stay.
Pipe.>
8) Remove the snap pin and washer from the range
select lever.
9) Remove the plate assembly from the transmis-
sion case.
10) Remove the three inhibitor switch securing
bolts.
11) Move the range select lever to the parking po-
sition (left side).
(B) Snap pin
(C) Select cable
(D) Washer
AT-01350
(A)
AT-00034
(C)
(B)
(A)
(D)
(A) Select cable
(B) Plate ASSY
(A) Inhibitor switch
AT-00035
( A)
( B)
(A)
AT-00036
(A)
AT-00037
4AT-49
Inhibitor Switch
12) Remove the inhibitor switch from the transmis-
sion.
13) Disconnect the inhibitor switch harness con-
nector from the inhibitor switch.
D: INSTALLATION
1) Connect the inhibitor switch harness connector
to the inhibitor switch.
2) Install the inhibitor switch to the transmission
case.
3) Move the range select lever to the neutral posi-
tion.
4) Tighten the three inhibitor switch securing bolts
using the ST.
ST 499267300 STOPPER PIN
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
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, 18.4 ft-lb)
7) Install the washer and snap pin to the range se-
lect lever.
AT-00038
(A)
AT-00038
(A)
(B) Range select lever
(A) Select cable
(B) Plate ASSY
(B) Snap pin
(C) Select cable
(D) Washer
(A)
AT-00039
(B)
ST
AT-00040
( A)
( B)
T
AT-00034
(C)
(B)
(A)
(D)
4AT-50
Inhibitor Switch
haust Pipe.>
10) Install the inhibitor switch connector to the stay.
11) Connect the inhibitor switch connector.
Chamber.>
13) Inspect the inhibitor switch. <Ref. to 4AT-47,
INSPECTION, Inhibitor Switch.>
AT-01350
(A)
4AT-51
Front Vehicle Speed Sensor
14.Front Vehicle Speed Sensor
A: REMOVAL
ber.>
4) Disconnect the transmission harness connector.
5) Remove the pitching stopper. <Ref. to 4AT-43,
6) Remove the transmission harness connector
from stay.
CAUTION:
yourself.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
11) Remove the front, center and rear exhaust
pipes and the muffler. <Ref. to EX(H4SO)-4, RE-
MOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO)-
8, REMOVAL, Rear Exhaust Pipe.> <Ref. to
EX(H4SO)-10, REMOVAL, Muffler.>
sion.
NOTE:
jack does not touch the cross.
bolt.
16) Lower the transmission jack.
NOTE:
Do not separate the transmission jack and trans-
mission.
17) Remove the ATF inlet and outlet pipes.
CAUTION:
When removing the outlet pipe, be careful not
to lose the ball and spring used together with
the retaining screw.
18) Remove the front vehicle speed sensor and
torque converter turbine speed sensor.
(A) Transmission harness connectors
(A) Oil pan
AT-01337
(A)
AT-01332
(B)
(A)
(A) Front vehicle speed sensor
(B) Torque converter turbine speed sensor
AT-00043
AT-00044
( A)
( B)
4AT-52
19) Disconnect the connector from the rear vehicle
speed sensor.
CAUTION:
Be careful not to allow foreign matter such as
dust or dirt to enter the oil pan.
21) Disconnect the control valve connector and
transmission ground terminal.
22) Remove the transmission harness assembly.
B: INSTALLATION
1) Pass the transmission harness assembly
through the hole of the transmission case.
2) Connect the control valve connector and trans-
mission ground.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
3) Apply proper amount of liquid gasket to the en-
tire oil pan mating surface.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
or equivalent
(A) Rear vehicle speed sensor
(A) Transmission ground
(B) Control valve connector
AT-02207
(A)
AT-00050
(B)
(A)
(B) Control valve connector
AT-00048
AT-00050
(B)
(A)
AT-02742
4AT-53
4) Fill the 3 locations of the transmission case ex-
cluding the bolt holes with liquid gasket.
Liquid gasket:
or equivalent
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 inlet and outlet pipes.
NOTE:
Use a new copper washer.
Tightening torque:
T1: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
T2: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
T3: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
9) Install the transmission rear crossmember bolt.
Tightening torque:
75 Nm (7.6 kgf-m, 55.3 ft-lb)
and the muffler.
14) Install the transmission harness connector to
the stay.
15) Install the pitching stopper. <Ref. to 4AT-43,
INSTALLATION, Transmission Mounting System.>
Chamber.>
17) Fill with the same amount of ATF as drained.
19) Inspect the level of ATF. <Ref. to 4AT-28, Au-
tomatic Transmission Fluid.>
tor.>
AT-01339
AT-03072
T2
T3
T1
4AT-54
Rear Vehicle Speed Sensor
15.Rear Vehicle Speed Sensor
A: REMOVAL
4) Disconnect the connector from the rear vehicle
speed sensor.
MP-T model
VTD model
5) Remove the rear vehicle speed sensor.
MP-T model
VTD model
B: INSTALLATION
NOTE:
Replace the O-ring with a new part.
Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
AT-02207
(A)
AT-00117
(A)
AT-01341
AT-00117
(A)
4AT-55
Torque Converter Turbine Speed Sensor
16.Torque Converter Turbine
Speed Sensor
A: REMOVAL
For removal procedure of the torque converter tur-
bine speed sensor, refer to Front Vehicle Speed
Sensor. <Ref. to 4AT-51, REMOVAL, Front Vehi-
cle Speed Sensor.>
B: INSTALLATION
For installation procedure of the torque converter
turbine speed sensor, refer to Front Vehicle Speed
Sensor. <Ref. to 4AT-52, INSTALLATION, Front
Vehicle Speed Sensor.>
4AT-56
Control Valve Strainer
17.Control Valve Strainer
A: REMOVAL
CAUTION:
The ATF will be extremely hot after driving. Be
careful not to receive burns.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
CAUTION:
8) Remove the magnet.
9) Clean the magnet.
10) Completely remove the remaining liquid gasket
on the transmission case and oil pan.
11) Remove the control valve strainer tightening
bolt, and remove control valve strainer from the
control valve body.
B: INSTALLATION
1) Check the control valve body for dust and other
foreign matter.
2) Mount new control valve strainer to the control
valve body.
(1) Apply ATF to the entire perimeter of the O-
ring on the control valve strainer.
CAUTION:
Protect the O-ring from dust and dirt while ap-
plying ATF.
(2) Install the control valve strainer to the con-
trol valve body from the O-ring side.
CAUTION:
If the control valve strainer is pushed in at an
angle, the O-ring may be damaged. Be sure to
push in the control valve strainer straight to in-
stall.
(3) Tighten the three bolts.
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
AT-03117
AT-03118
AT-04597
AT-04597
4AT-57
Control Valve Strainer
3) Attach the magnet at the specified position of the
oil pan.
Liquid gasket:
or equivalent
5) Fill the three holes aside from the bolt holes in
the transmission case, with liquid gasket.
Liquid gasket:
or equivalent
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
7) Fill ATF from the oil charge pipe.
Recommended fluid:
<Ref. to 4AT-3, HYDRAULIC CONTROL AND
LUBRICATION, SPECIFICATION, General De-
scription.>
Capacity:
8) Bleed the air of control valve. <Ref. to 4AT-61,
Air Bleeding of Control Valve.>
9) Check the ATF level. <Ref. to 4AT-28, Automat-
ic Transmission Fluid.>
C: INSPECTION
Check the control valve strainer for holes, damages
or adhesion of dust and other foreign particles.
AT-02743
AT-02742
AT-01339
4AT-58
Control Valve Body
18.Control Valve Body
A: REMOVAL
CAUTION:
yourself.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
CAUTION:
11) Disconnect the control valve connector.
12) Remove the oil cooler pipe.
13) Remove the control valve body.
NOTE:
The control valve body is replaced as an assembly
only, because it is a non-disassembly part.
AT-02928
AT-02929
AT-02743
AT-00058
AT-00059
AT-01717
4AT-59
Control Valve Body
B: INSTALLATION
foreign matter.
2) Temporarily install the control valve body and
ground cable to the transmission, then install the oil
cooler pipe.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
3) Tighten the bolts equally.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
4) Connect the control valve connector.
oil pan.
Liquid gasket:
or equivalent
7) Fill the 3 holes aside from the bolt holes in the
transmission case, with liquid gasket.
Liquid gasket:
or equivalent
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
Bolt length mm (in)
(1) 35 (1.38)
(2) 30 (1.18)
AT-00059
AT-01718
(1)
(1)
(2)
(2)
(2)
(2)
(2)
(2) (2) (2)
(2)
(2)
(2)
(A)
AT-00058
AT-02743
AT-02742
AT-01339
4AT-60
Control Valve Body
9) Fill ATF from the oil charger pipe.
Recommended fluid:
SUBARU ATF HP
Substitute fluid:
IDEMITSU ATF HP, Castrol Transmax J
Capacity:
10) Bleed the air of control valve body. <Ref. to
4AT-61, Air Bleeding of Control Valve.>
11) Check the ATF level.
<Ref. to 4AT-28, Automatic Transmission Fluid.>
tor.>
C: INSPECTION
Check parts for holes, damages or adhesion of
dust and other foreign particles.
4AT-61
Air Bleeding of Control Valve
19.Air Bleeding of Control Valve
When ATF is drained from the automatic trans-
mission, make sure to bleed air from the control
valve after filling with the specified amount of ATF.
Perform the procedures according to the mes-
sage displayed on the Subaru Select Monitor.
B: PROCEDURE
1. PREPARATION FOR AIR BLEEDING
1) Cool down until the ATF temperature displayed
on the Subaru Select Monitor reaches to 60C
(140 F) or lower.
2) Shift the select lever to P range.
CAUTION:
Be sure to keep the lowest edge of the tires 30
cm or more off the ground because the vehicle
vibrates during the work.
5) Connect the Subaru Select Monitor to the data
link connector.
7) Turn OFF all switches, which produce an electri-
cal load, including headlight, air conditioner, seat
heater, rear defogger, etc.
2. AIR BLEEDING
CAUTION:
Do not turn the power of the Subaru Select
Monitor to OFF or disconnect the data link con-
nector during the operation.
1) Select {Learning and inspection mode related to
AT} on the Transmission Diagnosis display
screen of Subaru Select Monitor.
2) Select {AT air bleeding mode} on the Learning
and inspection mode related to AT display screen
of Subaru Select Monitor.
3) Perform the procedures according to the mes-
NOTE:
During air bleeding in progress, SPORT indicator
light in the combination meter starts flashing at a
cycle of 2 Hz and air bleeding starts. The following
message is displayed on the screen when the indi-
cator light turns off.
4AT-62
Air Bleeding of Control Valve
4) When AT air bleeding normally ended. is dis-
played, air bleeding is completed.
NOTE:
If communication error occurs during air bleed-
ing, retry AT air bleeding from the beginning.
If Execute AT learning again after fixing troubles
of the vehicle is displayed during air bleeding, se-
lect [OK] to display the List of Diagnostics Trouble
Code. Retry AT air bleeding from the beginning af-
ter repairing the DTC detecting portion.
If AT air bleeding ended abnormally. is dis-
played, retry AT air bleeding from the beginning.
For details concerning the operation procedure, refer to the PC application help for Subaru Select Moni-
tor.
Message Primary cause of abnormal end
AT air bleeding ended abnormally. Fault is detected during AT air bleeding.
The accelerator pedal is depressed during AT air bleeding.
Operation which is not directed is performed during AT air
bleeding.
The brake pedal is not depressed fully.
The parking brake is not applied fully.
Abnormal idle rise occurs. Other similar causes are probable.
4AT-63
ATF Filter
20.ATF Filter
A: REMOVAL
NOTE:
The ATF filter is maintenance free.
2) Using the ST, remove the 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 care-
ful not to damage oil seal.
3) Tighten the ATF filter using ST.
Calculate the ATF filter tightening torque using fol-
lowing 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:
NOTE:
Attach ST to the torque wrench as straight as pos-
sible.
4) Fill the ATF.
5) Inspect the level of ATF. <Ref. to 4AT-28, Auto-
C: INSPECTION
Check for rusting, holes, ATF leaks or other dam-
age.
(A) ATF filter
Torque wrench length
mm (in)
Tightening torque
Nm (kgf-m, ft-lb)
100 (3.94) 7.7 (0.79, 5.7)
150 (5.91) 9.0 (0.92, 6.7)
200 (7.87) 10 (1.0, 7.2)
AT-00091
(A)
ST
4AT-64
Transmission Control Module (TCM)
21.Transmission Control Module
(TCM)
A: REMOVAL
2) Remove the instrument panel lower cover and
disconnect the connector.
3) Disconnect the connector from TCM.
4) Remove the TCM.
B: INSTALLATION
1) Install the TCM.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
2) Connect the connector to the TCM.
4) Execute the learning control promotion. <Ref. to
4AT(diag)-17, FACILITATION OF LEARNING
tor.>
(A) Transmission control module (TCM)
(B) Brake pedal
(B) Brake pedal
AT-02170
(A)
(B)
AT-02170
(A)
(B)
4AT-65
ATF Cooler Pipe and Hose
22.ATF Cooler Pipe and Hose
A: REMOVAL
6) Disconnect the ATF cooler hose from the radia-
tor.
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.
7) Disconnect the ATF cooler hoses from the pipes.
NOTE:
8) Disconnect the ATF cooler pipe from frame.
9) Remove the ATF inlet pipe and outlet pipe.
CAUTION:
When disconnecting the outlet pipe, be careful
not to lose the ball and spring used together
with the retaining screw.
AT-03402
AT-01345
AT-04449
(A) ATF inlet pipe
(B) ATF outlet pipe
AT-01347
AT-01348
(A)
(B)
4AT-66
B: INSTALLATION
1) Install the ATF inlet pipe and outlet pipe along
with new washers.
Tightening torque:
T1: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
T2: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
T3: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
2) Install the ATF cooler pipe to frame.
3) Connect the ATF cooler hose to the pipe on the
transmission side.
NOTE:
Install so that the hose is not folded over, exces-
sively bent or twisted.
Insert the hose to the specified position.
radiator side.
NOTE:
7) Install the battery.
8) Fill the ATF. <Ref. to 4AT-28, Automatic Trans-
mission Fluid.>
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
AT-03072
T2
T3
T1
AT-01347
AT-04449
AT-01345
AT-03402
4AT-67
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 trans-
mission, radiator, pipes, and hoses.
2) Check the clamp for deformation.
3) Lightly bend the hose and check for cracks in the
surface or other damages.
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-68
Air Breather Hose
23.Air Breather Hose
A: REMOVAL
ber.>
2) Disconnect the air breather hose.
B: INSTALLATION
1) Install the air breather hose.
Chamber.>
C: INSPECTION
Make sure the hose is not cracked or clogged.
(A) Air breather hose (Transmission case)
(B) Air breather hose (Oil pump housing)
(A) Air breather hose (Transmission case)
(B) Air breather hose (Oil pump housing)
AT-00099
AT-00099
4AT-69
Oil Charge Pipe
24.Oil Charge Pipe
A: REMOVAL
ber.>
2) Remove the oil charge pipe, and then remove
the O-ring from the flange side.
B: INSTALLATION
1) Apply ATF on a new O-ring and install together
with the oil charge pipe.
NOTE:
Use a new bolt.
Tightening torque:
38 Nm (3.9 kgf-m, 28.0 ft-lb)
Chamber.>
C: INSPECTION
Make sure the oil charge pipe is not deformed or
damaged.
(A) ATF level gauge
(B) Oil charge pipe
(A) ATF level gauge
(B) Oil charge pipe
AT-02209
(A)
(B)
AT-02209
(A)
(B)
4AT-70
Torque Converter Assembly
25.Torque Converter Assembly
A: REMOVAL
1) Remove the transmission assembly from vehicle
body. <Ref. to 4AT-36, REMOVAL, Automatic
2) Pull out the torque converter assembly and oil
pump shaft horizontally.
NOTE:
Be sure not to scratch the inside of bushing in oil
pump shaft.
3) Remove the input shaft.
NOTE:
When the torque converter assembly is removed,
the input shaft will also come off.
4) Remove the oil pump shaft from torque convert-
er assembly as necessary.
B: INSTALLATION
1) When the oil pump shaft is removed, install the
shaft to converter case.
2) Install the oil pump shaft to the torque converter
assembly, and make sure the clip is secured on the
groove.
3) Apply ATF to the O-ring and insert on the input
shaft while rotating the shaft slowly by hand.
Normal protrusion A:
50 55 mm (1.97 2.17 in)
4) While holding the torque converter assembly by
hand, carefully install it to the converter case. Take
care not to damage the bushing. Do not allow the
oil pump shaft bushing to touch the stator shaft sec-
tion of the oil pump cover inappropriately.
5) Slowly rotate the shaft by hand to engage the
splines securely, then check that dimension A is
within the specified range.
Dimension A:
2.7 2.9 mm (0.106 0.114 in)
6) Install the transmission assembly to the vehicle.
<Ref. to 4AT-39, INSTALLATION, Automatic
C: INSPECTION
Make sure the ring gear and protrusion of the
torque converter assembly end are not deformed or
damaged.
AT-00113
AT-00114
AT-00291
A
A
AT-04448
4AT-71
Extension Case
26.Extension Case
A: REMOVAL
1) Remove the transmission assembly.
<Ref. to 4AT-36, REMOVAL, Automatic Transmis-
sion Assembly.>
MP-T model
VTD model
3) Separate the transmission case and extension
case section.
B: INSTALLATION
1) Apply vaseline to the contact surface, and attach
the selected thrust needle bearing to the end sur-
face of the reduction drive gear.
NOTE:
Install the thrust needle bearing in the correct direc-
tion.
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, 18.4 ft-lb)
5) Install the rear vehicle speed sensor.
Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
MP-T model
VTD model
6) Install the transmission assembly.
AT-02207
(A)
AT-00117
(A)
AT-00118
AT-00118
AT-02207
(A)
AT-00117
(A)
4AT-72
Extension Case
C: DISASSEMBLY
1. MP-T MODEL
1) Hit the edges of the rear drive shaft lightly with a
plastic hammer, and take out the transfer clutch.
NOTE:
Be careful not to damage the oil seal of the exten-
sion case.
2) Remove the transfer clutch pipe while being
careful not to deform the pipe.
3) Remove the dust cover from extension case.
4) Remove the oil seal from the extension case.
2. VTD MODEL
1) Using ST1, ST2, ST3 and a press, remove the
snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 398663600 PLIER
2) Remove the test plug.
3) Send in compressed air, and remove the multi-
plate clutch (LSD) piston.
(A) Extension case
(B) Transfer clutch
(A) Extension case
(B) Transfer clutch pipe
AT-00119
(A)
(B)
AT-00120
(A)
(B)
(A) Extension case
(B) Test plug
AT-00121
ST3
ST2
ST1
AT-00122
(A)
(B)
AT-00123
4AT-73
Extension Case
4) Remove the multi-plate clutch pipe while being
careful not to deform the pipe.
D: ASSEMBLY
1. MP-T MODEL
1) Press-fit the new oil seal using ST and the press.
2) Press-fit the dust cover.
3) Install the transfer clutch pipe to the extension
case while being careful not to deform the pipe.
4) Install the transfer clutch assembly to the case.
NOTE:
Be careful not to damage the seal ring.
Insert the transfer clutch assembly all the way to
the bottom of the bearing shoulder.
2. VTD MODEL
3) Install the multi-plate clutch (LSD) pipe to the ex-
tension case while being careful not to deform the
pipe.
4) Apply ATF to a new O-ring and attach the test
plug.
Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)
5) Insert the multi-plate clutch, drive plate, driven
plate and spring retainer.
(A) Extension case
(B) Transfer pipe
(A) Transfer clutch ASSY
(B) Extension case
AT-00124
AT-00120
(A)
(B)
AT-00125
(A)
(B)
(A) Test plug
(B) Extension case
(A) Spring retainer
(B) Multi-plate clutch piston ASSY
AT-00124
AT-00122
(A)
(B)
AT-00126
(A)
(B)
4AT-74
Extension Case
6) Using ST1, ST2 and ST3, attach the snap ring.
ST2 498627100 SEAT
ST3 398663600 PLIER
E: INSPECTION
Blow with compressed air to make sure the
transfer pipe and extension case routes are not
clogged or leaking.
Inspect the extension end play, and adjust it to
within the standard value.
MP-T model:
<Ref. to 4AT-79, MP-T MODEL, ADJUSTMENT,
Transfer Clutch.>
VTD model:
<Ref. to 4AT-79, VTD MODEL, ADJUSTMENT,
Transfer Clutch.>
AT-00121
ST3
ST2
ST1
4AT-75
Transfer Clutch
27.Transfer Clutch
A: REMOVAL
2) Remove the extension case, and then remove
the transfer clutch. <Ref. to 4AT-71, REMOVAL,
Extension Case.> <Ref. to 4AT-72, DISASSEM-
BLY, Extension Case.>
B: INSTALLATION
1) Select the thrust needle bearing. <Ref. to 4AT-
79, ADJUSTMENT, Transfer Clutch.>
2) Install the transfer clutch assembly to the case.
3) Tighten the bolts to secure the case.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
C: DISASSEMBLY
1) Remove the seal ring.
2) Remove the ball bearing using the ST and the
press.
ST 498077600 REMOVER
3) Using a flat tip screwdriver, etc. remove the snap
ring, and take out the pressure plate, retaining
plate, drive plate and driven plate.
(A) Transfer clutch
(B) Extension case
AT-00125
(A)
(B)
AT-00118
(A) Seal ring
(B) Rear drive shaft
(A) Snap ring
AT-00127
AT-00128
AT-00129
4AT-76
Transfer Clutch
4) Using the ST1, ST2 and ST3, remove the snap
ring, then take out the return spring and transfer
clutch piston seal.
ST1 399893600 PLIERS
ST3 398623600 SEAT
5) Apply compressed air to the rear drive shaft, to
remove the transfer clutch piston.
D: ASSEMBLY
1) Install the transfer clutch piston.
2) Install the return spring to transfer clutch piston.
3) Apply ATF to the lip of transfer clutch piston seal,
then install.
4) Attach the ST to the rear drive shaft.
ST 499257300 SNAP RING OUTER GUIDE
(A) Snap ring
(B) Transfer clutch piston seal
(A) Transfer clutch piston
AT-00130
(B)
(A)
ST1
ST2
ST3
AT-00131
(B)
AT-00132
(A)
(A) Return spring
(A) Transfer clutch piston seal
(A) Rear drive shaft
(B)
AT-00133
(A)
(B)
AT-00134
(A)
AT-00135
(A)
ST
4AT-77
Transfer Clutch
5) Install the snap ring to the ST.
ST 499257300 SNAP RING OUTER GUIDE
6) Install the snap ring to the rear drive shaft using
ST1 and ST2.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER
7) Install the driven plate, drive plate, pressure
plate, retaining plate and snap ring.
8) Apply compressed air to see if the assembled
parts move smoothly.
9) Check clearance between the snap ring and
pressure plate. <Ref. to 4AT-78, INSPECTION,
Transfer Clutch.>
10) Press-fit new ball bearing using ST.
11) Apply vaseline to a new seal ring and attach to
the seal ring groove of the shaft.
NOTE:
While installing the seal ring, not to stretch the seal
ring excessively.
(A) Snap ring
(A) Snap ring
(A) Snap ring
AT-00136
(A)
(B)
ST
AT-00137
(A)
(B)
ST2
ST1
AT-00138
(A)
(A) Ball bearing
(A) Seal ring
AT-00139
AT-00140
(A)
ST
AT-00141
(A)
(B)
4AT-78
Transfer Clutch
12) Install the transfer clutch assembly while taking
care not to damage the seal ring.
E: INSPECTION
Inspect the drive plate facing for wear and dam-
age.
Make sure the snap ring is not worn and the re-
turn spring has no permanent distortion, damage,
or deformation.
Inspect the D-ring for damage.
MP-T model:
<Ref. to 4AT-79, MP-T MODEL, ADJUSTMENT,
Transfer Clutch.>
VTD model:
<Ref. to 4AT-79, VTD MODEL, ADJUSTMENT,
Transfer Clutch.>
pressure plate.
2) Before measuring clearance, place same thick-
ness shims on both sides to prevent the pressure
plate from tilting.
3) If the clearance exceeds the service limits, re-
place the plate set (drive plate and driven plate),
and select and adjust a retaining plate to be within
the initial standard value.
Initial standard:
0.7 1.1 mm (0.028 0.043 in)
Limit thickness:
1.6 mm (0.063 in)
4) Check for tight corner braking phenomenon
when the vehicle is moved forward with the steer-
ing fully turned. If tight corner braking occurs, per-
form 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 ac-
celeration and braking intermittently.
(2) If the tight corner braking phenomenon still
persists, drive the vehicle again in a circle for
several laps.
(A) Transfer clutch ASSY
(B) Extension case
AT-00125
(A)
(B)
Retaining plate
Part number Thickness mm (in)
31593AA151 3.3 (0.130)
31593AA161 3.7 (0.146)
31593AA171 4.1 (0.161)
31593AA181 4.5 (0.177)
AT-00142
4AT-79
Transfer Clutch
F: ADJUSTMENT
1. MP-T MODEL
1) Measure the distance A from the end of ST to
the rear drive shaft using the ST.
ST 398643600 GAUGE
2) Measure distance B from the transmission
case mating surface to the end of ST using ST1
and ST2.
ST1 398643600 GAUGE
ST2 499577000 GAUGE
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 mating surface of the trans-
mission case to the end of the ST
2. VTD MODEL
1) Insert the rear drive shaft into the reduction drive
gear and center differential assembly.
2) Using the ST, measure distance A, from the
mating surface of the extension case to the rear
drive shaft ball bearing outer ring contact surface.
ST 398643600 GAUGE
3) Using the ST, measure distance B, from the
mating surface of the transmission case to the end
face of the rear drive shaft ball bearing.
ST 398643600 GAUGE
A Measured value
B Measured value
Thrust needle bearing
806536020 3.8 (0.150)
806535030 4.0 (0.157)
806535040 4.2 (0.165)
806535050 4.4 (0.173)
806535060 4.6 (0.181)
806535070 4.8 (0.189)
806535090 5.0 (0.197)
A
ST
AT-01029
ST2 ST1
B
AT-02210
(A) Rear drive plate
(B) Center differential carrier
A Measured value
B Measured value
AT-02211
(A)
(B)
AT-01031
ST
A
AT-01032
B
ST
4AT-80
Transfer Clutch
When the clearance is 0.05 mm (0.0020 in), select
up to 4 adjustment shims that will meet the clear-
ance value on the table.
Calculation of T:
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 the extension case to
the end of rear drive shaft
B: Distance from the end of the transmission case
to the end of the reduction drive gear
T: Shim thickness
0.05 0.25 mm (0.0020 0.0098 in)
Adjustment shim
33281AA001 0.2 (0.008)
33281AA011 0.5 (0.020)
4AT-81
Multi-plate Clutch
28.Multi-plate Clutch
A: REMOVAL
Remove the multi-plate clutch in the same manner
as the extension case. <Ref. to 4AT-71, REMOV-
AL, Extension Case.>
B: INSTALLATION
Install the multi-plate clutch in the same manner as
the extension case. <Ref. to 4AT-71, INSTALLA-
TION, Extension Case.>
C: INSPECTION
Inspect the drive plate facing for wear and dam-
age.
or deformation.
Inspect the D-ring for damage.
Measure the clearance of the multi-plate clutch,
and adjust so that it is within the specification
range. <Ref. to 4AT-81, ADJUSTMENT, Multi-plate
Clutch.>
D: ADJUSTMENT
1) Remove the drive plate and driven plate from the
center differential carrier.
2) Using the ST, measure distance A, from the
mating surface of the extension case to the multi-
plate clutch piston.
ST 398643600 GAUGE
3) Using the ST, measure height B from the trans-
mission case mating surface to the end surface of
the center differential clutch drum.
ST 398744300 PISTON GUIDE
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)
When the usage limit is exceeded, replace the
plate set (drive and driven plate), select the retain-
ing plate of the multi-plate clutch piston, and set so
that it is within the standard.
A Measured value
AT-01031
ST
A
B Measured value
Retaining plate
31589AA041 1.6 (0.063)
31589AA050 2.0 (0.079)
31589AA060 2.4 (0.094)
31589AA070 2.8 (0.110)
B
ST
AT-01033
4AT-82
Rear Drive Shaft
29.Rear Drive Shaft
A: REMOVAL
2) Remove the rear wheel speed sensor, and sep-
arate the extension case from transmission case.
<Ref. to 4AT-71, REMOVAL, Extension Case.>
3) Pull out the rear drive shaft from center differen-
tial assembly.
4) Remove the drive plate and driven plate.
B: INSTALLATION
1) Select shims. <Ref. to 4AT-79, VTD MODEL,
ADJUSTMENT, Transfer Clutch.>
2) Install drive plate and driven plate.
3) Insert the rear drive shaft into the center differen-
tial assembly.
4) Join the transmission case and the extension
case, and then install the rear vehicle speed sen-
sor. <Ref. to 4AT-71, INSTALLATION, Extension
Case.>
C: DISASSEMBLY
1) Using a press, remove the revolution gear.
2) Using a press, remove the front and rear side
ball bearings and the clutch hub.
D: ASSEMBLY
NOTE:
Use new rear ball bearings and revolution gear.
Make sure the clutch hub is facing the correct di-
rection.
E: INSPECTION
Check each part for holes, damage or accumula-
tion of dust.
Inspect the play of the extension end, and adjust
it to be within the standard value. <Ref. to 4AT-79,
VTD MODEL, ADJUSTMENT, Transfer Clutch.>
(A) Rear drive shaft
(A) Revolution gear
AT-02211
(A)
(B)
AT-00149
(A)
(A) Rear ball bearing
(C) Clutch hub
(A) Front side
(B) Clutch hub
(C) Rear side
(D) Revolution gear
AT-00151
(A)
(B)
(C)
AT-00152
(A)
(B)
(C)
(D)
4AT-83
Reduction Driven Gear
30.Reduction Driven Gear
A: REMOVAL
1. MP-T MODEL
3) Set the range select lever to the P range.
4) Lift the crimped section, and then remove the
lock nut.
5) Using the ST1 and ST2, extract the reduction
driven gear.
ST1 499737000 PULLER
ST2 899524100 PULLER SET
2. VTD MODEL
3) Remove the rear drive shaft. <Ref. to 4AT-82,
REMOVAL, Rear Drive Shaft.>
5) Lift the crimped section, and then remove the
lock nut.
6) Using the ST1 and ST2, extract the reduction
driven gear.
7) Pull out the center differential assembly. <Ref. to
4AT-87, 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 drive pinion lock nut.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
3) After tightening, stake the lock nut securely.
Case.>
(A) Reduction driven gear
(B) Reduction drive gear
AT-02212
(A)
(B)
AT-00154
(A)
(B)
ST1
ST2
AT-00155
AT-02212
(A)
(B)
4AT-84
2. VTD MODEL
2) Use a plastic hammer to install reduction driven
gear assembly.
3) Use a plastic hammer to install the center differ-
ential.
4) Install a new self-locking nut and washer.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
5) After tightening, stake the lock nut securely.
6) Insert the rear drive shaft assembly. <Ref. to
4AT-82, INSTALLATION, Rear Drive Shaft.>
Case.>
C: DISASSEMBLY
1) Remove the snap ring from reduction driven
gear.
2) Remove the ball bearing from reduction driven
gear using ST.
3) Remove the snap ring from reduction driven
gear.
D: ASSEMBLY
1) Install the snap ring to reduction driven gear.
2) Install the new ball bearing to reduction driven
gear using press.
3) Install the snap ring to reduction driven gear.
E: INSPECTION
Make sure the ball bearing and gear is not de-
formed or damaged.
(A) Snap ring
AT-00155
AT-00156
(A)
(A) Ball bearing
(A) Ball bearing
(A) Snap ring
AT-00157
(A)
ST
AT-00158
(A)
AT-00156
(A)
4AT-85
Reduction Drive Gear
31.Reduction Drive Gear
A: REMOVAL
3) Remove the reduction driven gear. <Ref. to 4AT-
83, REMOVAL, Reduction Driven Gear.>
4) Using the ST, extract the reduction drive gear
assembly.
B: INSTALLATION
1) Install the reduction drive gear assembly.
NOTE:
Press-fit it to the bottom of bearing shoulder com-
pletely.
2) Install the reduction driven gear. <Ref. to 4AT-
83, INSTALLATION, Reduction Driven Gear.>
Case.>
C: DISASSEMBLY
1) Take out the seal ring.
2) Remove the ball bearing using ST.
3) Apply vaseline to the outer surface of seal ring
and shaft groove.
(A) Reduction drive gear ASSY
(A) Reduction drive gear ASSY
AT-00159
(A)
ST2
ST1
AT-02213
(A)
(A) Seal ring
(B) Reduction drive shaft
(A) Ball bearing
(A) Reduction drive gear
AT-00161
(A)
(B)
AT-00162
(A)
(B)
ST
AT-00163
(A)
4AT-86
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 onto the seal ring outer surface
and shaft grooves.
4) Apply ATF to new seal rings and install them.
E: INSPECTION
Rotate the bearing by hand, and check that it ro-
tates smoothly.
Check parts for holes, damage or adhesion of
dust and other foreign particles.
the standard value. <Ref. to 4AT-79, ADJUST-
MENT, Transfer Clutch.>
(A) Seal ring
(B) Reduction drive shaft
AT-00161
(A)
(B)
4AT-87
Center Differential Carrier
32.Center Differential Carrier
A: REMOVAL
3) Extract the rear drive shaft. <Ref. to 4AT-82, RE-
MOVAL, Rear Drive Shaft.>
4) Using ST, pull out the center differential carrier
assembly.
5) Pull out the shim(s) from transmission case.
B: INSTALLATION
1) Install the center differential assembly together
with shims.
NOTE:
Press-fit it to the bottom of bearing shoulder com-
pletely.
2) Insert the rear drive shaft. <Ref. to 4AT-82, IN-
STALLATION, Rear Drive Shaft.>
Case.>
C: DISASSEMBLY
2) Using a press and ST, remove the ball bearing.
3) Remove the snap ring, and pull out the shaft
from center differential assembly.
AT-00164
ST2
ST1
AT-00165
(A) Seal ring
(A) Snap ring
(B) Shaft
AT-00166
(A)
AT-00167
AT-00168
(A)
(B)
4AT-88
4) Remove the thrust washers, pinion gears and
washers from center differential assembly.
5) Pull out the intermediate shaft and thrust bear-
ing.
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 as-
sembly.
6) Using a press, install a new ball bearing into the
center differential assembly.
and shaft grooves.
8) Install a new seal ring.
E: INSPECTION
Check each part for holes, damage or accumula-
tion of dust.
Inspect the play of the extension end, and adjust
it to be within the standard value. <Ref. to 4AT-79,
VTD MODEL, ADJUSTMENT, Transfer Clutch.>
(A) Pinion gear
(A) Plate
AT-00169
(A)
AT-00170
(A)
(B)
ST
4AT-89
Parking Pawl
33.Parking Pawl
A: REMOVAL
3) Remove the reduction drive gear. (MP-T model)
<Ref. to 4AT-85, REMOVAL, Reduction Drive
Gear.>
4) Remove the center differential carrier. (VTD
model) <Ref. to 4AT-87, REMOVAL, Center Differ-
ential Carrier.>
5) Remove the parking pawl, return spring and
shaft.
B: INSTALLATION
1) Install the parking pawl, return spring and shaft.
2) Install the reduction drive gear. (MP-T model)
<Ref. to 4AT-85, INSTALLATION, Reduction Drive
Gear.>
3) Install the center differential carrier. (VTD model)
<Ref. to 4AT-87, INSTALLATION, Center Differen-
tial Carrier.>
4) Install the rear vehicle speed sensor and exten-
sion case. <Ref. to 4AT-71, INSTALLATION, Ex-
tension Case.>
C: INSPECTION
Check the tab of the parking pole on the reduction
gear for wear or other damage.
(A) Return spring
(B) Parking pawl
AT-02214
(B) (A)
(A) Return spring
(B) Parking pawl
AT-02214
(B) (A)
4AT-90
Converter Case
34.Converter Case
A: REMOVAL
2) Pull out the torque converter assembly. <Ref. to
4AT-70, REMOVAL, Torque Converter Assembly.>
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.
6) Remove the air breather hose. <Ref. to 4AT-68,
REMOVAL, Air Breather Hose.>
7) Remove the oil charge pipe. <Ref. to 4AT-69,
REMOVAL, Oil Charge Pipe.>
8) Remove the ATF inlet and outlet pipes. <Ref. to
4AT-65, REMOVAL, ATF Cooler Pipe and Hose.>
9) Remove the converter case alignment bolt, and
then separate the transmission case and converter
case by lightly tapping with a plastic hammer.
NOTE:
Be careful not to damage the oil seal and bush-
ing in the converter case with the oil pump cover.
Do not loosen the rubber seal.
10) Remove the seal pipe.
11) Remove the front differential assembly. <Ref.
to 4AT-104, REMOVAL, Front Differential Assem-
bly.>
12) Remove the oil seal from converter case.
B: INSTALLATION
1) Check the appearance of each component and
clean them.
2) Press-fit the new oil seal to the converter case
using the ST.
ST 398437700 DRIFT
(B) Inhibitor switch connector
AT-00114
AT-01351
(B)
(A)
(A) Seal pipe
AT-00175
AT-00176
AT-00177
4AT-91
Converter Case
3) Install the front differential assembly to the case.
<Ref. to 4AT-104, INSTALLATION, Front Differen-
tial Assembly.>
4) Install the right and left side retainers. <Ref. to
4AT-108, ADJUSTMENT, Front Differential As-
sembly.>
5) Install new seal pipe to converter case.
6) Install the rubber seal to converter case.
tire matching surface of converter case.
Liquid gasket:
equivalent
8) Install the converter case without damaging
bushing and oil seal.
Tightening torque:
Oil charge pipe section
38 Nm (3.9 kgf-m, 28.0 ft-lb)
Excluding the oil charge pipe section
41 Nm (4.2 kgf-m, 30.2 ft-lb)
9) Insert the inhibitor switch and transmission har-
ness connector to the stay.
10) Install the air breather hose. <Ref. to 4AT-68,
INSTALLATION, Air Breather Hose.>
11) Install the ATF cooler pipe. <Ref. to 4AT-66, IN-
STALLATION, ATF Cooler Pipe and Hose.>
12) Install the oil charge pipe with O-ring. <Ref. to
4AT-69, INSTALLATION, Oil Charge Pipe.>
13) Insert the input shaft while rotating it lightly by
hand, and then check the amount of protrusion.
50 55 mm (1.97 2.17 in)
14) Install the torque converter assembly. <Ref. to
4AT-70, INSTALLATION, Torque Converter As-
sembly.>
15) Install the transmission assembly to the vehi-
cle. <Ref. to 4AT-39, INSTALLATION, Automatic
C: INSPECTION
Measure the backlash, and then adjust it to be with-
in standard values. <Ref. to 4AT-101, ADJUST-
MENT, Drive Pinion Shaft Assembly.>
(A) Seal pipe
(A) Rubber seal
(A) THREE BOND 1215
(B) Rubber seal
AT-00176
AT-00178
(A)
(B)
(A)
AT-00179
AT-00175
AT-00291
A
4AT-92
Oil Pump Housing
35.Oil Pump Housing
A: REMOVAL
harness connector, and then remove it from the
stay.
stay.
8) Separate the converter case and transmission
case. <Ref. to 4AT-90, REMOVAL, Converter
Case.>
case section. <Ref. to 4AT-71, REMOVAL, Exten-
sion Case.>
10) Remove the reduction drive gear. (MP-T mod-
el) <Ref. to 4AT-85, REMOVAL, Reduction Drive
Gear.>
ential Carrier.>
12) Remove the reduction driven gear. <Ref. to
4AT-83, REMOVAL, Reduction Driven Gear.>
13) Loosen the oil pump housing mounting bolts.
14) Place two wooden blocks on the workbench,
and stand the transmission case with the rear end
facing down.
NOTE:
Be careful not to scratch the rear mating surface
of the transmission case.
Check the height of the wooden blocks to avoid
damaging the parking rod protruding from the mat-
ing surface, and the drive pinion.
15) Remove the oil pump housing and adjusting
thrust washer.
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)
AT-00114
AT-01034
(A) Oil pump housing
(A) Oil pump housing
AT-00181
(2.17in)
55mm
AT-00182
(A)
AT-01035
(A)
4AT-93
Oil Pump Housing
2) Install the converter case to the transmission
case assembly. <Ref. to 4AT-90, INSTALLATION,
Converter Case.>
Gear.>
tial Carrier.>
Case.>
9) Install the oil charge pipe together with an O-
ring. <Ref. to 4AT-69, INSTALLATION, Oil Charge
Pipe.>
50 55 mm (1.97 2.17 in)
sembly.>
C: DISASSEMBLY
1. OIL PUMP COVER
1) Remove the four seal rings.
2) Remove attachment bolts, then remove the cov-
er by lightly tapping the end of the stator shaft.
3) Remove the oil pump inner rotor and outer rotor.
AT-01351
(B)
(A)
AT-00291
A
(A) Seal ring
(A) Oil pump cover
(B) Oil pump housing
(A) Inner rotor
(B) Outer rotor
AT-00189
(A)
AT-00190
(A)
(B)
AT-01036
(A)
(B)
4AT-94
Oil Pump Housing
2. OIL SEAL RETAINER
1) Remove the oil seal retainer.
2) Remove the O-ring.
3) Remove the oil seal from the oil seal retainer.
D: ASSEMBLY
1. OIL PUMP COVER
1) Install the oil pump rotor assembly to oil pump
housing.
2) Align both pivots with the pivot holes of the cov-
er, and then install the oil pump cover while being
careful not to apply excessive force to the pivots.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
3) After assembling, turn the oil pump shaft to
check for smooth rotation of rotor.
(A) Oil seal retainer
(B) Drive pinion shaft
(A) O-ring
(A) Oil seal
(B) Oil seal retainer
AT-00183
(A)
(B)
AT-03361
(A)
AT-03360
(A)
(B)
(A) Inner rotor
(B) Outer rotor
(A) Oil pump cover
(B) Oil pump housing
AT-01036
(A)
(B)
AT-00190
(A)
(B)
4AT-95
Oil Pump Housing
4) Apply vaseline to the oil seal retainer and new
seal rings, and install them. After installing, adjust
the tooth contact with the drive pinion backlash.
<Ref. to 4AT-96, ADJUSTMENT, Oil Pump Hous-
ing.>
NOTE:
There are two types of seals. They are identified by
color. Install at the proper positions by referring to
the figure.
2. OIL SEAL RETAINER
1) Apply ATF to two new oil seals and install them
to the oil seal retainer in the proper direction using
the ST.
2) Apply ATF to a new O-ring and attach to the oil
seal retainer. Install the seal to the oil pump hous-
ing bore.
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)
(A) Seal ring (Black)
(B) Seal ring (Brown)
(A) Oil seal
(B) Oil seal retainer
AT-01307
(A)
(B)
AT-03360
(A)
(B)
(A) O-ring
(A) Oil seal retainer
(B) Drive pinion shaft
AT-03361
(A)
AT-00183
(A)
(B)
4AT-96
Oil Pump Housing
E: INSPECTION
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 inner rotor and outer rotor to the oil
pump. With rotor gears facing each other, mea-
sure the crest-to-crest clearance.
Tip clearance:
0.02 0.15 mm (0.0008 0.0059 in)
(2) Side clearance
Set a depth gauge to oil pump housing, then
measure the oil pump housing-to-rotor clear-
ance.
Side clearance:
0.02 0.04 mm (0.0008 0.0016 in)
(3) If the depth and/or side clearance are not
within the specification, replace the rotor as-
sembly.
Measure the total end play and adjust it to be
within specifications. <Ref. to 4AT-96, AD-
JUSTMENT, Oil Pump Housing.>
F: ADJUSTMENT
1) Using the ST, measure the length L, from the
mating surface of the transmission to the recessed
portion of the high clutch drum.
ST 398643600 GAUGE
2) Using the ST, measure the length from the oil
pump housing mating surface to the top surface of
the oil pump cover with the thrust needle bearing.
ST 398643600 GAUGE
(A) Thickness gauge
(B) Inner rotor
(C) Outer rotor
(A) Depth gauge
(B) Inner rotor
(C) Outer rotor
AT-01038
(B)
(C)
(A)
AT-01039
(A)
(B)
(C)
Oil pump rotor assembly
15008AA060 11.37 11.38 (0.4476 0.4480)
15008AA070 11.38 11.39 (0.4480 0.4484)
15008AA080 11.39 11.40 (0.4484 0.4488)
AT-00194
L
ST
AT-00195
ST
4AT-97
Oil Pump Housing
3) Calculation of total end play
Select a suitable bearing race 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
4) After completing the end play adjustment, insert
the bearing race into the high clutch race. Apply va-
seline, and install the thrust needle bearing to the
oil pump cover.
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.
C
Clearance between concave section of high
clutch and end of clutch drum support
L
Length from case mating surface to the concave
portion of the high clutch
G Gasket thickness [0.28 mm (0.0110 in)]
2
Height from the oil pump housing mating sur-
face to the upper surface of the oil pump cover
with the thrust needle bearing.
Thrust needle bearing
806528050 4.1 (0.161)
806528060 4.3 (0.169)
806528070 4.5 (0.177)
806528080 4.7 (0.185)
806528090 4.9 (0.193)
806528100 5.1 (0.201)
AT-00196
G
L
4AT-98
Drive Pinion Shaft Assembly
36.Drive Pinion Shaft Assembly
A: REMOVAL
stay.
the stay.
6) Disconnect the air breather hose. <Ref. to 4AT-
68, REMOVAL, Air Breather Hose.>
Case.>
case section. <Ref. to 4AT-71, REMOVAL, Exten-
sion Case.>
11) Remove the reduction drive gear. (MP-T mod-
el) <Ref. to 4AT-85, REMOVAL, Reduction Drive
Gear.>
ential Carrier.>
13) Remove the reduction driven gear. <Ref. to
4AT-83, REMOVAL, Reduction Driven Gear.>
14) Remove the drive pinion shaft mounting bolt
and remove the drive shaft assembly from oil pump
housing.
B: INSTALLATION
1) Assemble the drive pinion shaft assembly to the
oil pump housing.
NOTE:
Be careful not to bend the shim.
Be careful not to press-fit the pinion into housing
bore.
Tightening torque:
40 Nm (4.0 kgf-m, 29.5 ft-lb)
2) Join the torque converter case with the transmis-
sion case. <Ref. to 4AT-90, INSTALLATION, Con-
verter Case.>
Gear.>
tial Carrier.>
Case.>
8) Install the air breather hose. <Ref. to 4AT-68, IN-
STALLATION, Air Breather Hose.>
AT-00114
AT-01252
AT-01252
4AT-99
9) Install the ATF inlet and outlet pipes. <Ref. to
4AT-66, INSTALLATION, ATF Cooler Pipe and
Hose.>
10) Install the oil charge pipe with O-ring.
50 55 mm (1.97 2.17 in)
sembly.>
C: DISASSEMBLY
1) Flatten the lock nut tab, 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
3) Separate the rear roller bearing and outer race
from the drive pinion shaft using a press.
4) Separate the front roller bearing from the drive
pinion shaft using a press and the ST.
ST 498517000 REPLACER
AT-00291
A
(A) Outer race
(A) Front roller bearing
AT-00197
ST1
ST3
ST2
AT-00198
(A)
AT-00199
(A)
ST
4AT-100
D: ASSEMBLY
1) Measure the dimension A of the drive pinion
shaft.
ST 398643600 GAUGE
2) Using a press, press-fit the new roller bearing
into the specified position.
CAUTION:
Damage may result if too much force is applied
to the roller bearing.
3) After applying ATF to a new O-ring and attaching
it 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.
5) Tighten a new lock nut using the ST.
Calculate the lock washer and lock nut specifica-
tions 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:
NOTE:
Attach ST2 to torque wrench as straight as possi-
ble.
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, re-
place the roller bearing.
Starting torque:
7.6 38.1 N (0.776 3.88 kgf, 1.7 8.6 lb)
7) Crimp the locknut in two locations.
(A) Drive pinion shaft
(B) Roller bearing
A
AT-00200
AT-00201
(B)
(A)
m (in)
Tightening torque
Nm (kgf-m, ft-lb)
0.4 (15.75) 98 (10.0, 72)
0.45 (17.72) 100 (10.2, 73.8)
0.5 (19.69) 101 (10.3, 74.5)
0.55 (21.65) 102 (10.4, 75)
ST1
AT-00202
L1 [m (in)]
L2 [m (in)]
ST2
ST3
AT-00203
4AT-101
8) Measure the dimension B of the drive pinion
shaft.
ST 398643600 GAUGE
9) Calculate the thickness t (mm) of the drive pin-
ion shim.
t = 6.50.0625 (B A)
10) Select three or less shims from following table.
E: INSPECTION
Make sure that all component parts are free of
scratches, holes and other faults.
Adjust the tooth alignment. <Ref. to 4AT-101,
ADJUSTMENT, Drive Pinion Shaft Assembly.>
F: ADJUSTMENT
1) Remove the liquid gasket from the mating sur-
face completely.
2) Install the oil pump housing assembly to the con-
verter 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.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
3) Rotate the drive pinion a few times using ST1
and ST2.
4) Adjust the drive pinion and hypoid driven gear
backlash. <Ref. to 4AT-108, ADJUSTMENT, Front
Differential Assembly.>
Drive pinion shim
31451AA050 0.150 (0.0059)
31451AA060 0.175 (0.0069)
31451AA070 0.200 (0.0079)
31451AA080 0.225 (0.0089)
31451AA090 0.250 (0.0098)
31451AA100 0.275 (0.0108)
B
AT-00204
AT-00205
AT-00206
ST2
ST1
4AT-102
5) Apply lead-free red dye evenly on the surface of
three to four teeth of the 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 4AT-
108, ADJUSTMENT, Front Differential Assembly.>
Correct tooth contact
Check item: Tooth contact surface is slightly
shifted toward the toe side under a no-load con-
dition. (When driving, it moves towards the heel
side.)
Face contact
Check item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of the pinion
height adjusting washer according to the proce-
dures for moving the drive pinion shaft closer to the
hypoid driven gear.
Flank contact
Check item: Backlash is too small.
Contact pattern
Corrective action: Reduce the thickness of the pin-
ion height adjusting washer according to the proce-
dures for moving the drive pinion shaft away from
the hypoid driven gear.
(A) Toe side
(B) Heel side
(A)
(B)
MT-01401
AT-00208
AT-00212
AT-00209
AT-00213
4AT-103
Toe contact (inside contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of the pin-
dures for moving the drive pinion shaft away from
Heel contact (outside end contact)
Contact pattern
Corrective action: Increase the thickness of the pin-
dures for moving the drive pinion shaft closer to the
hypoid driven gear.
6) If tooth contact is correct, mark the differential
side retainer position and loosen. After fitting a new
O-ring and oil seal, screw in the differential side re-
tainer to the marked position. Tighten the lock plate
with specified torque.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-00210
AT-00213
(A) Lock plate
AT-00211
AT-00212
AT-00214
(A)
4AT-104
Front Differential Assembly
37.Front Differential Assembly
A: REMOVAL
stay.
5) Remove the inhibitor switch from the stay.
8) Separate the converter case from the transmis-
sion case. <Ref. to 4AT-90, REMOVAL, Converter
Case.>
9) Remove the seal pipe.
10) Remove the differential side retainers using
ST.
ST 18630AA010 WRENCH COMPL
RETAINER
NOTE:
ST WRENCH ASSEMBLY (499787000) can
also be used.
Hold the differential case assembly by hand to
avoid damaging the retainer mounting hole of the
converter case.
11) Remove the front differential assembly while
being careful not to damage the attachment part of
the retainer.
B: INSTALLATION
1) Install the front differential assembly to the con-
verter case.
NOTE:
Be careful not to damage the inside of the convert-
er case (especially the mating surface of the differ-
ential side retainer).
2) Install the O-ring to left and right side differential
retainers.
3) Install the differential side retainers using the ST.
<Ref. to 4AT-108, ADJUSTMENT, Front Differen-
tial Assembly.>
RETAINER
NOTE:
ST WRENCH ASSEMBLY (499787000) can also
be used.
4) Adjust the backlash of the front differential. <Ref.
to 4AT-108, ADJUSTMENT, Front Differential As-
sembly.>
5) Install the lock plate.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-00114
(A) Front differential ASSY
(A) Lock plate
AT-00215
(A)
AT-00214
(A)
4AT-105
6) Install new seal pipe to converter case.
case. <Ref. to 4AT-90, INSTALLATION, Converter
Case.>
Pipe.>
50 55 mm (1.97 2.17 in)
sembly.>
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Remove the taper roller bearing using the ST
and a press.
2) Secure the case in a vise, remove the hypoid
driven gear tightening bolts, and then separate the
hypoid driven gear into differential case (RH) and
differential case (LH).
3) Pull out the straight pin and pinion shaft, then re-
move the differential bevel gear, washer and differ-
ential bevel pinion.
(A) Seal pipe
AT-00176
AT-01351
(B)
(A)
AT-00291
A
(A) Hypoid driven gear
(B) Differential case (RH)
(C) Differential case (LH)
(A) Differential case (RH)
AT-00216
(B)
AT-00217
(A)
(C)
AT-00218
(A)
4AT-106
2. SIDE RETAINER
NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
3) Remove the split pin, and then remove the claw.
4) Attach the two claws to the outer race, and set
the ST on the differential side retainer.
5) Restore the removed claws to original position,
and install the pin and split pin.
6) Hold the shaft of ST to avoid detachment from
the differential side retainer, and remove the bear-
ing outer race.
NOTE:
Replace the bearing inner and outer races as a sin-
gle unit.
(A) Claw
(B) Split pin
(C) Pin
AT-00219
AT-00220
AT-00221
(A) Shaft
(B) Claw
(A) Shaft
(B) Side retainer
AT-00222
AT-00223
4AT-107
D: ASSEMBLY
1) Install the washer, differential bevel gear and dif-
ferential bevel pinion in the differential case (RH).
Insert the pinion shaft.
2) Attach the straight pin in the reverse direction.
3) Install the washer and differential bevel gear to
the differential case (LH). Put the differential case
(RH) on the case, and assemble two cases.
4) Install the hypoid driven gear and secure by
tightening the bolt.
Tightening torque:
62 Nm (6.3 kgf-m, 45.7 ft-lb)
5) Measurement of backlash (Selection of washer)
(1) Install the SUBARU genuine axle shaft to
differential case.
Part No. 38415AA070 AXLE SHAFT
(2) Measure the gear backlash using ST1 and
ST2, and then insert the ST2 though the access
window of case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
Place the tooth of the differential bevel pinion
against 2 teeth of the differential bevel gear, and
measure the backlash.
When measuring, fix the differential bevel pinion
gear in place with a screwdriver covered with waste
cloth, or a similar tool.
Standard:
0.13 0.18 mm (0.0051 0.0071 in)
(3) If the backlash is out of specification, select
a washer from the table below.
6) Using the ST, install the taper roller bearing.
AT-00218
(A)
(B)
AT-00217
(A)
(C)
Washer
803038021 0.95 (0.037)
803038022 1.00 (0.039)
803038023 1.05 (0.041)
(A) Taper roller bearing
AT-00224
ST2
ST1
AT-04377
4AT-108
2. SIDE RETAINER
1) Install the bearing outer race to the differential
side retainer.
2) Install a new oil seal using the ST and a hammer.
SEAL INSTALLER
3) Apply gear oil to a new O-ring and install.
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-108, ADJUSTMENT, Front Differen-
tial Assembly.>
F: ADJUSTMENT
1) Using the ST, screw-in the differential side re-
tainer until resistance is felt.
RETAINER
NOTE:
Screw-in the RH side slightly deeper than the LH
side.
ST WRENCH ASSEMBLY (499787000) can
also be used.
2) Remove the oil pump housing.
face completely.
4) Install the oil pump housing assembly to the con-
verter case, and secure them by tightening the four
bolts evenly.
NOTE:
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
AT-00226
ST
AT-00219
AT-00227
ST
AT-00205
4AT-109
and ST2.
6) Tighten the LH differential side retainer by rotat-
ing the shaft until resistance is felt. Then loosen the
RH side differential side retainer. Tighten the LH
differential side retainer until the pinion shaft no
longer turns, and continue to loosen the RH side.
This is the zero state.
7) After reaching the zero state, loosen the LH dif-
ferential side retainer by three notches and secure
it with the lock plate. Then after returning the RH
differential side retainer, retighten until it stops. Ro-
tate the drive pinion 2 or 3 times. Tighten the RH
differential side retainer further by 1-3/4 notches.
This sets the preload. Finally, secure the differen-
tial side retainer with the lock plate.
NOTE:
Turning the differential side retainer by one notch
changes the backlash approx. 0.05 mm (0.0020 in).
8) Install the Subaru genuine axle shafts to the right
and left sides of the front differential.
Install the axle shaft to both sides of the front differ-
ential section.
9) Turn the drive pinion several times using ST1,
and check to see if the backlash is within the spec-
ification using ST2, ST3, ST4 and ST5.
ST5 498255400 PLATE
Backlash:
0.13 0.18 mm (0.0051 0.0071 in)
10) Adjust the teeth contact of the front differential
and drive shaft. <Ref. to 4AT-101, ADJUSTMENT,
Drive Pinion Shaft Assembly.>
(A) Differential side retainer
(A) Lock plate
AT-00206
ST2
ST1
AT-00229
(A)
AT-00214
(A)
0.05 mm
(0.0020 in)
AT-00230
AT-00231
ST5
ST3
ST2
ST1
ST4
4AT-110
AT Main Case
38.AT Main Case
A: REMOVAL
stay.
the stay.
Case.>
10) Remove the oil pump housing.
<Ref. to 4AT-92, REMOVAL, Oil Pump Housing.>
11) Take out the high clutch, thrust needle bearing
and reverse clutch assembly.
12) Take out the high clutch hub and thrust bear-
ing.
13) Take out the front sun gear and thrust needle
bearing.
14) Pull out while being careful not to break the leaf
spring of the 2-4 brake.
(A) High clutch and reverse clutch ASSY
(B) Thrust needle bearing
AT-00114
AT-00232
(B)
(A)
(A) High clutch hub
(A) Front sun gear
(A) Leaf spring
(B) Retaining plate
AT-00233
(A)
(B)
AT-00251
(A)
(B)
AT-00252
(A)
(B)
4AT-111
AT Main Case
15) Remove the snap ring and thrust needle bear-
ing.
16) Take out the retaining plate, drive plate and
driven plate of the 2-4 brake.
17) Take out the thrust needle bearing, planetary
gear assembly and low clutch assembly.
18) Remove the 2-4 brake seal.
20) Take out the 2-4 brake spring retainer.
21) Remove the 2-4 brake piston and 2-4 brake
piston retainer while taking care not to damage
them.
(A) Snap ring
AT-00253
(A)
(B)
AT-00254
AT-00255
AT-02215
(A) Snap ring
(B) 2-4 brake piston
(A) 2-4 brake piston
(B) 2-4 brake piston retainer
AT-00285
(B)
(A)
AT-00286
AT-00287
(A)
(B)
4AT-112
AT Main Case
22) Pull out the leaf spring of the low & reverse
brake while being careful not to bend it.
24) Take out the retaining plate, drive plate, driven
plate and dish plate of the low & reverse brake.
25) Turn the transmission case upside down, and
then take out the socket bolts while holding the
one-way clutch inner race by hand.
26) Remove the spring retainer.
27) Take out the return spring.
28) Apply compressed air.
29) Take out the low & reverse brake piston.
(A) Leaf spring
(A) Snap ring
AT-00293
(A)
AT-00294
( A)
AT-00295
AT-00296
AT-00302
AT-00301
AT-00297
AT-00300
4AT-113
AT Main Case
B: INSTALLATION
1) Install the low & reverse brake piston.
NOTE:
Take care not to damage the lip seal.
Apply ATF to the lip.
2) Install the return spring.
3) Install the spring retainer.
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, 18.4 ft-lb)
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 retaining plate, 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 weighing less than 8.5 kgf (18.7
lb).
11) Put the flat board on retaining plate.
12) Using the following formula, read the push/pull
gauge, and calculate N.
N = 83 N (8.5 kgf, 18.7 lb) Z
N: Value indicated on push/pull gauge
83 N (8.5 kgf, 18.7 lb) : Load applied to clutch plate
Z: Flat board weight
AT-00300
AT-00301
AT-00302
AT-00296
AT-01720
4AT-114
AT Main Case
13) Press the center of retaining plate by applying a
force of N using push/pull gauge, and then mea-
sure and record the height A. Measure at three or
more locations spaced by equal distances and take
the average value.
NOTE:
If measuring in three locations, measure every
120. If measuring in four locations, measure every
90.
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.
15) Apply compressed air intermittently to check for
operation.
16) Place same thickness shims on both sides to
prevent plate from tilting, then measure and record
the clearance B.
NOTE:
Do not push in the shim down with force to a point
where the waves on the drive plate will be crushed.
17) Piston stroke calculation
Calculate with A and B dimensions recorded be-
fore. If the calculated value exceeds the service
limit, replace the drive plate with a new part and ad-
just it within the initial specification.
T = A + B
T: Piston stroke
A: Amount of drive plate compression
B: Clearance between retaining plate and snap ring
Initial standard:
2.15 2.65 mm (0.085 0.104 in)
Limit thickness:
2.95 mm (0.116 in)
(A) Dish plate
(B) Driven plate
(C) Drive plate
(D) Retaining plate
(A) Snap ring
AT-01721
(B)
(D)
(C)
(A)
A
AT-00294
( A)
Retaining plate
31667AA420 3.8 (0.150)
31667AA320 4.1 (0.161)
31667AA330 4.4 (0.173)
31667AA340 4.7 (0.185)
31667AA350 5.0 (0.197)
31667AA360 5.3 (0.209)
31667AA370 5.6 (0.220)
31667AA380 5.9 (0.232)
AT-00297
AT-02216
B
4AT-115
AT Main Case
18) Install the leaf spring of the low & reverse
brake.
19) Install the 2-4 brake piston and 2-4 brake re-
tainer by aligning the hole of the 2-4 brake retainer
with the hole on the transmission case.
20) Install the 2-4 brake piston spring retainer to
the transmission case.
21) Position the snap ring in the transmission. Us-
ing ST, press the snap ring into the specified loca-
tion.
ST 498677100 COMPRESSOR
22) Install the planetary gear and low clutch as-
sembly to the transmission case.
CAUTION:
When installing while rotating the low clutch
and planetary gear assembly, rotate slowly and
be careful not to damage the seal ring.
23) Place the dish plate, driven plate, drive plate
and retaining plate neatly in this order on surface
table.
its scale.
NOTE:
zero point.
NOTE:
Use a flat board weighing less than 10.2 kgf
(22.5 lb).
(A) Leaf spring
AT-00293
(A)
AT-00287
(A)
(B)
AT-00286
AT-00289
ST
AT-00255
4AT-116
AT Main Case
N = 100 N (10.2 kgf, 22.5 lb) Z
100 N (10.2 kgf, 22.5 lb) : Load applied to clutch
plate
the average value.
NOTE:
90.
29) Install the pressure plate, drive plate, driven
plate, retaining plate and snap ring.
30) Install a new 2-4 brake oil seal to the transmis-
sion case.
31) After all 2-4 brake component parts have been
installed, blow in air intermittently and confirm the
operation of the brake.
32) Measure the clearance B between the retaining
plate and snap ring.
(A) Driven plate
(B) Drive plate
(C) Retaining plate
AT-01720
AT-01723
(C)
(B)
(A)
A
AT-00254
AT-02215
AT-00290
AT-01724
B
4AT-117
AT Main Case
T = A + B
T: Piston stroke
Initial standard:
1.7 2.1 mm (0.067 0.083 in)
Limit thickness:
2.3 mm (0.091 in)
34) Be careful not to mistake the location of the leaf
spring to be installed.
35) Install the thrust needle bearing in the correct
direction.
36) Install the front sun gear and the thrust needle
bearing.
37) Apply vaseline, and attach the thrust needle
bearing to the high clutch hub, then engage the
splines of the front planetary carrier correctly to in-
stall the high clutch hub.
Retaining plate
31567AA991 5.6 (0.220)
31567AB001 5.8 (0.228)
31567AB011 6.0 (0.236)
31567AB021 6.2 (0.244)
31567AB031 6.4 (0.252)
31567AB041 6.6 (0.260)
(A) Leaf spring
(B) Retaining plate
AT-00252
(A)
(B)
(A) Snap ring
(C) Upside
(D) Downside
(E) Outside
(A) Front sun gear
(C) Upside
(D) Downside
(E) Outside
AT-02217
(A)
(B)
(C)
(D)
(E)
AT-02218
(A)
(B)
(C)
(D)
(E)
4AT-118
AT Main Case
direction.
39) Install the high clutch and reverse clutch as-
sembly.
40) Adjust the total end play. <Ref. to 4AT-96, AD-
direction.
42) Install a new gasket along with the oil pump
housing assembly. <Ref. to 4AT-92, INSTALLA-
TION, Oil Pump Housing.>
case assembly. <Ref. to 4AT-90, INSTALLATION,
Converter Case.>
Pipe.>
50 55 mm (1.97 2.17 in)
sembly.>
(A) High clutch hub
(C) Upside
(D) Downside
(E) Outside
(C) Upside
(D) Downside
(E) Outside
AT-02219
(C)
(D)
(E)
(A)
(B)
AT-00235
(A)
AT-02220
(A)
(B)
(C)
(D)
(E)
AT-01351
(B)
(A)
AT-00291
A
4AT-119
AT Main Case
C: DISASSEMBLY
1) Remove the snap ring, and then take out the re-
taining plate, drive plate and driven plate.
2) Remove the snap ring, and then take out the re-
taining plate, drive plate and driven plate.
3) Using the ST1 and ST2, remove the snap ring.
ST2 498627100 SEAT
4) Take out the clutch cover, spring retainer, high
clutch piston and reverse clutch piston.
5) Remove the seal ring and lip seal from the high
clutch piston and reverse clutch piston.
2. PLANETARY GEAR AND LOW CLUTCH
1) Remove the snap ring from low clutch drum.
(A) Snap ring
(A) Snap ring
(A) Snap ring
AT-00236
(A)
AT-00237
(A)
AT-00238
(A)
ST1
ST2
(A) Reverse clutch piston
(B) Clutch cover
(C) Return spring
(A) High clutch piston
(B) Reverse clutch piston
(A) Snap ring
(B) Low clutch drum
AT-00239
(A)
(B)
(C)
AT-00240
(A)
(B)
AT-00259
(A)
(B)
4AT-120
AT Main Case
2) Take out the front planetary carrier.
3) Take out the rear sun gear.
4) Take out the rear planetary carrier, washer and
thrust needle bearing.
5) Take out the rear internal gear.
6) Remove the snap ring from low clutch drum.
7) Compress the spring retainer of the low & re-
verse brake, and remove the snap ring from the low
clutch drum using ST1 and ST2.
ST1 498627100 SEAT
8) Remove the one-way clutch. <Ref. to 4AT-110,
REMOVAL, AT Main Case.>
(A) Front planetary carrier
(B) Low clutch drum
(A) Rear sun gear
(B) Rear planetary carrier
(A) Rear planetary carrier
(B) Low clutch drum
AT-00260
(B)
(A)
AT-00261
(B)
(A)
AT-00262
(B)
(A)
(A) Rear internal gear
(B) Low clutch drum
(A) Snap ring
(B) Low clutch drum
(A) Snap ring
(B) Low clutch drum
AT-00263
(B)
(A)
AT-00264
(B)
(A)
AT-00265
(B)
(A)
ST1
ST2
4AT-121
AT Main Case
9) Install the one-way clutch inner race to the low
clutch drum, and then apply compressed air to re-
move the low clutch piston.
10) Remove the one-way clutch inner race.
11) Remove the one-way clutch after taking out the
snap ring.
12) Remove the needle bearing after taking out the
snap ring.
3. 2-4 BRAKE
Separate the 2-4 brake piston and piston retainer.
4. ONE-WAY CLUTCH INNER RACE
2) Remove the needle bearing using ST.
5. ONE-WAY CLUTCH OUTER RACE
1) Remove the one-way clutch after taking out the
snap ring.
(A) Apply compressed air.
(B) One-way clutch inner race
(A) Snap ring
(B) Plate
(C) One-way clutch
(A) Needle bearing
(B) Snap ring
AT-00266
(B)
(A)
AT-00267
(A)
(C)
(B)
AT-00268
(B)
(A)
(A) One-way clutch inner race
(B) Seal ring
(A) Snap ring
(B) Plate
(C) One-way clutch
AT-00288
( A) ( B)
AT-00298
(B)
(A)
AT-00267
(A)
(C)
(B)
4AT-122
AT Main Case
2) Remove the needle bearing after taking out the
snap ring.
D: ASSEMBLY
1) Install the seal ring and lip seal to the high clutch
piston and reverse clutch piston.
2) Install the high clutch piston to the reverse clutch
piston.
NOTE:
Do not damage the D-ring and lip seal.
3) Install the reverse clutch piston to the high clutch
drum. Align the groove on reverse clutch piston
with the groove on high clutch drum during installa-
tion.
4) Install the spring retainer to the high clutch pis-
ton.
5) Attach the ST to the high clutch piston.
ST 498437000 HIGH CLUTCH PISTON
GUIDE
6) Install the high clutch piston cover while making
sure not to bend the high clutch piston seal.
(A) Needle bearing
(B) Snap ring
(A) High clutch piston
(B) Reverse clutch piston
AT-00268
(B)
(A)
AT-00240
(A)
(B)
(A) Reverse clutch piston
(B) High clutch drum
(A) Spring retainer
(B) High clutch drum
AT-00241
(A)
(B)
AT-00242
(B)
(A)
AT-00243
ST
4AT-123
AT Main Case
7) Install the snap ring using ST1 and ST2.
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON
GUIDE
8) Place the dish plate, driven plate, drive plate and
retaining plate neatly in this order on surface table.
its scale.
NOTE:
zero point.
NOTE:
(56.2 lb).
N = 250 N (25.5 kgf, 56.2 lb) Z
plate
the average value.
NOTE:
90.
14) Install the thickest driven plate to piston side,
and then install the driven plate, drive plate, retain-
ing plate to high clutch drum.
15) Install the snap ring to high clutch drum.
AT-00244
ST1
ST3
ST2
AT-01720
(A) Driven plate
(B) Drive plate
(C) Retaining plate
AT-01725
(C)
(B)
(A)
A
AT-00245
4AT-124
AT Main Case
operation.
17) Measure and record the clearance B between
the retaining plate and snap ring. (High clutch)
At this time, do not press down the retaining plate.
T = A + B
T: Piston stroke
Initial standard:
2.0 2.3 mm (0.079 0.091 in)
Limit thickness:
2.6 mm (0.102 in)
19) Place the dish plate, driven plate, drive plate
and retaining plate neatly in this order on surface
table.
its scale.
NOTE:
zero point.
NOTE:
(33.7 lb).
N =150 N (15.3 kgf, 33.7 lb) Z
plate
(A) Thickness gauge
High clutch retaining plate
31567AA710 4.7 (0.185)
31567AA720 4.8 (0.189)
31567AA730 4.9 (0.193)
31567AA740 5.0 (0.197)
31567AA670 5.1 (0.201)
31567AA680 5.2 (0.205)
31567AA690 5.3 (0.209)
31567AA700 5.4 (0.213)
AT-00246
AT-01726
(A)
B
AT-01720
4AT-125
AT Main Case
the average value.
NOTE:
90.
25) Install the driven plate, drive plate, retaining
plate and snap ring.
operation.
27) Measure and record the clearance B between
the retaining plate and snap ring. (Reverse clutch)
At this time, do not press down the retaining plate.
T = A + B
T: Piston stroke
Initial standard:
1.1 1.4 mm (0.043 0.055 in)
Limit thickness:
1.6 mm (0.063 in)
(A) Driven plate
(B) Drive plate
(C) Retaining plate
AT-01727
(C)
(B)
(A)
A
AT-00247
(A) Thickness gauge
Reverse clutch retaining plate
31567AA910 4.0 (0.157)
31567AA920 4.2 (0.165)
31567AA930 4.4 (0.173)
31567AA940 4.6 (0.181)
31567AA950 4.8 (0.189)
31567AA960 5.0 (0.197)
31567AA970 5.2 (0.205)
31567AA980 5.4 (0.213)
AT-00248
AT-01728
(A)
B
4AT-126
AT Main Case
1) Apply ATF to a new D-ring, and install it to the
low clutch piston.
2) Install the low clutch piston to low clutch drum.
NOTE:
Do not damage the D-ring.
3) Install the spring retainer to low clutch piston.
4) Attach the ST to the low clutch drum.
ST 498437100 LOW CLUTCH PISTON
GUIDE
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
6) Install the dish plate, driven plate, drive plate and
retaining plate, and then secure them with a snap
ring.
7) Check the low clutch for operation.
(1) Remove the one-way clutch. <Ref. to 4AT-
110, REMOVAL, AT Main Case.>
(2) Set the one-way clutch inner race, and apply
compressed air for checking.
(A) Low clutch piston
(B) Low clutch drum
(A) Spring retainer
(B) Low clutch drum
AT-00269
(B)
(A)
AT-00270
(A)
(B)
AT-00271
ST
(A) Snap ring
(B) Low clutch drum
(C) Dish plate
(D) Low clutch piston side
(A) Apply compressed air.
(B) Low clutch drum
AT-00272
ST2
ST3
ST1
AT-02221
(B)
(A)
(C)
(D)
AT-00274
(B)
(A)
4AT-127
AT Main Case
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)
Limit thickness:
1.6 mm (0.063 in)
If the clearance exceeds the service limits, re-
place the drive plate and select and adjust the
retaining plate to within default standard values.
9) Install the washer to the rear internal gear.
10) Install the rear internal gear.
direction.
12) Install the washer by aligning the protrusion of
the washer with the hole of the rear planetary carri-
er.
(A) Thickness gauge
(B) Low clutch drum
Retaining plate
31567AB050 3.8 (0.150)
31567AB060 4.0 (0.157)
31567AB070 4.2 (0.165)
31567AB080 4.4 (0.173)
31567AB090 4.6 (0.181)
(B) Washer
AT-00283
(A)
(B)
AT-00275
(A)
(B)
(B) Low clutch drum
(A) Thrust needle bearing
(B) Low clutch drum
(C) Rear planetary, carrier side
(D) Low clutch piston side
(A) Washer
AT-00276
(B)
(A)
AT-02222
(B)
(D)
(C)
(A)
AT-00278
(A)
(B)
4AT-128
AT Main Case
13) Install the rear planetary carrier to the low
clutch drum.
direction.
15) Install the rear sun gear in the correct direction.
16) Install the thrust needle bearing in the proper
direction.
17) Install the front planetary carrier to the low
clutch drum.
18) Install the snap ring to the low clutch drum.
(A) Rear planetary carrier
(B) Low clutch drum
(A) Rear sun gear side
(B) Rear planetary carrier side
(A) Rear sun gear
AT-00262
(B)
(A)
AT-02223
(B)
(A)
AT-00261
(B)
(A)
(A) Thrust needle bearing
(B) Front planetary carrier
(C) Rear sun, gear side
(D) Front planetary carrier side
(A) Front planetary carrier
(B) Low clutch drum
(A) Snap ring
(B) Front planetary carrier
AT-00280
(A)
(B)
(C)
(D)
AT-00260
(B)
(A)
AT-00281
(B)
(A)
4AT-129
AT Main Case
19) Install the needle bearing, and then secure with
the snap ring.
20) Install the one-way clutch and one-way clutch
inner race, then secure with the snap ring.
21) Set the inner race. Make sure that the clutch
locks in the clockwise direction and rotates freely in
the counterclockwise direction.
3. 2-4 BRAKE
1) Apply ATF to the new D-ring, then install to the 2-
4 brake piston.
2) Install 2-4 brake piston to 2-4 brake piston re-
tainer.
NOTE:
Do not damage the D-ring.
4. ONE-WAY CLUTCH INNER RACE
1) Install the needle bearing to inner race using ST
and a press.
ST 398497701 SEAT
2) Apply vaseline to the groove of the inner race
and to the new seal ring.
3) Install two seal rings to the one-way clutch inner
race.
5. ONE-WAY CLUTCH OUTER RACE
1) Install the needle bearing, and then secure with
the snap ring.
2) Install the one-way clutch, and then secure with
the snap ring.
(A) Needle bearing
(B) Snap ring
(A) Lock
(B) Free
AT-00268
(B)
(A)
AT-00282
(B)
(A)
AT-00288
( A) ( B)
(A) One-way clutch inner race
(B) Seal ring
(A) Needle bearing
(B) Snap ring
ST
AT-00299
AT-00298
(B)
(A)
AT-00268
(B)
(A)
4AT-130
AT Main Case
3) Set the inner race. Make sure that the clutch
locks in the clockwise direction and rotates freely in
the counterclockwise direction.
E: INSPECTION
Drive plate facing for wear or damage
Driven plate for discoloration (burned color)
Snap ring wear and spring retainer deformation
Wear and damage of the lip seal and D-ring
Piston and piston check ball operation
Adjust the total end play. <Ref. to 4AT-96, AD-
Snap ring wear and spring retainer deformation
within specifications. <Ref. to 4AT-96, ADJUST-
MENT, Oil Pump Housing.>
3. 2-4 BRAKE
Snap ring wear, leaf spring setting and break-
age, 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
Snap ring wear, leaf spring setting and break-
age, and spring retainer deformation
Lip seal wear and damage
(A) Lock
(B) Free
AT-00282
(B)
(A)
4AT-131
Transmission Control Device
39.Transmission Control Device
A: REMOVAL
stay.
stay.
7) Wrap vinyl tape around the nipple attached to
the air breather hose.
9) Remove the inhibitor switch.
10) Remove the control valve body assembly.
<Ref. to 4AT-58, REMOVAL, Control Valve Body.>
11) Pull out the straight pin of manual plate.
12) Remove the bolts securing select lever, and
then remove the select lever, manual plate and
parking rod.
NOTE:
Be careful not to damage the lips of press-fitted oil
seal in the case.
13) Remove the detention spring.
B: INSTALLATION
1) Install the detention spring to the transmission
case.
Tightening torque:
6 Nm (0.6 kgf-m, 4.4 ft-lb)
AT-00304
AT-02224
(A) Bolt
(C) Manual plate
(D) Parking rod
AT-02225
(A)
(B)
(C)
(D)
AT-00307
AT-00307
4AT-132
2) Insert the range select lever, then tighten the
bolts.
Tightening torque:
6 Nm (0.6 kgf-m, 4.4 ft-lb)
3) Insert the manual plate and parking rod.
4) Insert a new straight pin to manual plate.
5) Install the oil pan and the control valve assem-
bly. <Ref. to 4AT-59, INSTALLATION, Control
Valve Body.>
6) Turn over the transmission case to its original
position.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
8) Install and adjust the inhibitor switch. <Ref. to
4AT-47, Inhibitor Switch.>
50 55 mm (1.97 2.17 in)
sembly.>
C: INSPECTION
Make sure that the manual lever and detention
spring are not worn or otherwise damaged.
(A) Bolt
(C) Manual plate
(D) Parking rod
AT-00308
AT-02225
(A)
(B)
(C)
(D)
AT-02224
AT-01351
(B)
(A)
AT-00291
A
4AT(diag)-2
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
A: PROCEDURE
Step Check Yes No
1 CHECK PRE-INSPECTION.
occurred using the interview check list. <Ref. to
4AT(diag)-4, Check List for Interview.>
2) Before performing diagnosis, inspect the
following items which may influence AT prob-
lems.
General Inspection <Ref. to 4AT(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 Pres-
sure Test.>
Transfer clutch pressure test <Ref. to 4AT-35,
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.>
Is the unit that is thought to
influence the AT problem work-
ing properly?
each item.
2 ATF TEMPERATURE WARNING LIGHT IN-
SPECTION.
Start the engine and wait for 2 seconds or more.
Is the ATF temperature warning
light blinking?
SPECTION.
2) Check the ATF temperature warning light.
<Ref. to 4AT(diag)-23, INSPECTION, AT Oil
Temp Warning Light Display.>
3) Turn the ignition switch to ON and wait for at
least 2 seconds.
Is the ATF temperature warning
light blinking?
4 CHECK DTC.
Display DTC.
NOTE:
If the communication function of Subaru Select
Monitor cannot be executed normally, check
communication circuit. <Ref. to 4AT(diag)-25,
COMMUNICATION FOR INITIALIZING IM-
POSSIBLE, Diagnostic Procedure for Subaru
Select Monitor Communication.>
Is DTC displayed? Go to step 6.
NOTE:
Record all DTC.
Go to step 5.
5 PERFORM GENERAL DIAGNOSTICS.
1) Inspect using Diagnostic Procedure with-
out Diagnostic Trouble Code (DTC). <Ref. to
4AT(diag)-82, Diagnostic Procedure without
2) Inspect using General Diagnostic Table.
<Ref. to 4AT(diag)-93, General Diagnostic
Table.>
4AT(diag)-20, Inspection Mode.>
4) Display DTC.
Is DTC displayed? Go to step 6. Finish the diagno-
sis.
4AT(diag)-3
1) Inspect using the Diagnostic Procedure
with Diagnostic Trouble Code (DTC). <Ref. to
4AT(diag)-31, Diagnostic Procedure with Diag-
NOTE:
For DTC table, refer to List of Diagnostic Trou-
ble Code (DTC). <Ref. to 4AT(diag)-29, List of
2) Repair the trouble cause.
5) Display DTC.
Is DTC displayed? Inspect using the
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC). <Ref. to
4AT(diag)-31,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
Finish the diagno-
sis.
Step Check Yes No
4AT(diag)-4
A: CHECK
NOTE:
Customers name
Date of purchase
Date of repair
Transmission model Transmission V.I.N.
Odometer reading km (miles)
Frequency Continuous Intermittent ( times a day)
Weather Fine Cloudy Rainy Snowy
Others
( )
Place Highland Suburbs Inner city Uphill Rough road
Others
( )
Ambient air temperature Hot Warm Cool Cold
AT warning light (ATF temperature
warning light)
Blinks continuously Does not blink
Select lever position P R N D SPORT mode
Driving condition Not affected
At racing
While decelerating
At starting
While accelerating
While turning ( RH/
LH)
While idling
While cruising
SPORT mode ON OFF
Symptom No up-shift
No down-shift
No kick down
Vehicle does not move ( Any position Particular position)
Lock-up malfunction
Noise or vibration
Shift shock or slip
Select lever does not move
Others
( )
4AT(diag)-5
General Description
A: CAUTION
Supplemental Restraint System Airbag
The airbag system wiring harness is routed near
the TCM.
CAUTION:
connectors are colored yellow. Do not use an
electric test equipment to check these circuits.
wiring harness when performing TCM diagnos-
tics or servicing.
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
1. BATTERY
Measure the battery voltage and specific gravity of
the electrolyte.
Standard voltage: 12 V or more
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened
securely.
Chassis side
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
3. ATF LEVEL
Make sure that ATF level is the specified amount.
mission Fluid.>
4. FRONT DIFFERENTIAL OIL LEVEL
Make sure the front differential oil level is the spec-
ified amount. <Ref. to 4AT-30, INSPECTION, Dif-
ferential Gear Oil.>
AT-01464
(A) Level gauge
(B) Inspection position when HOT
(C) Upper level
(D) Lower level
(E) Inspection position when COLD
(A) Upper level
(B) Lower level
PI-00105
C
O
L
D
L
F
H
O
T
L
F
(A)
(C)
(D)
(C)
(D)
(E)
(B)
AT-00317
(A)
(B)
L
F
4AT(diag)-6
General Description
5. OPERATION OF SELECT LEVER
Make sure there is no noise, dragging or contact
pattern in each select lever range.
WARNING:
Stop the engine while checking operation of the
select lever.
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
AT-02048
ILLUSTRATION TOOL NUMBER TOOL NAME REMARKS
MONITOR III KIT
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and current.
Oscilloscope Used for measuring the sensor.
ST1B021XU0
4AT(diag)-7
A: LOCATION
1. CONTROL MODULE
(1) Engine control module (ECM) (3) Transmission control module
(TCM)
(5) Body integrated unit
(2) ATF temperature warning light
(AT temperature warning light)
(4) Data link connector
(3) (5) (2)
(1)
AT-01873
(4)
4AT(diag)-8
(1)
AT-01874 AT-03759
(2)
AT-01875
(3)
AT-01877
(4)
AT-01876
(5)
4AT(diag)-9
2. SENSOR
(1) Accelerator pedal position sensor (4) Rear vehicle speed sensor (6) ATF temperature sensor
(2) Front vehicle speed sensor (5) Torque converter turbine speed
sensor
(3) Inhibitor switch
(3) (6)
(5) (1) (2) (4)
AT-02979
4AT(diag)-10
(1)
AT-00375 AT-01474
(2) (4)
(3)
AT-00330
(5)
AT-00331
(6)
AT-00378
4AT(diag)-11
3. SOLENOID
(1) Line pressure linear solenoid (4) Low & reverse duty solenoid (6) Transfer duty solenoid
(2) High clutch duty solenoid (5) Low clutch duty solenoid (7) Lock-up duty solenoid
(3) 2-4 brake duty solenoid
AT-00379
(1)
(2) (3) (4)
(5)
(6)
(7)
(2) (3) (4)
(7) (6) (5)
(1)
AT-00380
4AT(diag)-12
Transmission Control Module (TCM) I/O Signal
5. Transmission Control Module (TCM) I/O Signal
Check with ignition switch ON.
Contents
Measured terminal
(Connector & Terminal No.)
Measuring
condition
Voltage (V) Resistance ()
Positive terminal Ground terminal
Backup power supply
(B55) No. 27 Chassis ground
10 13 (B55) No. 26 Chassis ground
ACC power supply (B55) No. 12 Chassis ground
Ignition
Switch ACC
10 13
Ignition power supply
Ignition
Switch ON
10 13
Inhibitor switch
P range switch (B55) No. 14 Chassis ground
Select lever
P range
Less than 1
Select lever
Except P
range
8 or more
N range switch (B55) No. 11 Chassis ground
Select lever
N range
Less than 1
Select lever
Except N
range
8 or more
R range switch (B55) No. 13 Chassis ground
Select lever
R range
Less than 1
Select lever
Except R
range
8 or more
D range switch (B55) No. 10 Chassis ground
Select lever
D range
Less than 1
Select lever
Except D
range
8 or more
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B55 TO TO
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B54
AT-03733
4AT(diag)-13
ATF temperature sensor (B54) No. 23 (B54) No. 12
ATF temperature
20C
(68F)
3.5 4.3 2.5k 7.0 k
ATF temperature
80C
(176F)
1.0 2.2 300 800
ATF temperature sensor ground (B54) No. 12 Chassis ground 0
Less than 1
(When inserting
connector)
(When
disconnecting
connector)
Rear vehicle speed sensor (B54) No. 26 (B54) No. 15
20 km/h
(12 MPH)
Vehicle speed
at least
2 or more
(AC range)

Rear vehicle speed sensor ground (B54) No. 15 Chassis ground 0
Less than 1
(When inserting
connector)
(When
disconnecting
connector)
Front vehicle speed sensor (B54) No. 27 (B54) No. 16 450 650
Front vehicle speed sensor ground (B54) No. 16 Chassis ground
Torque converter turbine speed
sensor
(B54) No. 1 (B54) No. 2
Engine idling
after warm-up
(D range)
0
450 650
Engine idling
after warm-up
(N range)
1 or more
(AC range)
Torque converter turbine speed
sensor ground
Engine speed signal (B55) No. 11 Chassis ground
Ignition switch
ON (engine
OFF)
Less than 1
Ignition switch
ON (with engine
ON)
5 or more
(AC range)

Line pressure linear solenoid (B54) No. 4 (B54) No. 3
Ignition switch
ON (with engine
OFF) Throttle
fully closed in
R range after
warm-up.
3.7 7.7
4.0 6.0
Ignition switch
ON (with engine
OFF) Throttle
fully opened in
R range after
warm-up.
1.1 5.1
Line pressure linear solenoid
ground
(B54) No. 3 Chassis ground Less than 1 Less than 1
Contents
Measured terminal
Measuring
condition
4AT(diag)-14
Lock-up duty solenoid (B54) No. 6 Chassis ground
When lock up
occurs.
10.5 or more
2.0 4.5
When lock up is
released.
Less than 1
Transfer duty solenoid (B54) No. 5 Chassis ground
With fuse
installed to FWD
switch
Less than 1
2.0 4.5
With fuse
removed from
FWD switch
(1st gear)
2.0 3.0
2-4 brake duty solenoid (B55) No. 4 Chassis ground
P or N range 5.0 or more
2.0 4.5
2nd or 4th gear Less than 1
High clutch duty solenoid (B55) No. 6 Chassis ground
3rd or 4th gear Less than 1
2.0 4.5
Low clutch duty solenoid (B55) No. 7 Chassis ground
1st or 2nd gear Less than 1
2.0 4.5
Low & reverse duty solenoid (B55) No. 5 Chassis ground
Except 1
range
5.0 or more
2.0 4.5
Driving at 1st
gear on manual
mode
(15 km/h
(9.3 MPH) or
more)
2.5 5.0
Data link signal (Subaru Select
Monitor)
CAN communication signal (+) (B54) No. 18 Chassis ground
Ignition switch
ON
Pulse signal
CAN communication signal () (B54) No. 17 Chassis ground
Ignition switch
ON
Pulse signal
FWD switch (B55) No. 10 Chassis ground
Fuse removed 10.5 or more
Fuse installed 1 or less
System ground circuit
(B55) No. 20 Chassis ground 0 Less than 1
Contents
Measured terminal
Measuring
condition
4AT(diag)-15
A: OPERATION
(DTC)
4AT(diag)-6, PREPARATION TOOL, General De-
scription.>
2) Prepare PC with Subaru Select Monitor in-
stalled.
3) Connect the SDI (Subaru Diagnostic Interface)
to the PC USB port (exclusively for Subaru Selector
Monitor) using a USB cable.
NOTE:
Port exclusively for Subaru Select Monitor refers to
the USB port used when installing Subaru Select
Monitor.
drivers side).
CAUTION:
Do not connect scan tools other than the Suba-
ru Select Monitor.
6) Start the PC.
7) Turn the ignition switch to ON (engine OFF) and
Monitor.
8) On the Main Menu, select {Each System
Check}.
9) On the System Selection Menu, select {Trans-
mission}.
10) After transmission type information pops up,
select [OK].
11) On the Transmission Diagnosis, select {DTC
Display}.
12) On the DTC Display, select {Temporary Di-
agnostic Code(s)} or {Memorized Diagnostic
Code(s)}.
NOTE:
For details concerning the operation procedure,
refer to the help on PC application for Subaru Se-
lect Monitor.
nostic Trouble Code (DTC). <Ref. to 4AT(diag)-
29, List of Diagnostic Trouble Code (DTC).>
AT-04371
4AT(diag)-16
2. READ CURRENT DATA
1) On the Main Menu, select {Each System Check}.
2) On the System Selection Menu, select {Transmission}.
3) After transmission type information pops up, select [OK].
4) On the Transmission Diagnosis, select {Current Data Display & Save}.
5) On the Current Data Display & Save, select {Normal sampling}.
NOTE:
For details concerning the operation procedure, refer to the PC application help for Subaru Select Monitor.
Battery voltage Battery Voltage V
Rear vehicle speed sensor signal Rear Wheel Speed km/h or MPH
Front vehicle speed sensor signal Front Wheel Speed km/h or MPH
Automatic transmission fluid temperature signal ATF Temp. C or F
Accelerator pedal position sensor Throttle voltage V
Gear position Gear Position
Line pressure control duty ratio Line Pressure Duty Ratio %
Lock up clutch control duty ratio Lock up Duty Ratio %
Transfer clutch control duty ratio Transfer Duty Ratio %
Accelerator pedal position sensor power supply Throttle Voltage V
Torque converter turbine speed signal Turbine Revolution Speed rpm
2 4 brake timing pressure control duty ratio Brake Clutch Duty Ratio %
Low clutch duty ratio L/C Duty %
High clutch duty ratio H/C Duty %
Low & reverse brake duty ratio L&R/B Duty %
Accelerator position Acceleration Opening Angle %
FWD switch signal FWD SW ON or OFF
Stop light switch signal Stop light SW ON or OFF
Anti lock brake system signal ABS signal ON or OFF
Parking range signal P Range Signal ON or OFF
Neutral range signal N Range Signal ON or OFF
Reverse range signal R Range Signal ON or OFF
Drive range signal D Range Signal ON or OFF
AT diagnosis light output signal Diagnosis Light ON or OFF
Cruise control signal Cruise Control Signal ON or OFF
ATF temperature light ATF temperature light ON or OFF
Up shift signal Up SW ON or OFF
Down shift signal Down SW ON or OFF
Sport mode signal Tiptronic Mode Switch ON or OFF
4AT(diag)-17
3. CLEAR MEMORY MODE
1) Check that the select lever is in P range.
Check}.
mission}.
4) After transmission type information pops up, se-
lect [OK].
5) On the Transmission Diagnosis, select {Clear
Memory}.
6) When the Done. Turn ignition switch to OFF
pops up, select [OK].
7) Turn Subaru Select Monitor and ignition switch
to OFF. To turn the ignition switch to ON again, wait
for 10 seconds or more.
NOTE:
If {Clear Memories 2} is selected and performed,
DTC and learned control memory are cleared. If
{Clear Memories 2} is performed, perform learning
control promotion. <Ref. to 4AT(diag)-17, FACILI-
TATION OF LEARNING CONTROL, OPERA-
refer to the PC application help for Subaru Select
Monitor.
4. FACILITATION OF LEARNING CONTROL
NOTE:
After performing the following services, perform
the transmission learning operation.
Replacement of TCM/Replacement or disassembly
of transmission assembly/Replacement of control
valve body/Performing Clear Memories 2.
1) Warm-up or cool down until the ATF tempera-
ture displayed on the Subaru Select Monitor reach-
es 60 80C (140 176 F).
CAUTION:
link connector.
7) Turn OFF all switches, which produce an electri-
cal load, including headlight, air conditioner, seat
heater, rear defogger, etc.
8) Turn the ECO switch to ON for model with ECO
switch. Turn the SPORT mode switch to OFF for
model with SPORT mode. Turn the POWER/HOLD
switch to OFF for model with POWER/HOLD
switch. Set to I mode for model with SI-DRIVE.
NOTE:
Error message is not displayed even when an in-
correct mode is set. While the operation is contin-
ued, AT learning promoting is displayed, but it
cannot end normally. If the message does not
change after 2 minutes have passed, retry AT
learning mode from the beginning.
CAUTION:
10) Select {AT learning mode} on the Learning
and inspection mode related to AT display screen
of Subaru Select Monitor.
4AT(diag)-18
NOTE:
During AT learning in progress, SPORT indicator
light in the combination meter starts flashing at 2
Hz and the learning operation starts. The following
message is displayed on the screen when the
SPORT indicator light turns off.
12) AT learning normally ended. is displayed,
simple AT learning is completed.
NOTE:
If communication error occurs during learning,
retry AT learning mode from the beginning.
of the vehicle is displayed during learning, select
[OK] to display the List of Diagnostics Trouble
Code. Retry AT learning mode from the beginning
after repairing the DTC detecting portion.
If AT learning ended abnormally. is displayed, retry AT learning mode from the beginning.
Monitor.
AT learning ended abnormally. Fault is detected during AT learning.
The accelerator pedal is depressed during AT learning.
Operation which is not directed is performed during AT learn-
ing.
4AT(diag)-19
7. Read Diagnostic Trouble
Code (DTC)
A: OPERATION
Refer to Subaru Select Monitor for information on
how to display a DTC. <Ref. to 4AT(diag)-15, OP-
ERATION, Subaru Select Monitor.>
For details concerning DTCs, refer to List of Diag-
nostic Trouble Code (DTC). <Ref. to 4AT(diag)-
4AT(diag)-20
Inspection Mode
8. Inspection Mode
A: PROCEDURE
WARNING:
Observe the traffic law when driving on public
roads.
1) Shift the select lever to D range, and then drive
the vehicle at 60 km/h (37 MPH) for at least 10 sec-
onds.
2) Drive the vehicle with manual mode.
4AT(diag)-21
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(diag)-17, CLEAR MEMORY MODE,
4AT(diag)-22
AT Oil Temp Warning Light Display
10.AT Oil Temp Warning Light Display
A: OPERATION
When any on-board diagnostics item is malfunctioning, the ATF temperature warning light blinks when a mal-
function is detected after starting the engine until the ignition switch is turned 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 ATF temperature warning light does not
show a problem (although a problem is occurring), the problem can be determined by checking the perfor-
mance characteristics of each sensor using the Subaru Select Monitor. Warning light signal patterns are
Perform the inspection when the ATF temperature warning light does not operate correctly. <Ref. to 4AT(di-
ag)-23, INSPECTION, AT Oil Temp Warning Light Display.>
(A) Ignition switch ON (engine OFF) (B) Normal (engine ON) (C) Faulty (engine ON)

(1) ON (3) 2 seconds (5) Blink
(2) OFF (4) 0.25 seconds
AT-02980
(4)
(3)
(1)
(2)
(1)
(2)
(1)
(2)
(3)
(5)
(A)
(B)
(C)
4AT(diag)-23
B: INSPECTION
DIAGNOSIS:
ATF temperature warning light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), the ATF temperature warning light does not illumi-
nate.
WIRING DIAGRAM:
3
2
1
2
2
i10
i84 A: B280 B:
A
2
6
A
2
7
B
2
0
B
3
0
1
8
1
7
B54
A
T
F

T
E
M
P
E
R
A
T
U
R
E

W
A
R
N
I
N
G

L
I
G
H
T
i10
i84
B280
B54
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
A:
B:
B365
i107
i106
9 8 7 6 5 4 3 2 1 10
11 12 13 14 15 16 17 18 19
i107 i106
**
1
*
2
*
1
*
2
*
*
:
:
1
*
2
*
:
*
4 3 2 1
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
5
E
B365
LCD
(SPORT SHIFT)
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
*
AT-04326
20
1 2 3 4 5 6 7 8
9 10 11 12 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
13
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
I
G
N
I
T
I
O
N
S
W
I
T
C
H
B
A
T
T
E
R
Y
BUZZER COMBINATION
METER
CAN
JOINT
CONNECTOR
TERMINAL No.
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
TCM
4AT(diag)-24
Step Check Yes No
SPECTION.
Turn the ignition switch to ON.
Does the ATF temperature
warning light illuminate?
Go to step 2. Perform the self-
diagnosis of com-
bination meter.
SPECTION.
After the ignition switch is ON, wait for at least 2
seconds.
Does the ATF temeprature
warning light illuminate?
SPECTION.
Start the engine.
Does the ATF temeprature
warning light go off?
Normal. Go back to
Basic Diagnostic
Procedure. <Ref.
to 4AT(diag)-2,
Basic Diagnostic
Procedure.>
Go to step 7.
4 CHECK SUBARU SELECT MONITOR COM-
MUNICATION.
Connect the Subaru Select Monitor to the data
link connector.
Is the communication between
Subaru Select Monitor and
TCM normal?
Go to step 5. Check the power
supply ground cir-
cuit of TCM and
Subaru Select
Monitor communi-
cation. <Ref. to
4AT(diag)-25,
Diagnostic Proce-
dure for Subaru
Select Monitor
Communication.>
5 CHECK TCM.
Display the current data of TCM using Subaru
Select Monitor.
Is the Diagnosis Light output
signal ON?
Go to step 6. Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
6 CHECK BODY INTEGRATED UNIT.
Display the current data of body integrated unit
using Subaru Select Monitor. <Ref. to
Monitor.>
Is the ATF oil temperature
light input signal on Illumi-
nate?
Replace the com-
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
Check DTC of
body integrated
unit. <Ref. to
LAN(diag)-12,
OPERATION, Sub-
aru Select Moni-
tor.>
7 CHECK TCM.
Select Monitor. <Ref. to 4AT(diag)-15, OPERA-
signal ON?
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Go to step 8.
Monitor.>
Is the ATF oil temperature
light input signal on Illumi-
nate?
Check DTC of
body integrated
unit. Perform the
diagnosis accord-
ing to DTC. <Ref.
to LAN(diag)-12,
OPERATION, Sub-
aru Select Moni-
tor.>
Perform the self-
diagnosis of com-
bination meter.
<Ref. to IDI-4,
INSPECTION,
Combination Meter
System.>
4AT(diag)-25
Diagnostic Procedure for Subaru Select Monitor Communication
11.Diagnostic Procedure for Subaru Select Monitor Communication
A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
Defective harness connector
TROUBLE SYMPTOM:
Subaru Select Monitor communication failure
WIRING DIAGRAM:
1
*
*
2
*
1
*
B40
B55
B136
B11
T4
B40
E
S
B
F
-
6
M
A
I
N

S
B
F
2
7
2
2
2
3
2 18
2
0
2
1
16
4
7
5
E E
B11
1
9
2
0
No.13
2
5
2
6
B53
2 1 3 4
8 7 6 5
B122
B122
B136
6
*
*
B53
1
*
2
*
1
*
2
*
2
*
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B55
M
/
B

N
o
.

1
2
F
/
B

N
o
.

1
2
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
9 8 7 6 5 4 3 2 1 10
11 12 13 14 15 16 17 18 19 20
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
AT-04327
BATTERY
DATA LINK
CONNECTOR
IGNITION
SWITCH
ECM
JOINT
CONNECTOR
CONTROL VALVE BODY
: TERMINAL No.
: TERMINAL No.
AMONG 4, 5, 14 AND 15
: TERMINAL No.
AMONG 6, 7, 16, AND 17
TCM
4AT(diag)-26
Step Check Yes No
1 CHECK INSTALLATION OF TCM CONNEC-
TOR.
Is TCM connector connected to
TCM?
Go to step 2. Connect the TCM
connector to TCM.
2 CHECK SUBARU SELECT MONITOR POW-
ER SUPPLY CIRCUIT.
Measure the voltage between data link connec-
Is the voltage 10 V or more? Go to step 3. Repair harness
connector between
the battery and
data link connec-
tor, and poor con-
tact of the
connector.
3 CHECK SUBARU SELECT MONITOR
GROUND CIRCUIT.
data link connector and ECM.
(B40) No. 4 (B136) No. 6:
(B40) No. 5 (B136) No. 6:
circuit of harness
between data link
connector and
ECM.
GROUND CIRCUIT.
data link connector and chassis ground.
more?
circuit of harness
between data link
connector and
ground terminals.
5 CHECK ENGINE GROUND CIRCUIT.
Check the engine ground circuit.
Is the engine ground circuit nor-
mal?
Go to step 6. Repair ground cir-
cuit of ECM.
LECT MONITOR.
whether communication to transmission system
can be executed normally.
Is the name of system dis-
played on Subaru Select Moni-
tor?
LECT MONITOR.
2) Disconnect the TCM connector.
3) Check whether communication to engine
system can be executed normally.
tor?
LECT MONITOR.
2) Connect the TCM connector.
3) Disconnect the connectors of TPM control
unit, airbag control module, body integrated
unit, and ABSCM&H/U.
CAUTION:
When disconnecting the connector from air-
bag control module, always follow the pre-
cautions on AB section. <Ref. to AB-4,
CAUTION, General Description.>
5) Check whether communication to transmis-
sion system can be executed normally.
tor?
Check each con-
trol module.
Go to step 9.
4AT(diag)-27
EACH CONTROL MODULE AND DATA LINK
CONNECTOR.
2) Disconnect the connectors of TCM, ECM,
TPM control unit, airbag control module, body
integrated unit, and ABSCM&H/U.
3) Measure the resistance between TCM con-
more?
Go to step 10. Check harness
and connector
between each con-
trol module and
data link connec-
tor.
10 CHECK OUTPUT SIGNAL OF TCM.
2) Measure the voltage between TCM and
chassis ground.
Is the voltage 1 V or more? Check harness
and connector
between each con-
trol module and
data link connec-
tor.
Go to step 11.
TCM AND DATA LINK CONNECTOR.
Measure the resistance between TCM connec-
tor and data link connector.
(B55) No. 8 (B40) No. 7:
Is resistance less than 1 ? Go to step 12. Repair the harness
and connector
between TCM and
data link connec-
tor.
12 CHECK INSTALLATION OF TRANSMISSION
HARNESS CONNECTOR.
Is the transmission harness
connector connected to bulk-
head harness connector?
Go to step 13. Connect the bulk-
head harness con-
nector to
transmission har-
ness connector.
13 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control
module power supply and data
link connector?
Repair the poor
contact.
Go to step 14.
14 CHECK POWER SUPPLY OF TCM.
3) Measure the voltage between TCM connec-
Is the voltage 10 13 V? Go to step 16. Go to step 15.
15 CHECK FUSE (NO. 12).
2) Remove the fuse (M/B No. 12).
Is the fuse (No. 12) blown out? Replace the fuse
(No. 12). If the
replaced fuse (No.
12) blows out eas-
ily, repair the short
circuit of harness
between fuse (No.
12) and TCM.
Repair the open
circuit of harness
between fuse (No.
12) and TCM, or
fuse (No. 12) and
battery, and poor
contact of the con-
nector.
16 CHECK IGNITION POWER SUPPLY CIR-
CUIT.
2) Measure the ignition power supply voltage
between TCM connector and chassis ground.
Step Check Yes No
4AT(diag)-28
Remove the fuse (F/B No. 12).
(No. 12). If the
replaced fuse (No.
12) blows out eas-
circuit of harness
between fuse (No.
12) and TCM.
Repair the open
circuit of harness
between fuse (No.
12) and TCM, or
fuse (No. 12) and
battery, and poor
contact of the con-
nector.
TCM AND TRANSMISSION.
2) Disconnect the connectors from TCM and
transmission.
TCM and transmission connector.
(B55) No. 20 (B11) No. 20:
(B55) No. 21 (B11) No. 20:
(B55) No. 22 (B11) No. 19:
(B55) No. 23 (B11) No. 19:
circuit of harness
between TCM and
transmission har-
ness connector,
and poor contact of
connector.
TRANSMISSION AND TRANSMISSION
GROUND.
Measure the resistance of the harness between
transmission and transmission ground.
(T4) No. 19 Transmission ground:
circuit of the har-
ness between
transmission and
transmission
ground.
20 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in TCM
power supply, ground and data
link connector?
Repair the connec-
tor.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Step Check Yes No
4AT(diag)-29
A: LIST
DTC Contents Diagnosis content Reference
P0705
Transmission Range
Sensor Circuit
(PRNDL Input)
Inhibitor switch malfunction short cir-
cuit
<Ref. to 4AT(diag)-31, DTC P0705 TRANSMIS-
SION RANGE SENSOR CIRCUIT (PRNDL
INPUT), Diagnostic Procedure with Diagnostic
P0712
Transmission Fluid
Temperature Sensor
Circuit Low Input
ATF temperature sensor is faulty or
input signal circuit is open.
SION FLUID TEMPERATURE SENSOR CIRCUIT
LOW INPUT, Diagnostic Procedure with Diagnostic
P0713
Transmission Fluid
Temperature Sensor
Circuit High Input
ATF temperature sensor is faulty or
input signal circuit is shorted.
SION FLUID TEMPERATURE SENSOR CIRCUIT
HIGH INPUT, Diagnostic Procedure with Diagnostic
P0715
Input/Turbine Speed
Sensor Circuit
Torque converter turbine speed sen-
sor malfunction, open or shorted
input signal circuit
<Ref. to 4AT(diag)-43, DTC P0715 INPUT/TUR-
BINE SPEED SENSOR CIRCUIT, Diagnostic Pro-
P0719
Torque Converter/
Brake Switch B Cir-
cuit Low
Brake switch malfunction, open input
signal circuit
<Ref. to 4AT(diag)-45, DTC P0719 BRAKE
SWITCH CIRCUIT LOW, Diagnostic Procedure with
P0720
Output Speed Sen-
sor Circuit
Front vehicle speed sensor malfunc-
tion, open or shorted input signal cir-
cuit
<Ref. to 4AT(diag)-48, DTC P0720 OUTPUT
SPEED SENSOR CIRCUIT, Diagnostic Procedure
P0724
Torque Converter/
Brake Switch B Cir-
cuit High
Brake switch malfunction, shorted
input signal circuit
SWITCH CIRCUIT HIGH, Diagnostic Procedure
P0725
Engine Speed Input
Circuit
Open or shorted engine speed output
signal circuit
<Ref. to 4AT(diag)-52, DTC P0725 ENGINE
SPEED INPUT CIRCUIT, Diagnostic Procedure
P0731
Gear 1 Incorrect
Ratio
Vehicle sensor, torque converter tur-
bine speed sensor or control valve
malfunction
<Ref. to 4AT(diag)-53, DTC P0731 GEAR 1
INCORRECT RATIO, Diagnostic Procedure with
P0732
Gear 2 Incorrect
Ratio
malfunction
P0733
Gear 3 Incorrect
Ratio
malfunction
P0734
Gear 4 Incorrect
Ratio
malfunction
P0736
Reverse Incorrect
Ratio
malfunction
<Ref. to 4AT(diag)-54, DTC P0736 REVERSE
P0741
Torque Converter
Clutch Circuit Perfor-
mance or Stuck Off
Lock-up clutch is faulty or valve is
stuck.
<Ref. to 4AT(diag)-55, DTC P0741 TORQUE CON-
VERTER CLUTCH CIRCUIT PERFORMANCE OR
STUCK OFF, Diagnostic Procedure with Diagnostic
P0743
Torque Converter
Clutch Circuit Electri-
cal
Lock-up solenoid is faulty or output
signal circuit is open or shorted.
<Ref. to 4AT(diag)-56, DTC P0743 TORQUE CON-
VERTER CLUTCH CIRCUIT ELECTRICAL, Diag-
nostic Procedure with Diagnostic Trouble Code
(DTC).>
P0748
Pressure Control
Solenoid A Electri-
cal
Line pressure linear solenoid is faulty
or output signal circuit is open or
shorted.
<Ref. to 4AT(diag)-59, DTC P0748 PRESSURE
CONTROL SOLENOID A ELECTRICAL, Diag-
(DTC).>
4AT(diag)-30
P0753
Shift Solenoid A
Electrical
Low clutch duty solenoid is faulty or
output signal circuit is open or
shorted.
<Ref. to 4AT(diag)-61, DTC P0753 SHIFT SOLE-
NOID A ELECTRICAL, Diagnostic Procedure with
P0758
Shift Solenoid B
Electrical
2-4 brake duty solenoid is faulty or
shorted.
NOID B ELECTRICAL, Diagnostic Procedure with
P0763
Shift Solenoid C
Electrical
High clutch duty solenoid is faulty or
shorted.
NOID C ELECTRICAL, Diagnostic Procedure with
P0768
Shift Solenoid D
Electrical
Low & reverse clutch duty solenoid is
faulty or output signal circuit is open
or shorted.
NOID D ELECTRICAL, Diagnostic Procedure with
P0801
Reverse Inhibit Con-
trol Circuit
Shift lock solenoid is faulty or output
INHIBIT CONTROL CIRCUIT, Diagnostic Proce-
P1706
AT Vehicle Speed
Sensor Circuit Mal-
function (Rear
Wheel)
Rear vehicle speed sensor is faulty
or input signal circuit is open or
shorted.
<Ref. to 4AT(diag)-75, DTC P1706 AT VEHICLE
SPEED SENSOR CIRCUIT MALFUNCTION
(REAR WHEEL), Diagnostic Procedure with Diag-
P1707
AT AWD Solenoid
Valve Circuit Mal-
function
Transfer duty solenoid is faulty or
shorted.
<Ref. to 4AT(diag)-77, DTC P1707 AT AWD SOLE-
NOID VALVE CIRCUIT MALFUNCTION, Diagnostic
P1718
CAN Communica-
tion Circuit
CAN communication circuit is open
or shorted.
<Ref. to 4AT(diag)-79, DTC P1718 CAN COMMU-
NICATION CIRCUIT, Diagnostic Procedure with
P1817
SPORT Mode Switch
Circuit
Sport shift switch is faulty or input
<Ref. to 4AT(diag)-80, DTC P1817 SPORT MODE
SWITCH CIRCUIT, Diagnostic Procedure with
DTC Contents Diagnosis content Reference
4AT(diag)-31
A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT)
Inhibitor switch is faulty.
At least 2 range signal is input.
TROUBLE SYMPTOM:
Shift characteristics are erroneous.
The range position of the select lever and the AT select lever position indicator light on the combination
meter do not match.
4AT(diag)-32
WIRING DIAGRAM:
Step Check Yes No
1 CHECK INDICATOR LIGHT.
Does the P range indicator
light on combination meter illu-
minate?
2 CHECK INDICATOR LIGHT. Does the R range indicator
minate?
i10
i84
B280
B54 A:
B12
T7
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
A:
B:
3
2
1
2
2
P R N D
i10
i84 A:
B280 B:
A
2
7
A
2
6
B
2
0
B
3
0
A
1
8
A
1
7
B
1
0
B
1
4
B
1
1
T7
B54 A: B55 B:
B12
T3
T3
B12
5
4
P
R
N
D
MAIN SBF SBF-6
E
E
B365
B365
9 8 7 6 5 4 3 2 1 10
11 12 13 14 15 16 17 18 19 20
i107 i106
**
**
*
2
*
*
2
*
i107
i106
4 3 2 1
B: B55
1
*
2
*
*
CAN JOINT
CONNECTOR
CAN JOINT
CONNECTOR
CAN JOINT
CONNECTOR
1
1
98
1
0
3
28 31
B
1
3
No.5
AT-04328
1 2 3 4 5 6 7 8
9 10 11 12 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
13
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
1 2 3 4
5 6 7 8
9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
B
A
T
T
E
R
Y
COMBINATION
METER
TCM
INHIBITOR
SWITCH
ARRANGEMENT
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
4AT(diag)-33
3 CHECK INDICATOR LIGHT. Does the N range indicator
minate?
4 CHECK INDICATOR LIGHT. Does the D range indicator
minate?
Read the data of P range using Subaru Select
Monitor.
Is ON displayed? Go to step 19. Go to step 6.
Shift the select lever to R range.
Does the R range indicator
minate?
7 CHECK R RANGE SWITCH.
Read the data of R range using Subaru Select
Monitor.
Shift the select lever to N range.
Does the P range indicator
minate?
9 CHECK N RANGE SWITCH.
Read the data of N range using Subaru Select
Monitor.
Shift the select lever to D range.
Does the D range indicator
minate?
Even if the ATF
temperature warn-
ing light blinks, the
circuit is in normal
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in TCM and
transmission.
Go to step 11.
11 CHECK D RANGE SWITCH.
Read the data of D range using Subaru Select
Monitor.
INHIBITOR SWITCH AND CHASSIS
GROUND.
switch.
inhibitor switch and chassis ground.
Is the resistance 1 or more? Go to step 13. Repair the open
circuit of harness
between inhibitor
switch and chassis
ground, and poor
contact of the con-
nector.
TCM AND INHIBITOR SWITCH.
2) Disconnect the connector from TCM and
inhibitor switch.
between TCM and inhibitor switch connector.
(B55) No. 14 (T7) No. 9:
circuit of harness
between TCM and
inhibitor switch
connector, and
poor contact of the
connector.
Step Check Yes No
4AT(diag)-34
14 CHECK INPUT SIGNAL FOR TCM.
2) Connect the connector to TCM and inhibitor
switch.
chassis ground.
1) Shift the select lever to any range other than
P.
chassis ground.
Is the voltage 8 V or more? Go to step 16. Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Read the data of inhibitor switch from Subaru
Select Monitor. <Ref. to LAN(diag)-12, OPERA-
Is 7 displayed? Go to step 17. Check the body
integrated unit.
Is DTC of CAN communication
displayed?
Perform the diag-
nosis according to
DTC.
Go to step 18.
Check the P range indicator light. <Ref. to IDI-
4, INSPECTION, Combination Meter System.>
Is the P range indicator light
bulb OK?
Go to step 41. Replace the com-
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
2) Disconnect the connectors from TCM, inhib-
itor switch and combination meter.
TCM connector and chassis ground.
more?
short circuit in P
range circuit.
inhibitor switch.
(B55) No. 13 (T7) No. 8:
circuit of harness
between TCM and
inhibitor switch
connector, and
poor contact of the
connector.
switch.
4) Shift the select lever to R range.
chassis ground.
Step Check Yes No
4AT(diag)-35
1) Shift the select lever to other than R range.
chassis ground.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Read the data of shift position from Subaru
integrated unit.
displayed?
Perform the diag-
nosis according to
DTC.
Go to step 25.
Check the R range indicator light. <Ref. to IDI-
Is the R range indicator light
OK?
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
more?
short circuit in R
range circuit.
inhibitor switch.
(B55) No. 11 (T7) No. 10:
circuit of harness
between TCM and
inhibitor switch
connector, and
poor contact of the
connector.
switch.
chassis ground.
N range.
chassis ground.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Read the data of shift position from Subaru
integrated unit.
Step Check Yes No
4AT(diag)-36
displayed?
Perform the diag-
nosis according to
DTC.
Go to step 32.
Check the N range indicator light. <Ref. to IDI-
Is the N range indicator light
OK?
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
more?
short circuit in N
range circuit.
inhibitor switch.
(B55) No. 10 (T7) No. 3:
circuit of harness
between TCM and
inhibitor switch
connector, and
poor contact of the
connector.
switch.
4) Shift the select lever to D range.
chassis ground.
D range.
chassis ground.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Read the data of inhibitor switch from Subaru
integrated unit.
displayed?
Perform the diag-
nosis according to
DTC.
Go to step 39.
Check the D range indicator light. <Ref. to IDI-
Is the D range indicator light
OK?
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
Step Check Yes No
4AT(diag)-37
more?
short circuit in D
range circuit.
41 CHECK POOR CONTACT. Is there poor contact in the
inhibitor switch circuit?
Repair the poor
contact.
Go to step 42.
42 CHECK INHIBITOR SWITCH. Is the inhibitor switch in the nor-
mal position?
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Adjust inhibitor
switch and select
cable. <Ref. to
4AT-47, Inhibitor
Switch.> <Ref. to
CS-27, Select
Cable.>
Step Check Yes No
4AT(diag)-38
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:
AT-04767
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
2
3
1
2
1
5
1
1
9 4
B54
B11
AT2
T4
TCM
B54
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
AT2
10 9 8 7 6
5 4 3 2 1
CONTROL VALVE BODY
ATF
TEMPERATURE
SENSOR
4AT(diag)-39
Step Check Yes No
TCM AND ATF TEMPERATURE SENSOR.
2) Disconnect the connector from transmis-
sion and TCM.
(B54) No. 23 (B11) No. 11:
circuit of harness
between TCM and
transmission con-
nector.
(B54) No. 12 (B11) No. 15:
circuit of harness
between TCM and
transmission con-
nector.
3 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 exceeds 80C (176F).
NOTE:
If the ambient temperature is below 0C (32F),
drive the vehicle until the ATF reaches its oper-
ating temperature.
sion.
sion connector terminals.
(T4) No. 11 No. 15:
800 ?
Measure the resistance between transmission
(T4) No. 11 No. 15:
Does the resistance value
increase while the ATF temper-
ature decreases?
5 CHECK INPUT SIGNAL FOR TCM USING
SUBARU SELECT MONITOR.
1) Connect the connector to transmission.
4) Read the data of ATF temperature sensor
gradually decrease?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness and poor
contact of ATF
temperature sen-
sor and transmis-
sion connector.
Go to step 6.
6 CHECK POOR CONTACT. Is there poor contact in ATF
temperature sensor circuit?
Repair the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-40
TRANSMISSION AND ATF TEMPERATURE
SENSOR.
sion.
3) Remove the transmission connector from
bracket.
5) Drain the automatic transmission fluid.
CAUTION:
Do not drain ATF until it cools down.
6) Remove the oil pan, and disconnect the
control valve connector.
ATF temperature sensor and transmission con-
nector.
(T4) No. 11 (AT2) No. 4:
circuit of harness
between ATF tem-
perature sensor
and transmission
connector.
SENSOR.
ATF temperature sensor and transmission con-
nector.
(T4) No. 15 (AT2) No. 9:
circuit of harness
between ATF tem-
perature sensor
and transmission
connector.
SENSOR.
transmission connector and transmission
ground.
more?
circuit of harness
between ATF tem-
perature sensor
and transmission
connector.
SENSOR.
ground.
more?
Replace the con-
trol valve body.
<Ref. to 4AT-58,
Control Valve
Body.>
Repair the short
circuit of harness
between ATF tem-
perature sensor
and transmission
connector.
Step Check Yes No
4AT(diag)-41
C: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH
INPUT
Input signal circuit to ATF temperature sensor is shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
Step Check Yes No
nector terminals.
(B54) No. 23 No. 12:
Is the resistance 500 or
more?
more?
3 CHECK HARNESS.
tor terminals while shaking the harness.
(B54) No. 23 No. 12:
Does the resistance change? Go to step 4. Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
sion.
more?
circuit of harness
between TCM and
transmission har-
ness.
AT-04767
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
2
3
1
2
1
5
1
1
9 4
B54
B11
AT2
T4
TCM
B54
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
AT2
10 9 8 7 6
5 4 3 2 1
CONTROL VALVE BODY
ATF
TEMPERATURE
SENSOR
4AT(diag)-42
more?
circuit of harness
between TCM and
transmission har-
ness.
(T4) No. 11 No. 15:
more?
Even if the ATF
temperature warn-
condition at this
time. A temporary
short circuit of con-
nector or harness
may be the cause.
Repair the harness
or connector.
Go to step 7.
7 CHECK TRANSMISSION HARNESS.
CAUTION:
4) Disconnect the harness connector from
control valve.
5) Measure the resistance between ATF tem-
perature sensor connector terminals.
sion connector and transmission ground.
more?
Go to step 8. Replace the trans-
mission harness.
8 CHECK TRANSMISSION HARNESS.
connector and transmission ground.
more?
mission harness.
Measure the resistance between control valve
Terminals
No. 4 No. 9:
more?
Even if the ATF
temperature warn-
condition at this
time. A temporary
short circuit of con-
nector or harness
may be the cause.
Repair the harness
or connector.
Replace the con-
trol valve body.
<Ref. to 4AT-58,
Control Valve
Body.>
Step Check Yes No
4AT(diag)-43
D: DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT
Input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
Step Check Yes No
1 CHECK TORQUE CONVERTER TURBINE
SPEED SENSOR.
sion.
sion connector receptacles terminals.
(T4) No. 5 No. 10:
650 ?
Go to step 2. Replace the torque
converter turbine
speed sensor.
<Ref. to 4AT-55,
Torque Converter
Turbine Speed
Sensor.>
TCM connector and transmission connector.
(B54) No. 1 (B11) No. 5:
circuit of harness
between TCM and
transmission con-
nector.
(B54) No. 2 (B11) No. 10:
circuit of harness
between TCM and
transmission con-
nector, and poor
contact of the con-
nector.
AT-04330
5
1
0
B11
T4
TCM B54
1
B11
2
B53
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
:
*
*
*
*
B54
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
JOINT
CONNECTOR
TORQUE
CONVERTER
TURBINE
SPEED SENSOR
ARRANGEMENT AMONG 2, 3 AND 13
4AT(diag)-44
more?
circuit of harness
between TCM and
transmission con-
nector.
more?
circuit of the har-
ness between
TCM and transmis-
sion connector,
and poor contact of
connector.
1) Connect the connectors to TCM and trans-
mission.
3) Turn the ignition switch to ON and run the
5) Shift the select lever to P or N range.
6) Read the data of Turbine Revolution
Speed using Subaru Select Monitor.
Compare the tachometer with Subaru Select
Monitor indications.
Is the revolution value same as
the tachometer reading shown
on the combination meter?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in TCM and
transmission.
Go to step 7.
7 CHECK POOR CONTACT. Is there poor contact in torque
converter turbine speed sensor
circuit?
Repair the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Step Check Yes No
4AT(diag)-45
E: DTC P0719 BRAKE SWITCH CIRCUIT LOW
Brake switch malfunction, open input signal circuit
TROUBLE SYMPTOM:
Gear is not shifted down when driving a down hill.
WIRING DIAGRAM:
1
*
2
*
B159
2 1 3 4
8 9 7 6 5
B280
B281 C:
B:
B159
B280 B:
B281 C:
C
2
3
B
2
0
B
3
0
3
5
9
MAIN SBF SBF-2
N
o
.
8
E
1
8
1
7
TCM B54
B365
2
4
3
B65
1 2
3 4
B65
B365
9 8 7 6 5 4 3 2 1 10
11 12 13 14 15 16 17 18 19
B225
1
*
2
*
1
*
2
*
7
.
5
A
B54
B225
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
CAN JOINT
CONNECTOR
20
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27 28
16 17 18 19
20 21
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
AT-04331
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
FUSE & RELAY
BOX (F/B)
FUSE
(RELAY BLOCK)
B
A
T
T
E
R
Y
STOP LIGHT
SWITCH
(BLACK)
4AT(diag)-46
Step Check Yes No
1 CHECK DTC. Is DTC of CAN communication
displayed?
Perform the diag-
nosis according to
DTC.
Go to step 2.
2) Remove the fuse (No. 8).
(No. 8). If the
replaced fuse (No.
8) has blown out
easily, repair the
ness between fuse
(No. 8) and stop
light switch.
Go to step 3.
3 CHECK FUSE (RELAY BLOCK) (7.5A).
Remove the fuse (relay block) (7.5 A).
Is the fuse (7.5A) blown out? Replace the fuse
(7.5A). If the
replaced fuse
(7.5A) blows out
easily, repair the
ness between fuse
(7.5A) and TCM.
Go to step 4.
6) Read the data of Stop Light Switch using
5 CHECK TCM.
Read the data of Stop Light Switch using Sub-
aru Select Monitor. <Ref. to 4AT(diag)-15,
Is ON displayed? A temporary poor
contact of connec-
tor or harness may
be the cause.
Check the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
6 CHECK BODY INTEGRATED UNIT INPUT
SIGNAL.
grated unit.
BODY INTEGRATED UNIT AND STOP LIGHT
SWITCH.
2) Disconnect the connector from stop light
switch.
body integrated unit and stop light switch.
(B281) No. 23 (B65) No. 3:
circuit of harness
between body inte-
grated unit and
stop light switch.
4AT(diag)-47
SWITCH.
more?
circuit of harness
between body inte-
grated unit and
stop light switch.
9 CHECK POOR CONTACT. Is there poor contact in input
signal of brake switch?
Repair the poor
contact.
Check the body
integrated unit.
Step Check Yes No
4AT(diag)-48
F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT
The vehicle speed signal is abnormal.
The harness connector between TCM and front vehicle speed sensor is shorted or open.
TROUBLE SYMPTOM:
Driving performance is poor.
WIRING DIAGRAM:
Step Check Yes No
transmission.
(B54) No. 27 (B11) No. 14:
circuit of harness
between TCM and
transmission con-
nector.
(B54) No. 16 (B11) No. 18:
circuit of harness
between TCM and
transmission con-
nector, and poor
contact of the con-
nector.
more?
circuit of harness
between TCM and
transmission con-
nector.
AT-04332
1
8
1
4
B11
T4
2
7
B11
TCM B54
B53
1
6
B53
*
*
*
B54
*
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
9 8 7 6 5 4 3 2 1 10
11 12 13 14 15 16 17 18 19 20
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
JOINT
CONNECTOR
ARRANGEMENT
AMONG 1, 11 AND 12
FRONT VEHICLE
SPEED SENSOR
4AT(diag)-49
more?
circuit of the har-
ness between
TCM and transmis-
sion connector,
and poor contact of
connector.
5 CHECK FRONT VEHICLE SPEED SENSOR.
connector receptacles terminals.
(T4) No. 14 No. 18:
650 ?
vehicle speed sen-
sor. <Ref. to 4AT-
51, Front Vehicle
Speed Sensor.>
6) Read the data of front wheel speed using
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:
wheels may illuminate the ABS warning light,
but this does not indicate a malfunction. When
AT control diagnosis is finished, perform the
ABS memory clearance procedure of on-board
diagnostics system. <Ref. to ABS(diag)-24,
Clear Memory Mode.>
Does the speedometer indica-
tion increase as the Subaru
Select Monitor front wheel
speed data increases?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness in of front
vehicle speed sen-
sor circuit.
Go to step 7.
7 CHECK POOR CONTACT. Is there poor contact in front
vehicle speed sensor circuit?
Repair the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Step Check Yes No
4AT(diag)-50
G: DTC P0724 BRAKE SWITCH CIRCUIT HIGH
Brake switch malfunction, open input signal circuit
TROUBLE SYMPTOM:
Gear is not shifted down when driving a down hill.
WIRING DIAGRAM:
1
*
2
*
B159
2 1 3 4
8 9 7 6 5
B280
B281 C:
B:
B159
B280 B:
B281 C:
C
2
3
B
2
0
B
3
0
3
5
9
MAIN SBF SBF-2
N
o
.
8
E
1
8
1
7
TCM B54
B365
2
4
3
B65
1 2
3 4
B65
B365
9 8 7 6 5 4 3 2 1 10
11 12 13 14 15 16 17 18 19
B225
1
*
2
*
1
*
2
*
7
.
5
A
B54
B225
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
CAN JOINT
CONNECTOR
20
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27 28
16 17 18 19
20 21
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
AT-04331
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
FUSE & RELAY
BOX (F/B)
FUSE
(RELAY BLOCK)
B
A
T
T
E
R
Y
STOP LIGHT
SWITCH
(BLACK)
4AT(diag)-51
Step Check Yes No
1 CHECK DTC. Is DTC of CAN communication
displayed?
Perform the diag-
nosis according to
DTC.
Go to step 2.
5) Read the data of Stop Light Switch using
Is OFF displayed? Go to step 3. Go to step 4.
3 CHECK TCM.
Read the data of Stop Light Switch using Sub-
Is OFF displayed? A temporary poor
contact of connec-
tor or harness may
be the cause.
Check the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
SIGNAL.
1) Disconnect the harness connector of body
integrated unit.
5 CHECK STOP LIGHT SWITCH.
switch.
stop light switch connectors.
Terminals
No. 2 No. 3:
more?
Go to step 6. Replace the stop
light switch.
SWITCH.
circuit of harness
between TCM and
stop light switch.
Repair the poor
contact.
Check the body
integrated unit.
4AT(diag)-52
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)
ATF temperature warning light remains ON when the vehicle speed is 0.
WIRING DIAGRAM:
AT-04333
1
1
B136 ECM
B55 TCM
2
2
B136
B55
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
4AT(diag)-53
I: DTC P0731 GEAR 1 INCORRECT RATIO
NOTE:
Refer to DTC P0736 for diagnostic procedure. <Ref. to 4AT(diag)-54, 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:
Step Check Yes No
TCM AND ECM.
ECM.
TCM and ECM.
(B55) No. 11 (B136) No. 22:
circuit of harness
between TCM and
ECM connector.
TCM AND ECM.
more?
circuit of harness
between TCM and
ECM connector.
1) Connect the connectors to TCM and ECM.
3) Start the engine, and run the Subaru Select
Monitor.
5) Read the data of Engine Speed using Sub-
aru Select Monitor.
Display shows engine speed signal value
sent from ECM.
Is the revolution value same as
the tachometer reading shown
on the combination meter?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in the TCM
and ECM.
Go to step 4.
4 CHECK POOR CONTACT. Is there poor contact in engine
speed signal circuit?
Repair the poor
contact.
Go to step 5.
5 CONFIRM DTC P0725.
Replace the ECM with a new part.
Does the DTC appear again,
after the memory has been
cleared?
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Replace the ECM.
4AT(diag)-54
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.
Step Check Yes No
SENSOR.
3) Read the value of Accel. opening angle on
Subaru Select Monitor display.
Does the value of Accel. open-
ing angle change from 0% to
100% smoothly when throttle is
operated from fully closed to
fully open?
Go to step 2. Check the acceler-
ator pedal position
sensor circuit.
2 CHECK FRONT VEHICLE SPEED SENSOR.
3) Shift the select lever to D range and slowly
increase vehicle speed.
NOTE:
but this indicates no malfunction. When AT con-
trol diagnosis is finished, perform the ABS
memory clearance procedure of on-board diag-
nostics system. <Ref. to ABS(diag)-24, Clear
Memory Mode.>
Does the vehicle speed dis-
played by Subaru Select Moni-
tor roughly correspond with
vehicle speed indicated by the
combination meter?
Go to step 3. Check the front
vehicle speed sen-
sor circuit.
SPEED SENSOR.
2) Idle the engine.
Does the value of torque con-
verter turbine speed sensor dis-
played by Subaru Select
Monitor roughly correspond
with the value of tachometer in
combination meter?
There are malfunc-
tions in TCM, TCM
connector poor
contact, or trans-
mission assembly
mechanical mal-
function.
Check the torque
converter turbine
speed sensor cir-
cuit.
4AT(diag)-55
N: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR
STUCK OFF
Lock up clutch malfunction
Sticky valve
TROUBLE SYMPTOM:
No lock-up occurs.
Step Check Yes No
1 CHECK LOCK-UP DUTY SOLENOID CIR-
CUIT.
Diagnose according to DTC P0743 procedure.
Is there any fault? Repair or replace
the lock up duty
solenoid circuit.
Go to step 2.
2 CHECK INHIBITOR SWITCH CIRCUIT.
Diagnose according to DTC P0705 procedure.
the inhibitor switch
circuit.
Go to step 3.
3 CHECK STOP LIGHT SWITCH CIRCUIT.
Diagnose according to DTC P0719 and P0724
procedures.
the stop light
switch circuit.
Go to step 4.
4 CHECK ATF TEMPERATURE SENSOR CIR-
CUIT.
Diagnose according to DTC P0712 AND P0713
procedure.
the ATF tempera-
ture sensor circuit.
Go to step 5.
SENSOR.
3) Read the value of Accel. opening angle on
Subaru Select Monitor display.
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. Check the acceler-
ator pedal position
sensor circuit.
SPEED SENSOR.
2) Idle the engine.
Does the value of turbine speed
displayed by Subaru Select
Monitor almost correspond with
the value of the tachometer?
Go to step 7. Check the torque
converter turbine
speed sensor cir-
cuit.
7 CHECK ENGINE SPEED SIGNAL.
Idle the engine.
Does the value of turbine speed
displayed by Subaru Select
Monitor almost correspond with
the value of the tachometer?
There is transmis-
sion assembly
mechanical mal-
function.
Check the engine
speed signal cir-
cuit.
4AT(diag)-56
O: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL
Output signal circuit of lock-up duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT-04768
TCM
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
6
B54
B11
AT2
T4
1
2
6
B54
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
AT2
10 9 8 7 6
5 4 3 2 1
CONTROL VALVE BODY
LOCK-UP
DUTY
SOLENOID
4AT(diag)-57
Step Check Yes No
1 CHECK DTC. Are multiple DTCs displayed? Go to other DTC. Go to step 2.
transmission.
(B54) No. 6 (B11) No. 12:
circuit of harness
between TCM and
transmission con-
nector.
Measure the resistance of the harness connec-
tor between TCM connector and chassis
ground.
more?
circuit of harness
between TCM and
transmission con-
nector.
4 CHECK LOCK-UP DUTY SOLENOID.
(T4) No. 12 No. 20:
6.0 ?
5 CHECK OUTPUT SIGNAL FROM TCM US-
ING SUBARU SELECT MONITOR.
mission.
Monitor.
5) Start the engine and warm-up the engine
until the ATF temperature exceeds 80C
(176F).
NOTE:
ating temperature.
6) Read the data of Lock Up Duty Ratio using
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.>
Is the measured value 95%? Go to step 6. Go to step 7.
4AT(diag)-58
Return the engine to idling speed, shift the
select lever to N range and read the data.
NOTE:
Clear Memory Mode.>
Is the measured value 5%? Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in TCM and
transmission.
Go to step 7.
7 CHECK POOR CONTACT. Is there poor contact in lock-up
duty solenoid circuit?
Repair the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
8 CHECK LOCK-UP DUTY SOLENOID (IN
TRANSMISSION).
1) Disconnect the transmission connector.
CAUTION:
connector from control valve body.
4) Measure the resistance between lock-up
duty solenoid and transmission ground.
(AT2) No. 6 Transmission ground:
6.0 ?
Go to step 9. Replace the con-
trol valve body.
<Ref. to 4AT-58,
Control Valve
Body.>
LOCK-UP DUTY SOLENOID AND TRANS-
MISSION.
lock-up duty solenoid and transmission connec-
tor.
(T4) No. 12 (AT2) No. 6:
circuit of harness
between TCM and
transmission con-
nector.
LOCK-UP DUTY SOLENOID AND TRANS-
MISSION.
ground.
more?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in lock-up
duty solenoid and
transmission.
Repair the short
circuit of harness
between lock-up
duty solenoid and
transmission con-
nector.
Step Check Yes No
4AT(diag)-59
P: DTC P0748 PRESSURE CONTROL SOLENOID A ELECTRICAL
Output signal circuit of line pressure linear solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
Step Check Yes No
sion and TCM.
(B54) No. 3 (B11) No. 2:
(B54) No. 4 (B11) No. 1:
circuit of harness
between TCM and
transmission con-
nector.
TCM AND CHASSIS GROUND.
more?
circuit of harness
between TCM and
transmission con-
nector.
3 CHECK LINE PRESSURE LINEAR SOLE-
NOID.
(T4) No. 1 No. 2:
8 ?
AT-04769
3
B11
AT2
T4
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
4
B54
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
1
0
12
5
B54 TCM
CONTROL VALVE BODY
LINE
PRESSURE
LINEAR
SOLENOID
AT2
10 9 8 7 6
5 4 3 2 1
4AT(diag)-60
NOID (IN TRANSMISSION).
bracket.
CAUTION:
4) Measure the resistance of line pressure lin-
ear solenoid connector terminals.
(AT2) No. 5 No. 10:
8 ?
trol valve body.
<Ref. to 4AT-58,
Control Valve
Body.>
TRANSMISSION AND LINE PRESSURE LIN-
EAR SOLENOID.
line pressure linear solenoid and transmission
connector.
(T4) No. 2 (AT2) No. 10:
(T4) No. 1 (AT2) No. 5:
circuit of harness
between line pres-
sure linear sole-
noid and
transmission con-
nector.
TRANSMISSION AND LINE PRESSURE LIN-
EAR SOLENOID.
ground.
more?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in line pres-
sure linear
solenoid and trans-
mission.
Repair the short
circuit of harness
between line pres-
sure linear sole-
noid and
transmission con-
nector.
Step Check Yes No
4AT(diag)-61
Q: DTC P0753 SHIFT SOLENOID A ELECTRICAL
Output signal circuit of low clutch duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT-04770
TCM
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
7
B55
B11
AT2
T4
4
2
B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
AT2
10 9 8 7 6
5 4 3 2 1
CONTROL VALVE BODY
LOW
CLUTCH
DUTY
SOLENOID
4AT(diag)-62
Step Check Yes No
transmission.
(B55) No. 7 (B11) No. 4:
circuit of harness
between TCM and
transmission con-
nector.
TCM connector and transmission ground.
more?
circuit of harness
between TCM and
transmission con-
nector.
3 CHECK LOW CLUTCH DUTY SOLENOID.
(T4) No. 4 No. 20:
6.0 ?
mission.
Monitor.
temperature exceeds 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 (with engine OFF).
6) Shift the select lever to P or N range, and
depress the accelerator pedal.
7) Read the data of Low Clutch Duty Ratio
Low clutch duty solenoid is indicated in %.
3) Read the data of Low Clutch Duty Ratio.
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in transmis-
sion.
Go to step 6.
6 CHECK POOR CONTACT. Is there poor contact in low
clutch duty solenoid circuit?
Repair the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-63
7 CHECK LOW CLUTCH DUTY SOLENOID (IN
TRANSMISSION).
bracket.
CAUTION:
4) Measure the resistance between low clutch
duty solenoid connector and transmission
ground.
6.0 ?
trol valve body.
<Ref. to 4AT-58,
Control Valve
Body.>
TRANSMISSION AND LOW CLUTCH DUTY
SOLENOID.
Measure the resistance of harness between low
clutch duty solenoid and transmission connec-
tor.
(T4) No. 4 (AT2) No. 2:
circuit of harness
between low clutch
duty solenoid and
transmission con-
nector.
TRANSMISSION AND LOW CLUTCH DUTY
SOLENOID.
ground.
more?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector of the low
clutch duty sole-
noid and transmis-
sion.
Repair the short
circuit of harness
between low clutch
duty solenoid and
transmission con-
nector.
Step Check Yes No
4AT(diag)-64
R: DTC P0758 SHIFT SOLENOID B ELECTRICAL
Output signal circuit of 2-4 brake duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT-04771
TCM
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
4
B55
B11
AT2
T4
3
8
B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
AT2
10 9 8 7 6
5 4 3 2 1
CONTROL VALVE BODY
2-4 BRAKE
DUTY
SOLENOID
4AT(diag)-65
Step Check Yes No
transmission.
(B55) No. 4 (B11) No. 3:
circuit of harness
between TCM and
transmission con-
nector.
more?
circuit of harness
between TCM and
transmission con-
nector.
3 CHECK 2-4 BRAKE DUTY SOLENOID.
(T4) No. 3 No. 20:
6.0 ?
Monitor.
(176F).
NOTE:
6) Shift the select lever to N range, and
depress the accelerator pedal.
7) Read the data of Brake Clutch Duty Ratio
2-4 brake duty solenoid is indicated in %.
Shift the select lever to 2nd on manual mode.
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in TCM and
transmission.
Go to step 6.
6 CHECK POOR CONTACT. Is there poor contact in 2-4
brake duty solenoid circuit?
Repair the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-66
7 CHECK 2-4 BRAKE DUTY SOLENOID (IN
TRANSMISSION).
bracket.
CAUTION:
connector from 2-4 brake duty solenoid.
2-4 brake duty solenoid connector and trans-
mission ground.
6.0 ?
trol valve body.
<Ref. to 4AT-58,
Control Valve
Body.>
2-4 BRAKE DUTY SOLENOID AND TRANS-
MISSION.
Measure the resistance of harness between 2-4
brake duty solenoid and transmission connec-
tor.
(T4) No. 3 (AT2) No. 8:
circuit of harness
between 2-4 brake
duty solenoid and
transmission con-
nector.
2-4 BRAKE DUTY SOLENOID AND TRANS-
MISSION.
ground.
more?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in 2-4 brake
duty solenoid and
transmission.
Repair the short
circuit of harness
between 2-4 brake
duty solenoid and
transmission con-
nector.
Step Check Yes No
4AT(diag)-67
S: DTC P0763 SHIFT SOLENOID C ELECTRICAL
Output signal circuit of high clutch duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT-04772
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
6
B55
B11
AT2
T4
7
3
B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
AT2
10 9 8 7 6
5 4 3 2 1
TCM
CONTROL VALVE BODY
HIGH
CLUTCH
DUTY
SOLENOID
4AT(diag)-68
Step Check Yes No
transmission.
(B55) No. 6 (B11) No. 7:
circuit of harness
between TCM and
transmission con-
nector.
Measure the resistance of the harness connec-
tor between TCM connector and chassis
ground.
more?
circuit of harness
between TCM and
transmission con-
nector.
3 CHECK HIGH CLUTCH DUTY SOLENOID.
(T4) No. 7 No. 20:
6.0 ?
mission.
Monitor.
5) Start the engine and warm-up the engine
until the ATF temperature exceeds 80C
(176F).
NOTE:
ating temperature.
6) Read the data of High Clutch Duty Ratio
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.>
4AT(diag)-69
Return the engine to idling speed and shift the
select lever to N range.
NOTE:
Clear Memory Mode.>
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in TCM and
transmission.
Go to step 6.
6 CHECK POOR CONTACT. Is there poor contact in high
clutch duty solenoid circuit?
Repair the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
7 CHECK HIGH CLUTCH DUTY SOLENOID (IN
TRANSMISSION).
bracket.
CAUTION:
control valve body connector.
4) Measure the resistance between high clutch
ground.
6.0 ?
trol valve body.
<Ref. to 4AT-58,
Control Valve
Body.>
HIGH CLUTCH DUTY SOLENOID AND
TRANSMISSION.
high clutch duty solenoid and transmission con-
nector.
(T4) No. 7 (AT2) No. 3:
circuit of harness
between TCM and
transmission con-
nector.
HIGH CLUTCH DUTY SOLENOID AND
TRANSMISSION.
ground.
more?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in high
clutch duty sole-
noid and transmis-
sion.
Repair the short
circuit of harness
between high
clutch duty sole-
noid and transmis-
sion connector.
Step Check Yes No
4AT(diag)-70
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:
AT-04773
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
5
B55
B11
AT2
T4
6
1
B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
AT2
10 9 8 7 6
5 4 3 2 1
TCM
CONTROL VALVE BODY
LOW &
REVERSE
DUTY
SOLENOID
4AT(diag)-71
Step Check Yes No
sion and TCM.
(B55) No. 5 (B11) No. 6:
circuit of harness
between TCM and
transmission con-
nector.
more?
circuit of harness
between TCM and
transmission con-
nector.
3 CHECK LOW & REVERSE DUTY SOLENOID.
(T4) No. 6 No. 20:
6.0 ?
Monitor.
(176F).
NOTE:
7) Read the data of L&R/B duty ratio using
Low & reverse duty solenoid is indicated in
%.
2) Shift the select lever to manual mode, and
then hold it on 1st. Slowly increase the vehicle
speed up to 15 km/h (9 MPH), and then return
the accelerator pedal.
NOTE:
Clear Memory Mode.>
3) Read the data of L&R/B duty ratio.
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in TCM and
transmission.
Go to step 6.
4AT(diag)-72
6 CHECK POOR CONTACT. Is there poor contact in the low
& reverse duty solenoid circuit?
Repair the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
7 CHECK LOW & REVERSE BRAKE DUTY SO-
LENOID (IN TRANSMISSION).
bracket.
CAUTION:
4) Measure the resistance between low &
reverse duty solenoid connector and transmis-
sion ground.
6.0 ?
trol valve body.
<Ref. to 4AT-58,
Control Valve
Body.>
TRANSMISSION AND LOW & REVERSE
DUTY SOLENOID.
Measure the resistance of harness between low
& reverse duty solenoid and transmission con-
nector.
(T4) No. 6 (AT2) No. 1:
Is resistance less than 1 ? Go to step 9. Repair open circuit
of harness
between low &
reverse duty sole-
noid and transmis-
sion connector.
TRANSMISSION AND LOW & REVERSE
DUTY SOLENOID.
ground.
more?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair har-
ness or connector
in low & reverse
duty solenoid and
transmission.
Repair the short
circuit of the har-
ness between the
low & reverse duty
solenoid and the
transmission con-
nector.
Step Check Yes No
4AT(diag)-73
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 R range during driving at 20 km/h (12 MPH) or more.
Gear cannot be shifted from N range to R range.
WIRING DIAGRAM:
Step Check Yes No
1) Start the integrated unit by force, and check
the operation of shift lock solenoid. <Ref. to
LAN(diag)-12, READ DIAGNOSTIC TROUBLE
CODE (DTC), OPERATION, Subaru Select
Monitor.>
2) Operate AT select lever without depressing
the brake pedal.
Does the AT select lever oper-
ate?
2 CHECK OUTPUT SIGNAL OF INTEGRATED
UNIT.
1) Display the following items using Subaru
Select Monitor.
Key warning SW
Shift position
P SW
Stop light switch
2) Step on the brake and shift the AT select
lever to P range.
Do the units of measure of
items displayed change?
Go to step 3. Check the circuits
of the items whose
values do not
change.
BODY INTEGRATED UNIT AND SHIFT LOCK
SOLENOID.
Measure the harness resistance between the
body integrated unit and chassis ground.
more?
circuit of harness
between body inte-
grated unit and
shift lock solenoid
connector.
6
E
B116
B116
3
4
B280
B280
1 2 3 4 5
6 7 8 9 10 11 12
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
AT-04340
SHIFT LOCK
SOLENOID
4AT(diag)-74
4 CHECK HARNESS BETWEEN SHIFT LOCK
SOLENOID AND CHASSIS GROUND TERMI-
NAL.
shift lock solenoid and chassis ground.
circuit of harness
between chassis
ground and shift
lock solenoid con-
nector.
terminals.
(B116) No. 3 No. 4:
18 ?
lock solenoid.
6 CHECK OUTPUT SIGNAL OF BODY INTE-
GRATED UNIT.
3) Shift the AT select lever to D range.
7 CHECK OUTPUT SIGNAL OF BODY INTE-
GRATED UNIT.
3) Shift the select lever to D range and slowly
increase vehicle speed to over 20 km/h (12
MPH).
NOTE:
Clear Memory Mode.>
Is the voltage less than 1 V? Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in the
reverse inhibitor
control circuit.
Go to step 8.
reverse inhibitor control circuit?
Repair the poor
contact.
Replace the body
integrated unit.
<Ref. to SL-55,
Body Integrated
Unit.>
Step Check Yes No
4AT(diag)-75
V: DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR
WHEEL)
TROUBLE SYMPTOM:
No lock up or tight corner braking phenomenon is occurred.
WIRING DIAGRAM:
Step Check Yes No
CUIT.
2) Disconnect the connector from rear vehicle
speed sensor.
between rear vehicle speed sensor connector
and transmission ground.
(AT13) No. 3 (+) Transmission ground
():
Is the voltage 10 V or more? Go to step 2. Check harness
between rear vehi-
cle speed sensor
and battery for
open circuit, short
or poor contact.
Repair the harness
if required.
TCM connector and rear vehicle speed sensor
connector.
(B54) No. 15 (AT13) No. 1:
circuit or poor con-
tact of the connec-
tor in harness
between TCM and
rear vehicle speed
sensor connector.
TCM connector and rear vehicle speed sensor
connector.
(B54) No. 26 (AT13) No. 2:
circuit or poor con-
tact of the connec-
tor in harness
between TCM and
rear vehicle speed
sensor connector.
1
5
2
6
B11
AT13
T4
9
1
7
1
3
312
B54
E
MAIN SBF
SBF-6
No.12
B11
AT13
1 2 3
TCM
B54
AT-04341
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
BATTERY IGNITION
SWITCH
REAR VEHICLE
SPEED SENSOR
4AT(diag)-76
more?
circuit of harness
between TCM and
rear vehicle speed
sensor connector.
more?
circuit of harness
between TCM and
rear vehicle speed
sensor connector.
6 PREPARE OSCILLOSCOPE. Do you have an oscilloscope? Go to step 8. Go to step 7.
mission.
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 con-
nector terminals.
(B54) No. 26 (+) No. 15 ():
Is the voltage approx. 2 V or
more?
Go to step 9. Replace the rear
vehicle speed sen-
sor.
OSCILLOSCOPE.
mission.
3) Set the oscilloscope to TCM connector ter-
minals.
Positive probe; (B54) No. 26:
Ground lead; (B54) No. 15:
4) Start the engine and set vehicle in 20 km/h
(12 MPH) condition.
NOTE:
Clear Memory Mode.>
5) Measure the signal voltage indicated on
oscilloscope.
Is the pulse voltage approx. 5
V?
Go to step 9. Replace the rear
vehicle speed sen-
sor.
9 CHECK POOR CONTACT. Is there poor contact in rear
vehicle speed sensor circuit?
Repair the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Step Check Yes No
4AT(diag)-77
W: DTC P1707 AT AWD SOLENOID VALVE CIRCUIT MALFUNCTION
Output signal circuit of transfer duty solenoid is open or shorted.
TROUBLE SYMPTOM:
Front wheel slips on the slippery road.
WIRING DIAGRAM:
AT-04774
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
5
B54
B11
AT2
T4
8
7
B54
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
AT2
10 9 8 7 6
5 4 3 2 1
TCM
CONTROL VALVE BODY
TRANSFER
DUTY
SOLENOID
4AT(diag)-78
Step Check Yes No
transmission.
(B54) No. 5 (B11) No. 8:
circuit of harness
between TCM and
transmission con-
nector.
Measure the resistance of harness connector
between TCM and chassis ground.
more?
circuit of harness
between TCM and
transmission con-
nector.
3 CHECK TRANSFER DUTY SOLENOID.
connector and transmission terminals.
(T4) No. 8 No. 20:
6.0 ?
mission.
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 AWD Duty Ratio using
Transfer duty solenoid is indicated in %.
Is the value approx. 5%? Go to step 5. Go to step 6.
2) Read the data of AWD Duty Ratio using
Transfer duty solenoid is indicated in %.
Is the measured value approx.
18 35%?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in TCM and
transmission.
Go to step 6.
6 CHECK POOR CONTACT. Is there poor contact in transfer
duty solenoid circuit?
Repair the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
4AT(diag)-79
X: DTC P1718 CAN COMMUNICATION CIRCUIT
NOTE:
Refer to Body Integrated Unit for diagnosis of P1718. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
7 CHECK TRANSFER DUTY SOLENOID (IN
TRANSMISSION).
CAUTION:
3) Remove the extension case, and discon-
nect the connector from transfer duty solenoid.
4) Measure the resistance between transfer
ground.
6.0 ?
trol valve body.
<Ref. to 4AT-58,
Control Valve
Body.>
TRANSFER DUTY SOLENOID AND TRANS-
MISSION.
transfer duty solenoid and transmission con-
nector.
(T4) No. 8 (AT2) No. 7:
circuit of harness
between transfer
duty solenoid and
transmission con-
nector.
TRANSFER DUTY SOLENOID AND TRANS-
MISSION.
ground.
more?
Even if the ATF
temperature warn-
condition at this
time. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or poor
contact in the
transfer duty sole-
noid and transmis-
sion.
Repair short circuit
of the harness
between the trans-
fer duty solenoid
and transmission
connector.
Step Check Yes No
4AT(diag)-80
Y: DTC P1817 SPORT MODE SWITCH CIRCUIT
Input signal circuit of SPORT/manual mode switch is shorted.
TROUBLE SYMPTOM:
Manual mode can not be set.
The SPORT indicator light does not illuminate.
No SPORT mode occurs.
WIRING DIAGRAM:
Step Check Yes No
Is DTC displayed? Perform the diag-
nosis according to
DTC.
Go to step 2.
SIGNAL.
1) Shift the AT select lever to P range.
2) Read the Tip mode SW data of body inte-
grated unit using Subaru Select Monitor. <Ref.
to LAN(diag)-12, OPERATION, Subaru Select
Monitor.>
SIGNAL.
1) Shift the AT select lever from P to D
range.
Monitor.>
Is the indication on each range
OFF?
Go to step 4. Replace the select
lever assembly.
<Ref. to CS-23,
Select Lever.>
AT-04343
1
*
1
*
2
*
1
*
2
*
2
*
B281 C:
B280 B:
B
2
0
B
3
0
C
2
5
C
1
5
1
8
1
7
B116
TCM B54
1
0
1
1
6
7
B280
B281
8
7 6 5 4 3 2 1
22 23 21
20 19 16 15 14 13 12 11 10 9 17
30
18
29 28 27 26 25 24
8
7 6 5 4 3 2 1
2223 21 20
19 16 15 14 13 12 11 10 9 1718
28 27 26 25 24
B116
E
B:
C:
B365
B365
B54
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
8
9
C
2
6
U
P
D
O
W
N
1 2 3 4 5
6 7 8 9 10 11 12
9 8 7 6 5 4 3 2 1 10
11 12 13 14 15 16 17 18 19 20
AT SELECT LEVER
JOINT
CONNECTOR
SPORT/
MANUAL
MODE SWITCH
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
4AT(diag)-81
SIGNAL.
1) Shift the AT select lever to SPORT mode.
Monitor.>
Is ON displayed? Go to step 5. Replace the select
lever assembly.
<Ref. to CS-23,
Select Lever.>
Shift the AT select lever from P to D range.
Is the indication of range posi-
tion indicator light in combina-
tion meter synchronized with
position of select lever?
Go to step 6. Adjust the inhibitor
switch and select
cable. <Ref. to
4AT-47, ADJUST-
MENT, Inhibitor
Switch.> <Ref. to
CS-31, ADJUST-
MENT, Select
Cable.>
6 CHECK INPUT SIGNAL FROM TCM.
range.
2) Read the Tip mode SW data of TCM using
Subaru Select Monitor. <Ref. to 4AT(diag)-15,
OFF?
Even if the ATF
temperature warn-
condition. A tem-
porary short circuit
of connector or
harness may be
the cause. Repair
the harness or con-
nector.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
GRATED UNIT AND SPORT/MANUAL MODE
SWITCH.
2) Disconnect the harness connector from
body integrated unit and AT select lever.
3) Measure the resistance between the body
integrated unit and chassis ground.
more?
circuit of harness
between body inte-
grated unit and
SPORT/manual
mode switch.
8 CHECK SPORT SHIFT SWITCH.
2) Measure the resistance of SPORT/manual
mode switch connector terminals.
Terminals
No. 9 No. 8:
more?
Check the body
integrated unit.
Replace the select
lever assembly.
<Ref. to CS-23,
Select Lever.>
Step Check Yes No
4AT(diag)-82
A: CHECK FWD SWITCH
DIAGNOSIS:
LED does not illuminate even with the fuse installed on FWD fuse holder.
FWD signal circuit is open or shorted.
WIRING DIAGRAM:
1
*
2
*
1
*
2
*
i10
i84
B281
F108
B361
A:
A:
B:
B:
3
2
1
2
2
i10
A
2
7
A
2
6
B
2
0
B
3
0
A
1
8
A
1
7
B
1
0
i84 A:
B281 B:
TCM
B54 A:
B55 B:
F27
B361
F108
9
1
1
8
1
3
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
5
E
E
B365
B365
i107
i106
**
**
B54
B55
i107
i106
1 4 3 2
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
FWD
FUSE
HOLDER
F27
12
11 10
18
19 16
15
17
9
20 21 22
8
4 5 3
2
1
7
6
14
13
*
2
*
1
*
AT-04344
9 8 7 6 5 4 3 2 1 10
11 12 13 14 15 16 17 18 19 20
1
7
2 3 4 5 6
8 9 10 11 12 13 14
1
9
2 3 8
10
4
11 12 13 14 15 16
5 6 7
17 18
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27 28
16 17 18 19
20 21
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
1 2 3 4 5 6 7 8
9 10 11 12 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
13
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
ARRANGEMENT
RELAY HOLDER
THROUGH JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
B
A
T
T
E
R
Y
I
G
N
I
T
I
O
N
S
W
I
T
C
H
COMBINATION
METER
AWD WARNING LIGHT/
FWD INDICATOR
4AT(diag)-83
Step Check Yes No
1 CHECK SPARE FUSE. Is the spare fuse OK? Go to step 2. Replace the fuse.
2 CHECK FWD FUSE HOLDER.
link connector.
When the fuse is inserted to
FWD fuse holder, does the LED
illuminate?
3 CHECK COMBINATION METER. Does the AWD warning light
illuminate?
Go to INSPEC-
TION FOR
SPORT/MANUAL
MODE SWITCH.
<Ref. to 4AT(diag)-
85, CHECK
SPORT SHIFT
SWITCH, Diag-
nostic Procedure
without Diagnostic
Trouble Code
(DTC).>
Go to step 9.
TCM AND FWD FUSE HOLDER.
TCM and FWD fuse holder.
(B55) No. 10 (F27) No. 18:
circuit of harness
between TCM and
FWD fuse holder.
FWD FUSE HOLDER AND CHASSIS
GROUND.
FWD fuse holder and chassis ground.
circuit of harness
between FWD fuse
holder and chassis
ground.
TCM AND FWD FUSE HOLDER.
between TCM and body to make sure that cir-
cuit does not short.
more?
circuit of harness
between TCM and
FWD fuse holder.
2) Connect the connector to TCM.
4) Measure the signal voltage for TCM with the
fuse installed to FWD fuse holder.
Measure the signal voltage for TCM with the
fuse removed from FWD fuse holder.
Is the voltage 10.5 V or more? Go to step 9. Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
displayed?
Perform the diag-
nosis according to
DTC.
Go to step 10.
Check the AWD warning light. <Ref. to IDI-4,
INSPECTION, Combination Meter System.>
Is the AWD warning light OK? Go to step 11. Replace the com-
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
4AT(diag)-84
11 CHECK POOR CONTACT. Is there poor contact in FWD
switch circuit?
Repair the poor
contact.
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Step Check Yes No
4AT(diag)-85
B: CHECK SPORT SHIFT SWITCH
DIAGNOSIS:
Input signal circuit of SPORT/manual mode switch is open or shorted.
TROUBLE SYMPTOM:
Does not shift on manual mode.
WIRING DIAGRAM:
AT-04343
1
*
1
*
2
*
1
*
2
*
2
*
B281 C:
B280 B:
B
2
0
B
3
0
C
2
5
C
1
5
1
8
1
7
B116
TCM B54
1
0
1
1
6
7
B280
B281
8
7 6 5 4 3 2 1
22 23 21
20 19 16 15 14 13 12 11 10 9 17
30
18
29 28 27 26 25 24
8
7 6 5 4 3 2 1
2223 21 20
19 16 15 14 13 12 11 10 9 1718
28 27 26 25 24
B116
E
B:
C:
B365
B365
B54
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
8
9
C
2
6
U
P
D
O
W
N
1 2 3 4 5
6 7 8 9 10 11 12
9 8 7 6 5 4 3 2 1 10
11 12 13 14 15 16 17 18 19 20
AT SELECT LEVER
JOINT
CONNECTOR
SPORT/
MANUAL
MODE SWITCH
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
4AT(diag)-86
Step Check Yes No
1) Move the AT select lever to SPORT mode.
2) Shift and hold the AT select lever to up side.
3) Read the Up Switch data of TCM using
READ CURRENT DATA, OPERATION, Subaru
Select Monitor.>
1) Shift and hold the AT select lever to down
side.
2) Read the Down Switch data of TCM using
Is ON displayed? Go to the proce-
dure INSPEC-
TION FOR SPORT
SHIFT INDICA-
TOR LIGHT.
<Ref. to 4AT(diag)-
89, CHECK
SPORT SHIFT
INDICATOR, Diag-
nostic Procedure
without Diagnostic
Trouble Code
(DTC).>
Go to step 12.
3) Read the TIP UP SW data of body inte-
Monitor.>
Check DTC of body integrated unit. <Ref. to
Monitor.>
displayed?
Perform the diag-
nosis according to
DTC.
Check the TCM.
5 CHECK GROUND CIRCUIT OF SPORT/MAN-
UAL MODE SWITCH.
2) Disconnect the connector from SPORT/
manual mode switch.
SPORT/manual mode switch connector and
chassis ground.
circuit of harness
between SPORT/
manual mode
switch and chassis
ground.
6 CHECK SPORT/MANUAL MODE SWITCH.
Measure the resistance between SPORT/man-
ual mode switch terminals.
(B116) No. 6 No. 7:
more?
Go to step 7. Replace the guide
plate assembly.
2) Measure the resistance between SPORT/
manual mode switch terminals.
(B116) No. 6 No. 7:
Is resistance less than 1 ? Go to step 8. Replace the guide
plate assembly.
4AT(diag)-87
BODY INTEGRATED UNIT AND SPORT/
MANUAL MODE SWITCH.
grated unit.
body integrated unit connector and SPORT/
manual mode switch connector.
(B116) No. 7 (B281) No. 15:
circuit of harness
between the
SPORT/manual
mode switch con-
nector and body
integrated unit
connector, or poor
contact of connec-
tor.
MANUAL MODE SWITCH.
chassis ground.
more?
circuit of harness
between SPORT/
manual mode
switch connector
and body inte-
grated unit con-
nector.
10 CHECK INPUT SIGNAL TO BODY INTE-
GRATED UNIT.
3) Check the signal voltage for body integrated
unit.
Is the voltage 1.5 8 V? Go to step 11. Replace the body
integrated unit.
GRATED UNIT.
1) Shift and hold the AT select lever to shift up
side.
unit.
Is the voltage less than 1 V? Go to step 21. Replace the body
integrated unit.
side.
3) Read the TIP DOWN SW data of body
integrated unit using Subaru Select Monitor.
Select Monitor.>
displayed?
Perform the diag-
nosis according to
DTC.
Check the TCM.
14 CHECK GROUND CIRCUIT OF SPORT/MAN-
UAL MODE SWITCH.
manual mode switch.
chassis ground.
(B116) No. 10 (+) Chassis ground:
circuit of harness
between SPORT/
manual mode
switch and chassis
ground.
(B116) No. 10 No. 11:
more?
plate assembly.
Step Check Yes No
4AT(diag)-88
side.
(B116) No. 10 No. 11:
Is resistance less than 1 ? Go to step 17. Replace the guide
plate assembly.
MANUAL MODE SWITCH.
grated unit.
(B116) No. 11 (B281) No. 25:
circuit of harness
between the
SPORT/manual
mode switch con-
nector and body
integrated unit
connector, or poor
contact of connec-
tor.
MANUAL MODE SWITCH.
chassis ground.
more?
circuit of harness
between SPORT/
manual mode
switch connector
and body inte-
grated unit con-
nector.
GRATED UNIT.
unit.
Is the voltage 1.5 8 V? Go to step 20. Go to step 21.
GRATED UNIT.
side.
unit.
integrated unit.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
SPORT/manual mode switch
circuit?
Repair the poor
contact.
Temporary poor
contact of the
SPORT/manual
mode switch circuit
connector or har-
ness.
Step Check Yes No
4AT(diag)-89
C: CHECK SPORT SHIFT INDICATOR
DIAGNOSIS:
Output signal circuit of SPORT shift indicator is open or shorted.
TROUBLE SYMPTOM:
SPORT shift indicator does not display or remains displayed.
SPORT shift indicator display does not change.
WIRING DIAGRAM:
3
2
1
2
2
i10
i84 A: B280 B:
A
2
6
A
2
7
B
2
0
B
3
0
1
8
1
7
B54
A
T
F

T
E
M
P
E
R
A
T
U
R
E

W
A
R
N
I
N
G

L
I
G
H
T
i10
i84
B280
B54
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
A:
B:
B365
i107
i106
9 8 7 6 5 4 3 2 1 10
11 12 13 14 15 16 17 18 19
i107 i106
**
1
*
2
*
1
*
2
*
*
:
:
1
*
2
*
:
*
4 3 2 1
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
5
E
B365
LCD
(SPORT SHIFT)
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
*
AT-04326
20
1 2 3 4 5 6 7 8
9 10 11 12 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
13
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
I
G
N
I
T
I
O
N
S
W
I
T
C
H
B
A
T
T
E
R
Y
BUZZER COMBINATION
METER
CAN
JOINT
CONNECTOR
TERMINAL No.
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
TCM
4AT(diag)-90
Step Check Yes No
displayed?
Perform the diag-
nosis according to
DTC.
Go to step 2.
2 CHECK TCM.
5) Shift the AT select lever to SPORT mode.
6) Shift up the AT select lever.
7) Read the Gear Position data of TCM using
Is the gear position 2? Go to step 3. Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
3 CHECK TCM.
1) Shift down the AT select lever.
2) Read the Gear Position data of TCM using
Is the gear position 1? Go to step 4. Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Read the data of SPORT shift gear position
Is the SPORT shift gear posi-
tion 2?
Go to step 5. Check the body
integrated unit.
<Ref. to IDI-4, INSPECTION, Combination
Meter System.>
Is the SPORT shift indicator
OK?
Inspection of
buzzer. <Ref. to
4AT(diag)-91,
CHECK BUZZER,
Diagnostic Proce-
dure without Diag-
nostic Trouble
Code (DTC).>
Replace the com-
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
4AT(diag)-91
D: CHECK BUZZER
DIAGNOSIS:
Output signal circuit of buzzer is open or shorted.
TROUBLE SYMPTOM:
Buzzer remains beeping.
WIRING DIAGRAM:
3
2
1
2
2
i10
i84 A: B280 B:
A
2
6
A
2
7
B
2
0
B
3
0
1
8
1
7
B54
A
T
F

T
E
M
P
E
R
A
T
U
R
E

W
A
R
N
I
N
G

L
I
G
H
T
i10
i84
B280
B54
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
A:
B:
B365
i107
i106
9 8 7 6 5 4 3 2 1 10
11 12 13 14 15 16 17 18 19
i107 i106
**
1
*
2
*
1
*
2
*
*
:
:
1
*
2
*
:
*
4 3 2 1
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
5
E
B365
LCD
(SPORT SHIFT)
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
*
AT-04326
20
1 2 3 4 5 6 7 8
9 10 11 12 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
13
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
I
G
N
I
T
I
O
N
S
W
I
T
C
H
B
A
T
T
E
R
Y
BUZZER COMBINATION
METER
CAN
JOINT
CONNECTOR
TERMINAL No.
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
TCM
4AT(diag)-92
Step Check Yes No
5) Read the data of SPORT shift (buzzer) of
body integrated unit using Subaru Select Moni-
tor.
Is the SPORT shift buzzer dis-
play ON?
Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).>
Go to step 2.
<Ref. to IDI-4, INSPECTION, Combination
Meter System.>
Is the buzzer OK? Refer to Symptom
Related Diagnos-
tic. <Ref. to
4AT(diag)-93,
General Diagnos-
tic Table.>
Replace the com-
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
4AT(diag)-93
A: INSPECTION
Starter does not operate when select lever is in P or N
range. Starter operates when select lever is in R or D range.
Inhibitor switch
Select cable
AT select lever
Starter motor and harness
Abnormal noise when select lever is in P or N.
Strainer
Transfer duty solenoid
Oil pump
Drive plate
ATF level too high or too low
Hissing noise occurs during standing start.
Strainer
ATF level too high or too low
Noise occurs while driving in D1. Final gear
Planetary gear
Reduction gear
Differential gear oil level too high or too low
Noise occurs while driving in D2.
Final gear
Low & reverse brake
Reduction gear
Final gear
Low & reverse brake
Planetary gear
Reduction gear
Vehicle moves when select lever is in N range.
Select cable
Inhibitor switch
TCM
Low clutch
Shock occurs when select lever is shifted from N to D range.
Accelerator pedal position sensor
ATF temperature sensor
Low clutch 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 select lever is shifted from N to R range.
TCM
Harness
Control valve
ATF deterioration
Excessive time lag occurs when the select lever is shifted from
N to R range.
Control valve
Low & reverse clutch
Reverse clutch
Seal ring
4AT(diag)-94
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)
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
Vehicle does not start in R range only. (Engine operates)
Select cable
AT select lever
Control valve
Reverse clutch
Vehicle does not start in R range only. (Engine stalls)
Low clutch
2-4 brake
Planetary gear
Parking brake mechanism
Vehicle does not start in D range. (Engine operates)
Low clutch
One-way clutch
Vehicle does not start in D range. (Engine stalls) Reverse clutch
Vehicle does not start in R range only. (Engine operates) Control valve
Acceleration during standing start is poor. (High rpm stall)
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 D 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
No shift occurs from 1st to 2nd gear.
TCM
Rear vehicle speed sensor
Front vehicle speed sensor
Control valve
2-4 brake
No shift occurs from 2nd to 3rd gear.
TCM
Control valve
High clutch
4AT(diag)-95
No shift occurs from 3rd to 4th gear.
TCM
Control valve
2-4 brake
Engine brake is not effected when select lever is shifted from
4th gear to 3rd gear.
Inhibitor switch
TCM
Control valve
3rd gear to 2nd gear.
Control valve
2nd gear to 1st gear.
Control valve
Low & reverse brake
Inhibitor switch
TCM
Control valve
Ground
No lock-up occurs.
TCM
Control valve
Lock-up facing
Engine speed signal
Parking brake does not function. Select cable
AT select lever
Parking mechanism
Shift lever cannot be moved or is hard to move from P range.
ATF spurts out. ATF level too high
Differential oil spurts out. Differential gear oil level too high
Differential oil level changes excessively.
Seal pipe
Double oil seal
Odor is produced from ATF supply pipe.
High clutch
2-4 brake
Reverse clutch
Lock-up facing
ATF deterioration
Shock occurs when shifting from 1st to 2nd gear.
TCM
Torque converter turbine speed sensor
2-4 brake duty solenoid
Control valve
2-4 brake
ATF deterioration
Engine performance
Low & reverse duty solenoid
Slippage occurs when shifting from 1st to 2nd gear.
TCM
Control valve
2-4 brake
4AT(diag)-96
Shock occurs when shifting from 2nd to 3rd gear.
TCM
Control valve
High clutch
2-4 brake
ATF deterioration
Engine performance
High clutch duty solenoid
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
Low clutch duty solenoid
2-4 brake
ATF deterioration
Engine performance
Slippage occurs when shifting from 3rd to 4th gear.
TCM
Control valve
2-4 brake
Shock occurs when shifting from 3rd to 2nd gear.
TCM
Control valve
2-4 brake
ATF deterioration
High clutch duty solenoid
Shock occurs when shifting from 2nd to 1st gear.
TCM
Control valve
ATF deterioration
Low & reverse brake duty solenoid
4AT(diag)-97
Shock occurs when accelerator pedal is released from medium
speed.
TCM
Control valve
Lock-up damper
Engine performance
Vibration occurs during straight-forward operation.
TCM
Lock-up duty solenoid
Lock-up facing
Lock-up damper
Vibration occurs during turns. (Tight corner braking phenome-
non)
TCM
Transfer clutch
Transfer valve
ATF deterioration
Harness
Front wheel slippage occurs during standing starts.
TCM
Control valve
Transfer clutch
Transfer valve
Transfer pipe
It is not set in FWD mode.
TCM
Transfer clutch
Transfer valve
Fuse
Select lever is hard to move.
Select cable
AT select lever
Detent spring
Manual plate
Select lever is excessively hard to move. (Unreasonable resis-
tance)
Detent spring
Manual plate
Select lever slips out of selected shift position during accelera-
tion or while driving on rough terrain.
Select cable
AT select lever
Detent spring
Manual plate
TCM
Body integrated unit
Gear does not change though the select lever is operated in
manual mode.
Up shift switch
Down shift switch
TCM
Body integrated unit
AWD warning light remains blinking or illuminated.
Tire size
Tire pressure
TCM
FWD fuse holder
Harness
4AT(diag)-98
5AT-2
General Description
A: SPECIFICATION
1. TORQUE CONVERTER CLUTCH
2. OIL PUMP
3. TRANSMISSION CONTROL ELEMENT
4. TRANSMISSION GEAR RATIO
5. PLANETARY GEAR AND PLATE
6. SELECTOR POSITION
7. HYDRAULIC CONTROL AND LUBRICATION
Model Turbo Non-turbo
Type
Symmetric, 3 element, single stage,
2 phase torque converter
Stall torque ratio 2.0 1.9
Nominal diameter 250 mm (9.84 in)
Stall speed
(at sea level)
2,300 3,200 rpm 1,900 2,200 rpm
One-way clutch Sprague type one-way clutch
Type Internal gear fixed displacement pump
Driving method Driven by engine
Number of teeth
Inner rotor 9
Outer rotor 10
Type
5-forward, 1-reverse,
double-row planetary gears
Multi-plate clutch 3 sets
Multi-plate brake 3 sets
One-way clutch
(sprague type)
2 sets
1st 3.540
2nd 2.264
3rd 1.471
4th 1.000
5th 0.834
Rev. 2.370
Model Turbo Non-turbo
Number of front internal gear teeth 106
Number of front carrier teeth 28
Number of front sun gear teeth 50
Number of mid internal gear teeth 78
Number of mid carrier teeth 18
Number of mid sun gear teeth 42
Number of rear internal gear teeth 110
Number of rear carrier teeth 24
Number of rear sun gear teeth 62
Number of front brake drive plates 2
Number of input clutch drive plates 6 5
Number of high & low reverse clutch
drive plates
4
Number of direct clutch drive plates 5
Number of reverse brake drive plates 5
Number of forward brake drive plates 5 4
P (Park)
Transmission is in neutral, output member
is immovable, engine start is possible
R (Reverse) Transmission is in reverse.
N (Neutral)
Transmission is in neutral and engine
start is possible
D (Drive)
Automatic gear change
1st 2nd 3rd 4th 5th
Manual mode (+)
Manual gear change
1st 2nd 3rd 4th 5th
Manual mode ()
Manual gear change
1st 2nd 3rd 4th 5th
Control method Wire cable type
Type
Electronic/hydraulic control
[5 forward gear changes
made by electronic signals of
vehicle speed and accelera-
tor (throttle) opening]
Fluid
Specified fluid: SUBARU ATF
Recommended fluid:
IDEMITSU ATF HP
Castrol Transmax J
NOTE:
Use of the recommended flu-
id is permitted only in regions
where the specified fluid is
not available.
Fluid
capacity
2 (US qt, Imp qt)
9.6 10.0
(10.1 10.6, 8.4 8.8)
Lubrication system
Forced feed lubrication with
oil pump
5AT-3
General Description
8. COOLING AND HARNESS
9. TRANSFER
10.FINAL REDUCTION GEAR
11.RECOMMENDED GEAR OIL
Cooling system Liquid-cooler incorporated in radiator
Transmission harness 20 + 8 poles
Transfer type Variable torque distribution (VTD)
Number of transfer
clutch drives and
driven plates
3
Reduction gear ratio 1.000 (41/41)
Model
3.0 R
OBK 2.5 XT
LTD
OBK 3.0 R
2.5 GT LTD
Front final reduction
gear ratio
3.272 3.083
Lubrication oil
(1) Item (3) API standard
(2) Front differential gear oil (4) SAE viscosity No. and appli-
cable temperature
Front differential oil
capacity
2 (US qt, Imp qt) 1.3 1.5 (1.4 1.6, 1.1 1.3)
(1)
(4)
GL-5
(3)
(2)
( C)
( F)
-30 -26 -15 15
90
85W
80W
75W -90
25 30 -5 0
-22 -15 23 32 86 59 77 5
MT-00001
5AT-4
General Description
B: COMPONENT
1. TORQUE CONVERTER CLUTCH & TRANSMISSION ASSEMBLY
T7
T5
T3
T6
T1
T2
T4
T3
(12)
(11)
(7) (6)
(10)
(21)
(20)
(23)
(26)
(25)
(24)
(27)
(30)
(19)
(22)
(18)
(17)
(34)
(32)
(16)
(15)
(14)
(13)
(28)
(4)
(5)
(1)
(2)
(3)
(8)
(29)
(33)
(31)
(9)
(17)
AT-04325
5AT-5
General Description
(1) Torque converter ASSY (16) O-ring (30) O-ring
(2) Circlip (17) Gasket (31) Oil seal
(3) Oil pump shaft (18) Union screw (32) Dust cover
(4) Differential oil level gauge (19) Ball (33) Floating bracket
(5) Pitching stopper bracket (20) Spring (34) Turbine speed sensor 1
(6) Differential oil drain plug (21) Union screw
(7) Gasket (22) ATF outlet pipe Tightening torque:Nm (kgf-m, ft-lb)
(8) Oil seal (23) ATF inlet pipe T1: 5 (0.5, 3.7)
(9) Lock plate (24) Magnet T2: 20 (2.0, 14.8)
(10) Side retainer (25) Oil pan T3: 25 (2.5, 18.4)
(11) O-ring (26) Gasket T4: 40 (4.1, 29.5)
(12) Oil seal (27) ATF drain plug T5: 41 (4.2, 30.2)
(13) ATF level gauge (28) Breather hose T6: 45 (4.6, 33.2)
(14) O-ring (29) Nipple T7: 70 (7.1, 51.6)
(15) Oil charge pipe
5AT-6
General Description
2. OIL PUMP & FRONT BRAKE
(1) O-ring (10) Needle bearing (19) Retainer plate
(2) Washer (11) D-ring (Inner) (20) Snap ring
(3) Oil pump housing (12) D-ring (Outer) (21) Stator shaft
(4) Oil pump rotor (13) Front brake piston (22) Needle bearing
(5) O-ring (14) Return spring
(6) Air breather hose (15) Retainer Tightening torque:Nm (kgf-m, ft-lb)
(7) Oil pump cover (16) Snap ring T1: 10 (1.0, 7.4)
(8) O-ring (17) Driven plate T2: 13 (1.3, 9.6)
(9) Nipple (18) Drive plate
AT-03806
(7)
(9)
(20)
(19)
(16)
(17)
(5)
(6)
(18)
(8)
(15)
(4)
(3)
(2)
(2)
(1)
(14)
(13)
(12)
(11)
(21)
(22)
(10)
T1
T2
5AT-7
General Description
3. FRONT PLANETARY CARRIER AND MIDDLE & REAR PLANETARY CARRIER
(1) Thrust bearing (8) Thrust bearing (15) Rear carrier ASSY
(2) Front sun gear ASSY (9) Input clutch ASSY (16) Thrust bearing
(3) Snap ring (10) Rear internal gear ASSY (17) Middle & rear sun gear ASSY
(4) Front carrier ASSY (11) Thrust bearing (18) Washer
(5) Race bearing (12) Middle carrier ASSY (19) Thrust bearing
(6) O-ring (13) Thrust bearing (20) Seal ring
(7) Seal ring (14) Race bearing
AT-03006
(2)
(6)
(7)
(8)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(9)
(3)
(4)
(5)
(1)
(20)
5AT-8
General Description
4. DIRECT CLUTCH AND HIGH & LOW REVERSE CLUTCH
(1) Thrust bearing (2) High & low reverse clutch ASSY (3) Direct clutch ASSY
AT-02018
(3)
(2)
(1)
5AT-9
General Description
5. REVERSE BRAKE
(1) Snap ring (6) Dish plate (10) Reverse brake piston
(2) Retainer plate (7) Snap ring (11) D-ring (Outer)
(3) Leaf spring (8) Retainer (12) D-ring (Inner)
(4) Drive plate (9) Leaf spring (13) AT main case
(5) Driven plate
AT-03007
(1)
(6)
(5)
(7)
(8)
(9)
(10)
(11)
(12)
(4)
(2)
(3)
(13)
5AT-10
General Description
6. SHORT AT ASSEMBLY
(1)
Short AT ASSY
(Non-disassembled)
(2) Thrust bearing (4) Thrust bearing
(3) Seal ring
(1)
AT-04385
(2)
(3)
(4)
5AT-11
General Description
7. CONTROL VALVE & TRANSMISSION HARNESS
(1) Rear vehicle speed sensor (4) Harness bracket Tightening torque:Nm (kgf-m, ft-lb)
(2) Transmission harness ASSY (5) Clip T: 7 (0.7, 5.2)
(3) Front vehicle speed sensor (6) Control valve ASSY
AT-04215
(1)
(3)
(4)
(5)
(6)
(2)
T
T
T
5AT-12
General Description
8. DIFFERENTIAL GEAR
(1) Lock plate (8) Pinion shaft (14) Differential bevel pinion
(2) Differential side retainer RH (9) Straight pin (15) Differential side retainer LH
(3) O-ring (10) Differential case RH
(4) Oil seal (11) Differential case LH Tightening torque:Nm (kgf-m, ft-lb)
(5) Taper roller bearing (12) Differential bevel gear T1: 25 (2.5, 18.4)
(6) Hypoid driven gear (13) Washer T2: 70 (7.1, 51.6 )
(7) Drive pinion shaft
AT-03807
(1)
(7)
(8)
(13)
(12)
(12)
(14)
(13)
(1)
(2)
(3)
(5)
(10)
(6)
(9)
(11)
(5)
(3)
(15)
(4)
(4)
(14)
T1
T2
T1
5AT-13
General Description
9. TRANSFER CASE, EXTENSION CASE & REDUCTION GEAR
AT-03533
(45)
(47)
(48)
(46)
(43)
(44)
(10)
(12)
(13)
(15)
(14)
(4)
(3)
(6)
(5)
(7)
(8)
(9)
(11)
(2)
(18)
(20)
(34)
(33)
(32)
(35)
(37)
(36)
(38)
(40)
(42)
(41)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(19)
(17)
(16)
(1)
(39)
(49)
5AT-14
General Description
(1) Seal ring (18) Transfer clutch hub (34) Reduction driven gear
(2) Reduction gear shim (19) Transfer clutch plate (35) Snap ring
(3) Ball bearing (20) Driven plate No. 3 (36) Ball bearing
(4) Snap ring (21) Ball bearing (37) Shim
(5) Planetary pinion washer (22) Rear drive shaft shim (38) Shim
(6) Needle bearing (23) Revolution gear (39) Extension case
(7) Spacer (24) Snap ring (40) Transmission hanger
(8) Pinion gear (25) Clutch spring retainer (41) Oil seal
(9) Washer (26) Return spring (42) Dust cover
(10) Planetary carrier ASSY (27) Spring retainer (43) Taper roller bearing
(11) Planetary pinion shaft ASSY (28) Pressure plate (44) Drive pinion shim
(12) Snap ring (29) Ball bearing (45) Oil seal
(13) Thrust bearing (30) O-ring (46) Drive pinion collar
(14) Intermediate shaft (31) D-ring (47) O-ring
(15) Thrust washer (32) Drive pinion shaft (48) Lock nut
(16) Rear drive shaft (33) Ball bearing (49) O-ring
(17) Ball bearing
5AT-15
General Description
10.TRANSMISSION CONTROL DEVICE & PARKING SUPPORT
(1) Bracket (9) Parking support actuator (17) Ball bearing
(2) Floating bracket (10) Parking pawl shaft
(3) AT main case (11) Return spring Tightening torque:Nm (kgf-m, ft-lb)
(4) Range select lever (12) Parking pawl T1: 6 (0.6, 4.4)
(5) Straight pin (13) Ball bearing T2: 7 (0.7, 5.2)
(6) Detent spring (14) Snap ring T3: 25 (2.5, 18.4)
(7) Manual plate (15) Parking gear T4: <Ref. to 5AT-78, Parking Pawl.>
(8) Parking rod (16) Reduction driven gear
T3
T3
T4
T1
T2
(1)
(2)
(3)
(10)
(11)
(8)
(7)
(5)
(4)
(6)
(12)
(13)
(14)
(15)
(16)
(17)
(9)
AT-03872
5AT-16
General Description
11.TRANSMISSION CONTROL MODULE
(1) Transmission control module
(TCM)
(3) Lateral G sensor Tightening torque:Nm (kgf-m, ft-lb)
T1: 7.5 (0.76, 5.5)
(2) Relay T2: 18 (1.8, 13.3)
AT-04381
(3)
(2)
(1)
T1
T2
T1
5AT-17
General Description
(1) Pitching stopper Tightening torque:Nm (kgf-m, ft-lb)
(2) Rear cushion rubber T1: 35 (3.6, 25.8)
(3) Crossmember T2: 40 (4.1, 29.5)
(4) Stopper T3: 50 (5.1, 36.9)
T4: 58 (5.9, 42.8)
T5: 75 (7.6, 55.3)
(2)
(3)
(4)
(1)
T4
T5
T5
T2
T2
T1
T3
AT-04382
5AT-18
General Description
C: CAUTION
forming any work.
Until the oil pan is removed, do not place with the
oil pan side facing up to prevent foreign matter from
entering the valve body.
moval, disassembly and replacement.
loy parts, disassemble them by slightly tapping with
a plastic hammer. Do not pry apart with screwdriv-
ers or other tools.
equivalent. Do not mix them of different grades or
manufacturers.
Be sure to tighten bolts and nuts to the specified
torque.
points.
Apply gear oil onto sliding or revolving surfaces
before installation.
new parts.
cient amount of ATF fluid to avoid damage and de-
formation.
move the old seal.
5AT-19
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
GAUGE ASSY
Used for measuring oil pressure.
498897200 ADAPTER Used together with oil pump cover installed on
when measuring line pressure.
ADAPTER
Used for measuring transfer clutch pressure.
498545400 OIL FILTER
WRENCH
Used for removing and installing the ATF filter.
ST-498575400
ST-498897200
ST-498897700
ST-498545400
5AT-20
General Description
498277200 STOPPER SET Used for removing and installing automatic
transmission assembly to engine.
Used for preventing the torque converter from
falling.
41099AA010 ENGINE SUPPORT
BRACKET
Used for supporting engine.
41099AA020 ENGINE SUPPORT Used for supporting engine.
bearing.
Used for removing the extension oil seal.
retainer bearing outer race.
retainer oil seal.
ST-498277200
ST41099AA010
ST41099AA020
ST-398527700
ST-498057300
5AT-21
General Description
bearing.
RETAINER
Used for removing and installing the differential
side retainer.
398487700 DRIFT Used for installing the front differential taper
roller bearing.
498255400 PLATE Used for measuring the backlash of hypoid gear.
498247001 MAGNET BASE Used for measuring the gear backlash.
Used together with the DIAL GAUGE
(498247100).
ST-498077000
ST18630AA010
ST-398487700
ST-498255400
ST-498247001
5AT-22
General Description
498247100 DIAL GAUGE Used for measuring the gear backlash.
Used together with the MAGNET BASE
(498247001).
498517000 REPLACER Used for removing the front roller bearing.
499787700 WRENCH Used for removing and installing the drive pinion
lock nut.
398744300 PISTON GUIDE Used for measuring height from mating surface
of the main case to pressure plate.
ST-498247100
ST-498517000
ST-499787700
ST-398643600
ST-398744300
5AT-23
General Description
499737100 PULLER SET Used for removing the reduction driven gear
assembly.
498077600 REMOVER Used for removing the ball bearing.
18667AA010 HOLDER Used for removing and installing the drive pin-
ion lock nut.
Used as a handle to rotate gear when check-
ing tooth contact.
MONITOR III KIT
SIDE OIL SEAL
INSTALLER
seal.
ST-499737100
ST-498077600
ST18667AA010
ST1B021XU0
ST18675AA000
5AT-24
General Description
18654AA000 INSTALLER Used for removing and installing the ball bearing.
28399SA010 OIL SEAL PROTEC-
TOR
Used for protecting oil seal when installing front
drive shaft.
18763AA000 COMPRESSOR
SHAFT
Used for disassembling multi-plate clutch for shift
transmission.
SUPPORT
transmission.
18676AA020 TORX
WRENCH Used for disassembling torque converter case.

ST18654AA000
ST28399SA010
ST18763AA000
ST18765AA000
ST18676AA020
5AT-25
General Description
18854AA000 ANGLE GAUGE Used for tightening parking support.
498077300 REMOVER Used for removing ball bearing of reduction
driven gear.
499587100 OIL SEAL
INSTALLER
Used for installing the oil seal.
499787500 ADAPTER Used for removing and installing drive pinion lock
nut.
499575400 GAUGE Used for measuring height of total end play.
ST18854AA000
ST-498077300
ST-499587100
ST-499787500
ST-499575400
5AT-26
General Description
SPECIAL TOOL
transmission.
499755602 PRESS Used for installing the parking gear.
18680AA010 HOLDER GEAR Used for removing reduction driven gear assem-
bly. (2-piece set)
18766AA000 SUPPORT PULLER Used for removing reduction driven gear assembly.
18767AA000 REMOVER Used to pull out the parking gear.
Used to pull out the bearing from the VTD
assembly.
ST18762AA000
ST-499755602
ST18680AA010
ST18766AA000
ST18767AA000
5AT-27
General Description
2. GENERAL TOOL
TOOL NAME REMARKS
Thickness gauge Used for measuring clearance of the clutch, brake and oil
pump.
Micrometer Used for measuring thickness of the drive pinion.
Spring scale Used for measuring the starting torque of the drive pinion.
Circuit tester Used for measuring resistance and voltage.
TORX
T70 Used for removing and installing differential gear oil drain plug.
Snap ring pliers Used for removing and installing each snap ring.
5AT-28
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.
176F) displayed on Subaru Select Monitor.
<Ref. to 5AT(diag)-17, READ CURRENT DATA,
3) After selecting all positions (P, R, N, D), set the
select lever in P range. Idle the engine for 1 or 2
4) Make sure that the ATF level is between upper
and lower marks of the HOT side.
5) If the ATF level is below the lower mark, add rec-
ommended ATF until the fluid level is between up-
per and lower marks.
CAUTION:
Be careful not to exceed the upper level.
When the transmission is cold, be careful not
to add ATF to the upper level on HOT side.
Overfilling of ATF may cause oil splashing.
176F) displayed on Subaru Select Monitor.
7) Check the ATF for leaks.
Visually check for leaks in the transmission. If there
are leaks, replace the gasket, oil seal, plug or other
parts.
B: REPLACEMENT
2) Remove the ATF drain plug to drain ATF.
CAUTION:
Directly after the vehicle has been running or
the engine has been long idle running, the ATF
is hot. Be careful not to burn yourself.
3) Check the condition of ATF.
<Ref. to 5AT-29, CONDITION CHECK, Automatic
4) Tighten the ATF drain plug.
NOTE:
Use a new gasket.
Tightening torque:
20 Nm (2.0 kgf-m, 14.8 ft-lb)
Specified fluid:
SUBARU ATF
Recommended fluid:
IDEMITSU ATF HP
Castrol Transmax J
NOTE:
Use of the recommended fluid is permitted only in
regions where the specified fluid is not available.
Capacity:
Capacity when transmission is overhauled:
9.6 10.0 2 (10.1 10.6 US qt, 8.4 8.8 Imp qt)
7) Check the level and leaks of ATF.
mission Fluid.>
(A) ATF level gauge
(B) Upper level
(C) Lower level
AT-04217
C
O
L
DL
F
H
O
T
L
F
(C)
(C)
(B)
(B)
(A)
(A) Oil pan
(B) ATF drain plug
(A)
AT-03126
(B)
5AT-29
C: CONDITION CHECK
NOTE:
When replacing ATF, check the inside condition of transmission body by inspecting the drained ATF.
Fluid condition Trouble and possible cause Corrective action
Large amount of metallic pieces are
found.
Internal metal parts of transmission body are
excessively worn.
Replace ATF and check if AT operates
correctly.
Is thick and is a varnish-form fluid. Clutch etc. is burned.
Replace ATF and check the AT body or
vehicle for faulty.
Clouded fluid or bubbles are found in
fluid.
Water is mixed.
Replace ATF and check the water enter-
ing point.
5AT-30
A: INSPECTION
4) Reinsert the level gauge all the way. Make sure
the level gauge is inserted correctly and in the
proper orientation.
5) Remove the oil level gauge again, and check the
level of differential gear oil. If the differential gear oil
level is below L line, add oil to bring the level up to
F line.
NOTE:
To prevent overfilling the differential gear oil, do not
add oil above the F line.
B: REPLACEMENT
TORX

oil.
CAUTION:
Immediately after the vehicle has been run-
ning or after idling for a long time, the differen-
tial gear oil will be 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.
3) Tighten the differential gear oil drain plug using
TORX
BIT T70.
NOTE:
Use a new gasket.
Tightening torque:
70 Nm (7.1 kgf-m, 51.6 ft-lb)
5) Pour gear oil into the gauge hole.
Gear oil capacity:
1.3 1.5 2 (1.4 1.6 US qt, 1.1 1.3 Imp qt)
6) Check the level of differential gear oil.
<Ref. to 5AT-30, INSPECTION, Differential Gear
Oil.>
(A) Upper level
(B) Lower level
AT-00017
( A)
( B)
L
F
(A) Oil pan
(B)
AT-03127
(A)
5AT-31
Road Test
4. Road Test
A: INSPECTION
1. GENERAL PRECAUTION
Road tests should be conducted to properly diag-
nose the condition of automatic transmission.
NOTE:
When performing the test, do not exceed posted
speed limit.
2. D RANGE SHIFT FUNCTION
Check shifting between 1st 2nd 3rd
4th 5th while driving on normal city streets.
3. D RANGE SHIFT SHOCK
Check the shock level when shifting up during nor-
mal driving.
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Check the shock
level during kick-down at the same time.
5. ENGINE BRAKE OPERATION
Check the 4th gear engine brake by shifting
down from 5th to 4th range while driving in 5th gear
Check the 3rd gear engine brake by shifting
down from 4th to 3rd range while driving in 4th gear
Check the 2nd gear engine brake by shifting down
from 3rd to 2nd range while driving in 3rd gear of man-
ual mode [40 50 km/h (25 31 MPH)].
Check the 1st gear engine brake by shifting down
from 2nd to 1st range while driving in 2nd gear of man-
ual mode [20 30 km/h (12 19 MPH)].
6. LOCK-UP FUNCTION
When the accelerator is lightly depressed while
driving on a flat road in lock-up range, check that
rpm does not change abruptly.
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 dur-
ing shifting.
9. OIL LEAKAGE
After the driving test, inspect for oil leaks from the
transmission body.
5AT-32
Stall Test
5. Stall Test
A: INSPECTION
NOTE:
The stall test is extremely important in diagnosing
the condition of an automatic transmission and en-
gine. It should be conducted to measure the engine
stall speeds in 2nd of manual mode.
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) Raise the ATF temperature to 70 to 80C (158 to
176F) by driving a distance of 5 to 10 km (3 to 6
miles). Confirm the ATF temperature on Subaru Se-
lect Monitor. <Ref. to 5AT(diag)-17, READ CUR-
RENT DATA, OPERATION, Subaru Select Monitor.>
7) Place the wheel chocks at the front and rear of
all wheels and apply the parking brake.
8) Move the manual linkage to ensure it operates
properly, then set to 2nd gear of manual mode.
9) While stepping hard on the brake pedal, gradu-
ally step on the accelerator pedal.
10) When the engine speed is stabilized, 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 one minute or more.
NOTE:
Do not continue the stall test for five seconds or
more at a time (from fully closed throttle to fully
open throttle until stall speed reading). Doing so will
make the engine oil and ATF deteriorate and the
clutch and brake to be adversely affected.
After performing the stall test, be sure to cool
down the engine for at least one minute with the se-
lect lever set in P or N range, and at an idle
speed of 1,200 rpm or less.
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.
Perform the stall test in S mode.
When depressing the accelerator pedal again af-
ter performing the stall test for five seconds or
more, the electronic throttle control remains closed
for approx. 60 seconds.
When the stall test is performed for 15 seconds
or more continuously, the test is completed forcibly
to protect the transmission unit.
When depressing the accelerator pedal again, the
electronic throttle control remains closed for ap-
prox. 60 seconds.
Stall speed (at sea level):
Turbo model
2,300 3,200 rpm
Non-turbo model
1,900 2,200 rpm
Stall speed (at sea level) Range Possible faulty parts
Over specified value
2nd gear of manual
mode
Forward brake
Direct clutch
3rd one-way clutch
5AT-33
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 be-
fore shock is felt. Using this, check the condition of
forward brake, reverse brake, 1st one-way clutch
and 3rd one-way clutch.
Perform the test at normal operation fluid tem-
perature of 70 80C (158 176F).
Be sure to allow one minute or more interval be-
tween tests.
Make three measurements and take the average
value.
Check the idle speed (A/C OFF).
3) Shift the select lever from N to D range. Using
a stop watch, measure the time-lag from shifting
the lever until the shock is felt.
Time-lag
Specification: 1.2 seconds or less
If N D time-lag is longer than specification:
Forward brake worn
One-way clutch not operating properly
4) In the same manner, measure the time lag of
N R.
Time-lag
Specification: 1.5 seconds or less
If N R time lag is longer than specification:
Reverse brake worn
5AT-34
Line Pressure Test
7. Line Pressure Test
A: MEASUREMENT
NOTE:
If the clutch or brake shows a sign of slippage, or shift-
ing interval is not correct, check the line pressure.
Excessive shock during up-shift may be due to
the line pressure being too high.
Slippage or inability to operate the vehicle may,
in most cases, be due to loss of oil pressure for the
operation of clutch, brake or control valve.
3) Remove the test plug and attach the ST.
4) Set the ST1 and ST2.
ST1 498897200 OIL PRESSURE ADAPTER
ASSY
5) Lower the vehicle, and pull ST1 and ST2 into the
vehicle.
ASSY
link connector and read the current data. <Ref. to
AT-01752
5AT-35
Line Pressure Test
7) Perform the line pressure test.
NOTE:
Do not perform the line pressure test for 5 sec-
onds or more at a time. Doing so will make the en-
gine oil and ATF deteriorate and the clutch and
brake to be adversely affected.
After performing the line pressure test, be sure to
cool down the engine for at least one minute with
the select lever set in P or N range and with the
idle speed at 1,200 rpm or less.
Fully open or fully close the throttle valve angle in
order to match the P/L Solenoid Pressure dis-
played on the Subaru Select Monitor.
Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)
Range of the
selector lever
Throttle valve
angle
ATF temperature
condition
P/L Solenoid Pressure
Monitor
kPa
Standard line pressure
kPa (kg/cm
2
, psi)
2nd gear of
manual mode
Full closed
45 55C
(113 131F)
500 700
Target pressure 10 +190
(Target pressure 0.10 +1.94,
Target pressure 1.45 +27.5)
Full open 2,150
1,320 1,520
(13.46 15.50, 191.4 220.4)
R Full closed 2,150
1,660 1,860
(16.93 18.97, 240.7 269.7)
5AT-36
8. Transfer Clutch Pressure
Test
A: INSPECTION
2) Remove the bolts holding the heat shield cover,
and move the heat shield cover to the rear.
3) Remove the test plug and attach the ST.
CAUTION:
Be careful not to cut yourself on the heat shield
cover when removing the test plugs and setting
the ST.
ST 498897800 ADAPTER SET
4) Set the ST.
ASSY
5) Lower the vehicle, and pull ST3 into the vehicle.
ST2 498897800 ADAPTER SET
ASSY
link connector and read the current data. <Ref. to
AT-03275
5AT-37
7) Perform the transfer clutch pressure test.
NOTE:
Do not perform the transfer clutch pressure test
for 5 seconds or more at a time. Doing so will make
the engine oil and ATF deteriorate and the clutch
and brake to be adversely affected.
After performing the transfer clutch pressure
test, be sure to cool down the engine for at least
one minute with the select lever set in the P or N
range, and at an idle speed of 1,200 rpm or less.
Adjust the throttle valve angle in order to obtain
the T/F Solenoid Pressure displayed on the Sub-
aru Select Monitor.
Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)
Range of the
selector lever
Throttle valve
angle
ATF temperature
condition
T/F Solenoid Pressure
Monitor
kPa
Standard transfer clutch pressure
kPa (kg/cm
2
, psi)
2nd gear of
manual mode
Full open
45 55C
(113 131F)
1,200
990 1,190
(10.09 12.13, 143.5 172.5)
Partial throttle 500
400 600
(4.08 6.12, 58.0 87.0)
N Full closed 0
0 50
(0 0.51, 0 7.3)
5AT-38
Assembly
A: REMOVAL
2) Open the front hood and support with the hood
stay.
er.>
model) <Ref. to IN(H6DO)-7, REMOVAL, Air Intake
Chamber.>
7) Remove the intake boot. (Non-turbo model)
8) Remove the air breather hose. <Ref. to 5AT-64,
REMOVAL, Air Breather Hose.>
MOVAL, Starter.>
10) Disconnect the following connectors.
Turbo model
Non-turbo model
11) Remove the engine hanger. (Turbo model)
12) Disconnect the engine harness connectors,
and then remove the engine hanger rear. (Non-tur-
bo model)
13) Remove the water by-pass pipe. (Turbo model)
(1) Front oxygen (A/F) and rear oxygen sensor
connector
AT-04406
(1)
(2) (2)
AT-04383
(2) (2)
(1) (1)
(A) Engine harness connectors
(B) Engine hanger rear
AT-04407
(B)
(A)
(A)
AT-02023
AT-01366
5AT-39
14) Separate the torque converter from drive plate.
CAUTION:
Be careful not to drop bolts into converter
housing.
verter to drive plate.
(3) Remove the four bolts by rotating the crank
pulley a little at a time.
(4) Make sure the torque converter moves free-
ly by rotating with finger through the starter in-
stallation hole.
18) Set the ST.
19) Remove the air intake duct. (Turbo model)
<Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake
Duct.>
20) Remove the air cleaner case. (Turbo model)
<Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner
Case.>
21) Remove the transmission mounting bolt (upper
side).
22) Lift up the vehicle. (Turbo model)
23) Remove the under cover. (Turbo model)
the muffler. (Turbo model) <Ref. to EX(H4DOTC)-9,
REMOVAL, Center Exhaust Pipe.> <Ref. to
EX(H4DOTC)-13, REMOVAL, Rear Exhaust Pipe.>
<Ref. to EX(H4DOTC)-15, REMOVAL, Muffler.>
25) Remove the front exhaust pipe, rear exhaust
pipe and muffler. (Non-turbo model) <Ref. to
AT-01367
AT-00103
ST
AT-03873
AT-04234
AT-02984
ST
AT-03237
5AT-40
28) Remove the oil charge pipe.
29) Disconnect the connector from turbine speed
sensor 1.
30) Remove the turbine speed sensor 1 connector
mounting bolt and rotate the sensor by 180.
CAUTION:
Failure to follow this procedure may cause the
interference between vehicle body and sensor
while removing/installing transmission, and re-
sulting in damage.
32) Remove the shift select cable. <Ref. to CS-27,
REMOVAL, Select Cable.>
33) Disconnect the hose from the ATF inlet and
outlet pipes.
34) Remove the front crossmember support plate.
<Ref. to FS-16, REMOVAL, Front Crossmember
Support Plate.>
(A) Oil pan
(B) ATF drain plug
AT-01331
(A)
AT-01361
(B)
AT-01371
AT-01642
AT-01640
AT-01390
5AT-41
35) Remove the two clutch housing cover securing
bolts.
36) Remove the front stabilizer bracket. <Ref. to
FS-17, REMOVAL, Front Stabilizer.>
37) Remove the bolts which secure front ball joint
to the housing. <Ref. to FS-18, REMOVAL, Front
Ball Joint.>
38) Pull out the drive shaft from transmission.
39) Set the transmission jack under the transmission.
40) Remove the rear crossmember.
41) Remove the transmission mounting bolt and
nut (lower side).
NOTE:
Turn the engine support assembly from the vehi-
cle under body to the left (to shorten the engine
support length), and lower the rear of the engine for
easy disassembly.
Be careful not to allow breather pipe and etc. to
touch the vehicle body when detaching the automatic
transmission assembly by pulling it backward.
AT-01373
AT-01374
AT-01376
AT-01377
AT-03238
5AT-42
B: INSTALLATION
1) Replace the front differential side retainer oil seal.
(1) Remove the oil seal by using flat tip screw-
driver etc.
(2) Install a new oil seal using ST.
SEAL INSTALLER
NOTE:
Apply oil to the oil seal lips.
Be sure to replace the differential side oil seal af-
ter the procedure of removing front drive shaft from
transmission.
2) Attach the ST to converter case.
(1) Lift up the transmission gradually using
transmission jack.
(2) Engage at the spline.
4) Install the engine mounting bolt and nut (lower side).
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
5) Install the transmission rear crossmember.
Tightening torque:
75 Nm (7.6 kgf-m, 55.3 ft-lb)
8) Install the engine mounting bolt (upper side).
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
9) Remove the ST from converter case.
11) Install the torque converter to drive plate.
CAUTION:
Be careful not to drop bolts into converter
housing.
(1) Install the bolts which hold torque converter
to drive plate.
(2) Install all four bolts by rotating the crank pul-
ley a little at a time.
(3) Install the service hole.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-00029
ST
AT-00103
ST
AT-03238
AT-01377
AT-03237
5AT-43
12) Remove the ST and install the pitching stopper
bracket.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
15) Set the ST to side retainer.
16) Install the front drive shaft into the transmission.
NOTE:
Replace the circlip of drive shaft with a new part.
17) Install the front drive shaft into transmission, re-
move the ST and insert the drive shaft securely.
18) Install the inlet and outlet hoses to the ATF inlet
and outlet pipes.
19) Insert the ball joint into housing. <Ref. to FS-18,
INSTALLATION, Front Ball Joint.>
20) Install the front stabilizer bracket. <Ref. to FS-
17, INSTALLATION, Front Stabilizer.>
21) Install the clutch housing cover securing bolts.
22) Install the front cross support plate. <Ref. to
FS-16, INSTALLATION, Front Crossmember Sup-
port Plate.>
24) Install the shift select cable. <Ref. to CS-28, IN-
STALLATION, Select Cable.>
AT-04234
T2
T1
AT-03874
AT-00110
ST
AT-01390
AT-01373
AT-01374
5AT-44
25) Install the turbine speed sensor 1 and harness,
and then connect the connector.
Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
26) Install the oil charge pipe.
NOTE:
Use new bolts.
Tightening torque:
38 Nm (3.9 kgf-m, 28.0 ft-lb)
muffler. (Turbo model) <Ref. to EX(H4DOTC)-10,
INSTALLATION, Center Exhaust Pipe.> <Ref. to
Pipe.> <Ref. to EX(H4DOTC)-15, INSTALLATION,
Muffler.>
29) Install the front exhaust pipe, rear exhaust pipe
and muffler. (Non-turbo model) <Ref. to
EX(H6DO)-5, INSTALLATION, Front Exhaust
Pipe.> <Ref. to EX(H6DO)-8, INSTALLATION,
Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10, IN-
32) Install the air cleaner case.
<Ref. to IN(H4DOTC)-8, INSTALLATION, Air
Cleaner Case.>
<Ref. to IN(H4DOTC)-9, INSTALLATION, Air In-
take Duct.>
Turbo model
Non-turbo model
35) Install the engine hanger. (Turbo model)
AT-01736
AT-01371
AT-01331
(1) Front oxygen (A/F) and rear oxygen sensor
connector
AT-04406
(1)
(2) (2)
AT-04383
(2) (2)
(1) (1)
AT-04407
5AT-45
36) Install the engine hanger rear, and then con-
nect the engine harness connector. (Non-turbo
model)
37) Install the water by-pass pipe. (Turbo model)
38) Pour ATF from the oil charge pipe. <Ref. to
5AT-28, REPLACEMENT, Automatic Transmis-
sion Fluid.>
40) Install the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, INSTALLATION, Intercooler.>
41) Install the air intake chamber. (Non-turbo mod-
el) <Ref. to IN(H6DO)-7, INSTALLATION, Air In-
take Chamber.>
42) Install the intake boot. (Non-turbo model)
45) Perform Clear Memory 2 operation. <Ref. to
5AT(diag)-19, CLEAR MEMORY MODE, OPERA-
5AT(diag)-23, GENERAL DESCRIPTION, Learning
Control.>
47) Perform the inspection at the end of repair
work, and make sure there is no faulty as below;
Oil leakage from the transmission body, etc.
Occurrence of noise caused by interference etc.
(A) Engine harness connectors
(B) Engine hanger rear
(B)
(A)
(A)
AT-02023
AT-01366
5AT-46
10.Transmission Mounting
System
A: REMOVAL
1. PITCHING STOPPER
<Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.>
Chamber.>
& REAR CUSHION RUBBER
2) Jack-up the vehicle and support it with rigid
racks.
the muffler. (Turbo model)
AL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-
15, REMOVAL, Muffler.>
4) Remove the front exhaust pipe, rear exhaust
pipe and muffler. (Non-turbo model) <Ref. to
6) Set the transmission jack under transmission.
jack does not touch the oil pan.
7) Remove the transmission rear crossmember.
8) Remove the rear cushion rubber from transmission.
AT-03873
AT-01331
AT-01377
5AT-47
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, 42.8 ft-lb)
2) Install the intercooler. (Turbo model)
<Ref. to IN(H4DOTC)-12, INSTALLATION,
Intercooler.>
3) Install the air intake chamber. (Non-turbo model)
<Ref. to IN(H6DO)-7, INSTALLATION, Air Intake
Chamber.>
1) Install the rear cushion rubber to the transmission.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
2) Install the cross member.
Tightening torque:
75 Nm (7.6 kgf-m, 55.3 ft-lb)
muffler. (Turbo model)
6) Install the front exhaust pipe, rear exhaust pipe
and muffler. (Non-turbo model) <Ref. to EX(H6DO)-
5, INSTALLATION, Front Exhaust Pipe.> <Ref. to
EX(H6DO)-8, INSTALLATION, Rear Exhaust
Pipe.> <Ref. to EX(H6DO)-10, INSTALLATION,
Muffler.>
C: INSPECTION
Repair or replace parts if the results of the inspec-
tion below are not satisfied.
1. PITCHING STOPPER
Check pitching stopper for bends or damage.
Check that there are no cracks, hardening or dam-
age on rubber parts.
Check crossmember for bends or damage. Check
that there are no cracks, hardening, or damage on
cushion rubbers.
T2
T1
AT-03874
AT-01377
AT-01331
5AT-48
Extension Case Oil Seal
11.Extension Case Oil Seal
A: INSPECTION
Inspect there is no ATF leakage from the joint of
transmission and propeller shaft. If a leak is found,
replace the oil seal. <Ref. to 5AT-48, REPLACE-
MENT, Extension Case Oil Seal.>
B: REPLACEMENT
CAUTION:
Immediately after the vehicle has been running
or after idling for a long time, the ATF will be
hot. Be careful not to burn yourself.
NOTE:
Use a new gasket.
Tightening torque:
20 Nm (2.0 kgf-m, 14.8 ft-lb)
5) Remove the rear exhaust pipe and muffler. (Tur-
bo model)
AL, Muffler.>
(Non-turbo model) <Ref. to EX(H6DO)-7, REMOV-
AL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9,
REMOVAL, Muffler.>
13) Install the rear exhaust pipe and muffler. (Turbo
model)
14) Install the rear exhaust pipe and muffler. (Non-
turbo model) <Ref. to EX(H6DO)-8, INSTALLA-
Specified fluid:
SUBARU ATF
Recommended fluid:
IDEMITSU ATF HP
Castrol Transmax J
NOTE:
Use of the recommended fluid is permitted only in
regions where the specified fluid is not available.
Capacity:
16) Check the level and leaks of the ATF. <Ref. to
5AT-28, Automatic Transmission Fluid.>
(A) Oil pan
(B) ATF drain plug
(A)
AT-01361
(B)
AT-01331
AT-01331
5AT-49
12.Differential Side Retainer Oil
Seal
A: INSPECTION
Check for leakage of gear oil from differential side
retainer oil seal part. If there is an oil leak, replace
the oil seal.
B: REPLACEMENT
2) Remove the front exhaust pipe and center exhaust
pipe. (Turbo model) <Ref. to EX(H4DOTC)-6, RE-
MOVAL, Front Exhaust Pipe.> <Ref. to
EX(H4DOTC)-9, REMOVAL, Center Exhaust Pipe.>
3) Remove the front exhaust pipe. (Non-turbo mod-
el) <Ref. to EX(H6DO)-4, REMOVAL, Front Ex-
haust Pipe.>
TORX

oil.
CAUTION:
ning or after idling for a long time, the differen-
tial gear oil will be hot. Be careful not to burn
yourself.
smoke or fire. If differential gear oil is spilled on
the exhaust pipe, wipe it off completely.
5) Tighten the differential gear oil drain plug.
NOTE:
Use a new gasket.
Tightening torque:
70 Nm (7.1 kgf-m, 51.6 ft-lb)
Shaft.>
7) Remove the differential side retainer oil seal us-
ing driver wrapped with vinyl tape etc.
SEAL INSTALLER
9) Apply oil to the oil seal lips.
haust pipe. (Turbo model) <Ref. to EX(H4DOTC)-
7, INSTALLATION, Front Exhaust Pipe.> <Ref. to
EX(H4DOTC)-10, INSTALLATION, Center Ex-
haust Pipe.>
12) Install the front exhaust pipe. (Non-turbo mod-
el) <Ref. to EX(H6DO)-5, INSTALLATION, Front
Exhaust Pipe.>
14) Pour gear oil into the level gauge hole.
Gear oil capacity:
1.3 1.5 2 (1.4 1.6 US qt, 1.1 1.3 Imp qt)
15) Check the level of differential gear oil. <Ref. to
5AT-30, INSPECTION, Differential Gear Oil.>
(A) Oil pan
(B)
AT-01362
(A)
AT-00029
ST
5AT-50
Inhibitor Switch
13.Inhibitor Switch
A: INSPECTION
Inhibitor switch cannot be checked, because the in-
hibitor switch is installed on control valve assembly.
When a malfunction occurs, refer to 5AT (diag) sec-
tion. <Ref. to 5AT(diag)-34, DTC P0705 TRANS-
MISSION RANGE SENSOR CIRCUIT (PRNDL
5AT-51
14.Front Vehicle Speed Sensor
A: REMOVAL
2) Disconnect the rear vehicle speed sensor connector.
NOTE:
Secure the harness of the transmission harness to
the transmission body using wire etc.
3) Remove the extension case.
4) Remove the center differential carrier. <Ref. to
5) Lay along the transmission case, and then re-
move the oil pan.
6) Remove the old gasket on the oil pan and trans-
mission case completely.
7) Disconnect the front vehicle speed sensor connector.
8) Remove the front vehicle speed sensor securing
bolt.
9) Remove the front vehicle speed sensor through
the hole of AT transmission main case.
AT-04218
AT-03226
AT-04219
AT-03227
5AT-52
B: INSTALLATION
1) Install the front vehicle speed sensor.
Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
2) Connect the front vehicle speed sensor connector.
Liquid gasket:
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
5) Install the center differential carrier. <Ref. to 5AT-
76, INSTALLATION, Center Differential Carrier.>
6) Install the extension case.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
7) Connect the rear vehicle speed sensor connector.
<Ref. to 5AT-42, INSTALLATION, Automatic Trans-
mission Assembly.>
9) Pour ATF from the oil charge pipe. <Ref. to 5AT-28,
REPLACEMENT, Automatic Transmission Fluid.>
10) Check the level and leaks of ATF. <Ref. to 5AT-
28, INSPECTION, Automatic Transmission Fluid.>
AT-03227
AT-04219
AT-03249
AT-03226
AT-04218
5AT-53
15.Rear Vehicle Speed Sensor
A: REMOVAL
5) Drain the ATF completely. <Ref. to 5AT-28, RE-
PLACEMENT, Automatic Transmission Fluid.>
6) Remove the center and rear exhaust pipes and the
muffler. (Turbo model) <Ref. to EX(H4DOTC)-9, RE-
MOVAL, Center Exhaust Pipe.> <Ref. to
EX(H4DOTC)-13, REMOVAL, Rear Exhaust Pipe.>
<Ref. to EX(H4DOTC)-15, REMOVAL, Muffler.>
(Non-turbo model) <Ref. to EX(H6DO)-7, REMOV-
AL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9,
REMOVAL, Muffler.>
10) Place the transmission jack under the transmission.
NOTE:
jack does not touch the cross.
bolt.
NOTE:
Do not separate the transmission jack and transmission.
AT-01331
AT-01377
AT-04218
AT-04261
5AT-54
B: INSTALLATION
Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
3) Install the transmission rear crossmember bolt.
Tightening torque:
75 Nm (7.6 kgf-m, 55.3 ft-lb)
muffler. (Turbo model)
7) Install the rear exhaust pipe and muffler. (Non-
turbo model) <Ref. to EX(H6DO)-8, INSTALLA-
9) Pour ATF from the oil charge pipe. <Ref. to 5AT-28,
REPLACEMENT, Automatic Transmission Fluid.>
10) Check the level and leaks of ATF. <Ref. to 5AT-
28, INSPECTION, Automatic Transmission Fluid.>
AT-04261
AT-04218
AT-01331
5AT-55
Turbine Speed Sensor 1
16.Turbine Speed Sensor 1
A: REMOVAL
1) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, REMOVAL, Intercooler.>
Chamber.>
4) Disconnect the turbine speed sensor 1 connector.
5) Remove the turbine speed sensor 1.
B: INSTALLATION
1) Install the turbine speed sensor 1.
Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
2) Connect the turbine speed sensor 1 connector.
Chamber.>
AT-01387
AT-01387
5AT-56
Control Valve Body
17.Control Valve Body
A: REMOVAL
CAUTION:
Immediately after the vehicle has been running
or after idling for a long time, the ATF will be
hot. Be careful not to burn yourself.
NOTE:
Use a new gasket.
Tightening torque:
20 Nm (2.0 kgf-m, 14.8 ft-lb)
CAUTION:
Be sure to prevent the entering of dust and oth-
er foreign matters into oil pan.
11) Disconnect the control valve connector and
front vehicle speed sensor connector.
12) Remove the control valve body.
NOTE:
The control valve body is replaced as an assembly
only, because it is a non-disassembly part.
(A) Control valve connector
(B) Front vehicle speed sensor connector
AT-01959
AT-04220
(A)
(B) (A)
AT-04221
5AT-57
Control Valve Body
B: INSTALLATION
foreign matter.
2) Install the control valve body to transmission by
equally tightening the bolts.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
3) Connect the control valve connector.
oil pan.
5) Apply liquid gasket to the oil pan.
Liquid gasket:
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
7) Pour ATF through the oil charge pipe.
Specified and recommended fluid:
<Ref. to 5AT-2, SPECIFICATION, General De-
scription.>
Capacity:
8) Check the ATF level.
<Ref. to 5AT-28, Automatic Transmission Fluid.>
5AT(diag)-23, GENERAL DESCRIPTION, Learning
Control.>
C: INSPECTION
Check each parts for holes, damages or other for-
eign matters.
(1) 30 mm (1.18 in)
(2) 40 mm (1.57 in)
(A) Control valve connector
(B) Front vehicle speed sensor connector
AT-04222
(1)
(1)
(1)
(1)
(1)
(1)
(2)
(1)
(1)
(2)
(1)
(1)
(1)
AT-04220
(A)
(B) (A)
AT-01959
AT-01955
5AT-58
ATF Filter
18.ATF Filter
A: REMOVAL
NOTE:
The ATF filter is maintenance free.
1) Disconnect the battery ground cable and remove
the battery from the vehicle.
2) Remove the harness securing bracket.
3) Using the ST, remove the 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 care-
ful not to damage oil seal.
3) Tighten the ATF filter using ST.
Calculate the ATF filter tightening torque using fol-
lowing 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:
NOTE:
Align the ST with the torque wrench while tighten-
ing the ATF filter.
4) Fill ATF.
5) Inspect the level of ATF. <Ref. to 5AT-28, Auto-
6) Install the harness securing bracket.
C: INSPECTION
Check for rust, hole, ATF leaks or other damage.
Replace the part if any damage is found in the in-
spection.
IN-00203
AT-01381
mm (in)
Tightening torque
Nm (kgf-m, ft-lb)
100 (3.94) 7.7 (0.79, 5.7)
150 (5.91) 9.0 (0.92, 6.7)
200 (7.87) 10 (1.0, 7.4)
5AT-59
Transmission Control Module (TCM)
19.Transmission Control Module
(TCM)
A: REMOVAL
2) Remove the lower cover and then disconnect
the connector.
4) Remove the TCM.
B: INSTALLATION
1) Install the TCM.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
2) Connect the connector to the TCM.
5AT(diag)-23, GENERAL DESCRIPTION, Learn-
ing Control.>
6) Perform the inspection at the end of repair work,
and make sure there is no faulty as below;
(B) Steering column
(B) Steering column
AT-04384
(A)
(B)
AT-04384
(A)
(B)
5AT-60
Lateral G Sensor
20.Lateral G Sensor
A: REMOVAL
2) Disconnect the connector from the lateral G sensor.
3) Remove the lateral G sensor.
B: INSTALLATION
Tightening torque:
T1: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
T2: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
AT-01343
AT-01719
T2
T1
5AT-61
21.ATF Cooler Pipe and Hose
A: REMOVAL
5) Remove the radiator under cover.
6) Disconnect the ATF cooler hose from the radiator.
NOTE:
7) Disconnect the ATF cooler hoses from the pipes.
NOTE:
8) Disconnect the ATF cooler pipe from frame.
9) Remove the ATF inlet pipe and outlet pipe.
NOTE:
When disconnecting the outlet pipe, be careful not
to lose the ball and spring used together with re-
taining screw.
CO-02355
AT-01345
AT-04451
(A) ATF outlet pipe
(B) ATF inlet pipe
AT-01347
AT-01383
(A)
(B)
5AT-62
B: INSTALLATION
1) Install the ATF inlet pipe and outlet pipe with new
washers.
NOTE:
Use new bolts for the contact area of the converter
case.
Tightening torque:
T1: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
T2: 38 Nm (5.9 kgf-m, 28.0 ft-lb)
T3: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
2) Install the ATF cooler pipe to frame.
transmission side.
NOTE:
radiator side.
NOTE:
5) Install the radiator under cover.
Tightening torque:
4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
8) Fill ATF. <Ref. to 5AT-28, Automatic Transmis-
sion Fluid.>
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
AT-03133
T2
T1 T2
T3
AT-01347
AT-04451
AT-01345
CO-02355
5AT-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 trans-
mission, radiator, pipes, and hoses.
2) Check the clamp for deformation.
3) Lightly bend the hose and check for cracks in the
surface or other damages.
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.
5AT-64
Air Breather Hose
22.Air Breather Hose
A: REMOVAL
Chamber.>
B: INSTALLATION
1) Connect the air breather hose.
Chamber.>
C: INSPECTION
AT-03252
AT-03252
5AT-65
Oil Charge Pipe
23.Oil Charge Pipe
A: REMOVAL
<Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.>
Chamber.>
3) Remove the oil charge pipe, and then remove
the O-ring from flange side.
B: INSTALLATION
1) Install the oil charge pipe with a new O-ring.
NOTE:
Use new bolts.
Tightening torque:
38 Nm (3.9 kgf-m, 28.0 ft-lb)
Chamber.>
C: INSPECTION
Make sure the oil charge pipe is not deformed or
damaged.
(A) ATF level gauge
(B) Oil charge pipe
(A) ATF level gauge
(B) Oil charge pipe
AT-01386
(B)
(A)
AT-01386
(B)
(A)
5AT-66
Torque Converter Assembly
24.Torque Converter Assembly
A: REMOVAL
2) Pull out the torque converter and oil pump shaft
horizontally.
NOTE:
Be sure not to scratch the inside of bushing in oil
pump shaft.
Be careful that the oil pump shaft may drawn out
simultaneously.
3) Remove the oil pump shaft from torque convert-
er as necessary.
B: INSTALLATION
1) When the oil pump shaft is removed, install the
shaft to torque converter.
NOTE:
Make sure the clip is firmly inserted.
2) Install the oil pump shaft to torque converter, and
then make sure that the clip is secured on groove.
3) Apply ATF to the revolving and sliding surface of
the oil pump shaft.
4) Holding the torque converter assembly by hand,
lightly rotate it to engage with the oil pump rotor.
5) Check the protruding dimension of the torque
converter assembly.
Dimension A:
8 mm (0.31 in) or less
mission Assembly.>
C: INSPECTION
Make sure the ring gear and protrusion of torque
converter end are not deformed or damaged.
AT-00113
AT-04452
A
5AT-67
Extension Case
25.Extension Case
A: REMOVAL
1) Remove the transmission assembly.
<Ref. to 5AT-38, REMOVAL, Automatic Transmis-
sion Assembly.>
B: INSTALLATION
1) Attach the selected reduction driven gear shim
to end surface of reduction driven gear with vase-
line. <Ref. to 5AT-75, ADJUSTMENT, Reduction
Driven Gear.>
NOTE:
Use a new gasket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
mission Assembly.>
AT-04218
AT-04261
AT-03226
AT-03226
AT-04261
AT-04218
5AT-68
Extension Case
C: DISASSEMBLY
1) Take out the transfer clutch and multi-plate
clutch hub assembly by lightly tapping the end of
rear drive shaft.
NOTE:
Be careful not to damage the oil seal of the extension.
2) Remove the snap ring using the ST and press.
ST 18762AA000 COMPRESSOR SPECIAL
TOOL
3) Remove the clutch piston by applying com-
pressed air.
D: ASSEMBLY
3) Insert the transfer clutch assembly, spring re-
tainer, return spring and clutch spring retainer.
4) Using the ST and compressor, install the snap
ring.
ST 18762AA000 COMPRESSOR SPECIAL
TOOL
5) Install the transfer clutch. <Ref. to 5AT-69, IN-
STALLATION, Transfer Clutch.>
6) Install the multi-plate hub assembly.
E: INSPECTION
Use compressed air to make sure the extension
case routes are not clogged or leaking.
<Ref. to 5AT-69, ADJUSTMENT, Transfer Clutch.>
AT-03228
ST
AT-03229
(A) Clutch spring retainer
(B) Return spring
(C) Spring retainer
(D) Transfer clutch piston ASSY
AT-03230
(A)
(B)
(C)
(D)
AT-03228
ST
5AT-69
Transfer Clutch
26.Transfer Clutch
A: REMOVAL
2) Remove the extension case, and then remove
the transfer clutch. <Ref. to 5AT-67, REMOVAL,
Extension Case.>, <Ref. to 5AT-68, DISASSEM-
BLY, Extension Case.>
B: INSTALLATION
1) Select the rear drive shaft shim. <Ref. to 5AT-69,
ADJUSTMENT, Transfer Clutch.>
2) Select driven plate No. 3. <Ref. to 5AT-69, AD-
JUSTMENT, Transfer Clutch.>
3) Install the extension case. <Ref. to 5AT-67, IN-
STALLATION, Extension Case.>
mission Assembly.>
C: INSPECTION
Inspect the drive plate facing for wear and damage.
or deformation.
Check that the D-ring is not damaged.
within the standard value. <Ref. to 5AT-69, AD-
D: ADJUSTMENT
1. REAR DRIVE SHAFT SHIM SELECTION
1) Insert the rear drive shaft into the reduction drive
gear and center differential assembly.
2) Using the ST, measure the depth A, which is
from mating surface of extension case to ball bear-
ing outer ring contact surface.
ST 398643600 GAUGE
3) Using the ST, measure the height B from the
AT main case mating surface to ball bearing outer
ring contact surface.
ST 398643600 GAUGE
A Measured value
B Measured value
AT-03231
AT-03232
A
AT-03233
B
5AT-70
Transfer Clutch
When clearances are 0.05 mm (0.0020 in):
T (mm) = A B + 0.23
[T (in) = A B + 0.009]
T (mm) = A B + 0.03
[T (in) = A B + 0.001]
A: Depth from end of extension case to ball bearing
outer ring contact surface
B: Height from end of AT main case contact surface
to the ball bearing outer ring contact surface
T: Shim thickness
Standard:
0.05 0.25 mm (0.0020 0.0098 in)
NOTE:
Calculation formula for T above is applied when
measuring with the ST (398643600 GAUGE).
When not using the ST,
T (mm) = (A ) ((B ) 0.28) 0.05
[T (in) = (A ) ((B ) 0.011) 0.0020]
T (mm) = (A ) ((B ) 0.28) 0.25
[T (in) = (A ) ((B ) 0.011) 0.0098]
is applied.
T: Shim thickness
A: Depth from end of extension case to ball bearing
outer ring contact surface
B: Height from end of AT main case contact surface
to the ball bearing outer ring contact surface
: Thickness of collar used when measuring A
: Thickness of collar used when measuring B
0.28 (0.011): Gasket thickness (Unit mm (in))
2. SELECTION OF DRIVEN PLATE NO. 3
1) Install the drive plate and driven plate to the cen-
ter differential carrier.
2) Measure the depth A from the mating surface
of the extension case to the multi-plate clutch
(LSD) piston.
3) Using the ST, measure the height B from the
AT main case mating surface to end of ST, and
then subtract the thickness of ST (piston guide)
(50 mm (1.97 in)) from measured value.
ST 398744300 PISTON GUIDE
Adjustment shim
33281AA040 0.2 (0.008)
33281AA050 0.5 (0.020)
33281AA060 0.3 (0.012)
A Measured value
B Measured value
AT-03234
A
AT-03235
B
5AT-71
Transfer Clutch
T (mm) = A B + 0.08
[T (in) = A B + 0.0031]
T (mm) = A B 0.32
[T (in) = A B 0.0126]
T: Thickness of driven plate No. 3
A: Depth from mating surface of extension case to
multi-plate clutch (LSD) piston
B: Height from AT main case mating surface to end
of ST
Standard:
0.2 0.6 mm (0.008 0.024 in)
NOTE:
Calculation formula for T is applied when measur-
ing using ST (398643600 GAUGE, 398744300
PISTON GUIDE). When not using the ST,
T (mm) = A (B 0.28) 0.2
[T (in) = A (B 0.011) 0.008]
T (mm) = A (B 0.28) 0.6
[T (in) = A (B 0.011) 0.024]
is applied.
T: Thickness of driven plate No. 3
A: Depth from mating surface of extension case to
multi-plate clutch (LSD) piston
B: Height from the AT main case mating surface to
the contact face of the tool that was used as the
substitute of the ST.
: Thickness of tool used when measuring B
0.28 (0.011): Gasket thickness (Unit mm (in))
If it is out of specification, select the driven plate No.
3 to adjust within the specification.
Driven plate No. 3
31589AA041 1.6 (0.063)
31589AA050 2.0 (0.079)
31589AA060 2.4 (0.094)
31589AA070 2.8 (0.110)
5AT-72
Rear Drive Shaft
27.Rear Drive Shaft
A: REMOVAL
body. <Ref. to 5AT-38, REMOVAL, Automatic Trans-
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
remove the extension case. <Ref. to 5AT-67, RE-
MOVAL, Extension Case.>
3) Pull out the rear driveshaft from center differen-
tial assembly.
4) Remove the drive plate and driven plate.
B: INSTALLATION
1) Select the shim. <Ref. to 5AT-69, ADJUST-
MENT, Transfer Clutch.>
2) Install drive plate and driven plate.
3) Insert the rear driveshaft into the center differen-
tial assembly.
4) Combine the extension case, and then install the
rear vehicle speed sensor. <Ref. to 5AT-67, IN-
mission Assembly.>
C: DISASSEMBLY
1) Using a press, remove the revolution gear.
2) Using a press, remove the front and rear side
ball bearings and clutch hub.
D: ASSEMBLY
NOTE:
Use new ball bearings and revolution gear.
Make sure the clutch hub is facing the correct direction.
E: INSPECTION
Check each parts for holes, damages or other
foreign matters.
(A) Revolution gear
AT-03231
AT-00149
(A)
(A) Rear ball bearing
(C) Clutch hub
(A) Front side
(B) Clutch hub
(C) Rear side
(D) Revolution gear
AT-00151
(A)
(B)
(C)
AT-00152
(A)
(B)
(C)
(D)
5AT-73
A: REMOVAL
mission Assembly.>
5) Using ST1, ST2 and ST3, pull out the reduction
driven gear.
ST2 18680AA010 GEAR HOLDER
ST3 18766AA000 SUPPORT PULLER
B: INSTALLATION
2) Use a plastic hammer to install reduction driven
gear assembly.
3) Select the reduction gear shims. <Ref. to 5AT-
75, ADJUSTMENT, Reduction Driven Gear.>
Case.>
mission Assembly.>
C: DISASSEMBLY
1) Remove the ball bearing from reduction driven
gear using ST.
2) Remove the ball bearing on the reverse side with
the same procedure as step 1).
3) Remove the snap ring of the parking gear.
AT-03271
ST2
ST1
ST2
ST3
(A)
(A) Ball bearing
(A) Ball bearing
AT-00157
(A)
ST
AT-01969
(A)
ST
AT-03264
5AT-74
4) Using the ST, remove the parking gear.
ST 18767AA000 REMOVER
D: ASSEMBLY
1) Using the ST, install the parking gear.
ST 499755602 PRESS
3) Install the new ball bearing to reduction driven
gear using press.
ST 18654AA000 INSTALLER
4) Install the ball bearing on the reverse side with
the same procedure as step 3).
E: INSPECTION
Make sure the ball bearing and gear is not de-
formed or damaged.
(A) Ball bearing 1
AT-03265
ST
AT-03266
ST
AT-03264
AT-03267
ST
AT-03268
ST
5AT-75
F: ADJUSTMENT
1) Using the ST, measure the height A from the
AT main case mating surface to ball bearing outer
ring contact surface.
ST 499575400 GAUGE
2) Using the ST, measure the depth B, which is
from mating surface of extension case to ball bear-
ing outer ring contact surface.
ST 499575400 GAUGE
Select the ball bearing shim from the table to adjust
clearances within 0.05 0.25 mm
(0.0020 0.0098 in).
T (mm) = B A + 0.23
[T (in) = B A + 0.0091]
T (mm) = B A + 0.03
[T (in) = B A + 0.0011]
T: Shim clearance
A: Height from the mating surface of the AT main
case to the ball bearing outer ring end surface
B: Depth from mating surface of extension case to
ball bearing outer ring contact surface
A Measured value
B Measured value
Reduction gear shim
31288AA030 0.2 (0.008)
31288AA050 0.5 (0.020)
31288AA060 0.3 (0.012)
AT-03269
ST
A
AT-03270
ST
B
5AT-76
29.Center Differential Carrier
A: REMOVAL
mission Assembly.>
3) Extract the rear drive shaft. <Ref. to 5AT-72, RE-
MOVAL, Rear Drive Shaft.>
4) Pull out the center differential carrier assembly.
5) Pull out the shim(s) from transmission case.
B: INSTALLATION
1) Install the center differential assembly with the
shim(s).
NOTE:
Press-fit it to the bottom of bearing shoulder completely.
2) Insert the rear drive shaft. <Ref. to 5AT-72, IN-
STALLATION, Rear Drive Shaft.>
Case.>
mission Assembly.>
C: DISASSEMBLY
2) Using a press and ST, remove the ball bearing.
3) Remove the snap ring, and pull out the shaft
from center differential assembly.
AT-01972
AT-01972
(A) Seal ring
(A) Snap ring
(B) Shaft
(A)
AT-02015
AT-00167
AT-01973
(A)
(B)
5AT-77
4) Remove the thrust washers, pinion gears and
washers from center differential assembly.
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.
and shaft grooves.
8) Install a new seal ring.
E: INSPECTION
Check each parts for holes, damages or other
foreign matters.
(A) Pinion gear
(A) Plate
AT-00169
(A)
AT-00170
(A)
(B)
ST
5AT-78
Parking Pawl
30.Parking Pawl
A: REMOVAL
mission Assembly.>
2) Remove the extension case. <Ref. to 5AT-67,
REMOVAL, Extension Case.>
4) Remove the front vehicle speed sensor. <Ref. to
5AT-51, REMOVAL, Front Vehicle Speed Sensor.>
5) Remove the parking support actuator.
6) Remove the parking pawl, parking pawl shaft
and return spring.
B: INSTALLATION
1) Set the transmission to the N range.
2) Install the parking pawl, parking pawl shaft and
return spring.
3) Install the parking support actuator.
Tightening torque:
102 Nm (1.00.2 kgf-m, 7.41.5 ft-lb)
AT-03236
AT-03272
AT-03272
AT-03236
5AT-79
Parking Pawl
4) Using the ST, tighten the bolts which tightened in
step 3) with specified angle.
Tightening angle:
172
ST 18854AA000 ANGLE GAUGE
NOTE:
Do not use extension as much as possible.
5) Make sure that the return spring is sticking out of
the parking pole hole.
6) Install the front vehicle speed sensor. <Ref. to
5AT-52, INSTALLATION, Front Vehicle Speed
Sensor.>
mission Assembly.>
C: INSPECTION
Make sure that the tab of parking pawl on reduction
driven gear is not worn or otherwise damaged.
(A) Parking pawl
(B) Return spring
AT-02071
ST
AT-02072
ST
AT-03370
B
(A)
(B)
B
B B
5AT-80
Converter Case
31.Converter Case
A: REMOVAL
mission Assembly.>
2) Remove the torque converter assembly. <Ref. to
from stay.
4) Remove the turbine speed sensor 1. <Ref. to
5AT-55, REMOVAL, Turbine Speed Sensor 1.>
7) Remove the converter case attachment bolts.
8) Lay along the transmission body, and then re-
move the oil pan.
9) Remove the three converter case mounting bolts
(TORX
).
ST 18676AA020 TORX
WRENCH
10) Separate the converter case by lightly tapping
with plastic hammer.
11) Remove the front differential assembly. <Ref. to
5AT-92, REMOVAL, Front Differential Assembly.>
12) Remove the oil seal from converter case.
B: INSTALLATION
1) Check the appearance of each component and
clean them.
2) Press-fit the oil seal to converter case using ST.
3) Install the front differential assembly to the case.
<Ref. to 5AT-92, INSTALLATION, Front Differen-
tial Assembly.>
4) Install the right and left side retainers. <Ref. to 5AT-
96, ADJUSTMENT, Front Differential Assembly.>
tire matching surface of converter case.
Liquid gasket:
6) Install the converter case assembly without
damaging bushing and oil seal.
NOTE:
Use new bolts for the oil charge pipe and ATF cool-
er pipe.
Tightening torque:
Oil charge pipe and ATF cooler pipe
38 Nm (3.9 kgf-m, 28.0 ft-lb)
Other than above
41 Nm (4.2 kgf-m, 30.2 ft-lb)
AT-04224
AT-01979
ST
AT-01975
5AT-81
Converter Case
7) Install the three converter case mounting bolts
(TORX
).
ST 18676AA020 TORX
WRENCH
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
tire oil pan mating surface, and then install it.
Liquid gasket:
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
9) Install the transmission harness connector to the
stay.
12) Install the oil charge pipe with O-ring. <Ref. to
5AT-65, INSTALLATION, Oil Charge Pipe.>
13) Install the torque converter assembly. <Ref. to 5AT-
66, INSTALLATION, Torque Converter Assembly.>
C: INSPECTION
Measure the backlash, and then adjust it to be with-
in standard values. <Ref. to 5AT-89, ADJUST-
MENT, Drive Pinion Shaft Assembly.>
AT-04224
AT-03249
5AT-82
Oil Pump Cover
32.Oil Pump Cover
A: REMOVAL
mission Assembly.>
from stay.
Case.>
7) Remove the oil pump cover mounting bolt, and
then separate the oil pump cover from the AT main
case by lightly tapping with plastic hammer.
B: INSTALLATION
1) Secure the oil pump cover.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
2) Install the converter case assembly to the trans-
mission case assembly. <Ref. to 5AT-80, INSTAL-
LATION, Converter Case.>
stay.
Pipe.>
Transmission Assembly.> AT-01976
AT-01976
5AT-83
Oil Pump Cover
C: DISASSEMBLY
1. FRONT BRAKE
2) Remove the retainer plate, drive plate and driven
plate.
3) Using the ST1, ST2 and ST3, remove the snap
ring.
ST1 18762AA000 COMPRESSOR SPECIAL
TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 18763AA000 COMPRESSOR SHAFT
4) Remove the retainer and return spring.
5) Remove the front brake piston using compressed
air.
6) Remove the D-ring from front brake piston.
2. OIL PUMP
1) Take out the oil pump housing.
2) Take out the oil pump body.
AT-01980
AT-01981
ST1
ST2
ST3
AT-02349
AT-01982
5AT-84
Oil Pump Cover
D: ASSEMBLY
1. FRONT BRAKE
1) Apply ATF to D-ring, and then install it to the
front brake piston.
2) Install the front brake piston to oil pump cover.
NOTE:
Install by aligning the mark on front brake pis-
ton surface with the oil pump cover rib.
3) Install the retainer and return spring.
4) Install the front brake piston assembly using
ST1, ST2 and ST3.
TOOL
5) Install the genuine driven plate instead of retain-
er plate, and temporarily assemble the drive plate
and driven plate.
Part No. 31536AA290 DRIVEN PLATE
7) Measure the clearance between retainer plate
and snap ring, and then select the suitable retainer
plate from table.
Front brake clearance specification:
0.7 1.1 mm (0.028 0.043 in)
8) Remove the snap ring, replace the drive plate
used in measurement of clearance with the retainer
plate, and then reassemble.
2. OIL PUMP
1) Apply ATF to oil pump assembly, and then install
it to oil pump housing.
2) Install the O-ring to oil pump cover.
3) Install the oil pump housing to the oil pump cover.
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
AT-02350
AT-01981
ST1
ST2
ST3
Front brake retainer plate
31567AB130 3.4 (0.134)
31567AB140 3.6 (0.142)
31567AB150 3.8 (0.150)
31567AB160 4.0 (0.157)
AT-01980
AT-01983
AT-01982
5AT-85
Oil Pump Cover
E: INSPECTION
1. FRONT BRAKE
Drive plate facing for wear and damage
Snap ring for wear, return spring for damage,
and retainer for damage
Piston for damage
D-ring for damage
2. OIL PUMP
Oil pump cover and oil seal for breakage or damage
Oil pump body for scratch or damage
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 inner rotor and outer rotor to oil pump
housing. With rotor gears facing each other,
measure the crest-to-crest clearance.
Tip clearance:
0.02 0.15 mm (0.0008 0.0059 in)
(2) Side clearance
Set a depth gauge to oil pump housing, then mea-
sure the oil pump housing-to-rotor clearance.
Side clearance:
0.02 0.045 mm (0.0008 0.0018 in)
(3) If the depth and/or side clearance are not with-
in the specification, replace the rotor assembly.
within specifications. <Ref. to 5AT-107, AD-
JUSTMENT, AT Main Case.>
(A) Thickness gauge
(B) Inner rotor
(C) Outer rotor
AT-01977
(A)
(B)
(C)
(A) Depth gauge
(B) Inner rotor
(C) Outer rotor
Oil pump rotor assembly
15008AA130 11.37 11.38 (0.4476 0.4480)
15008AA140 11.38 11.39 (0.4480 0.4484)
15008AA150 11.39 11.40 (0.4484 0.4488)
AT-01978
(A)
(C)
(B)
5AT-86
A: REMOVAL
mission Assembly.>
from stay.
Case.>
8) Remove the drive pinion shaft mounting bolts,
and then remove the drive pinion shaft assembly
from oil pump cover.
9) Remove the oil pump cover from AT main case.
<Ref. to 5AT-82, Oil Pump Cover.>
B: INSTALLATION
1) Assemble the drive pinion assembly to oil pump
cover.
NOTE:
Be careful not to bend the shim.
Tightening torque:
70 Nm (7.1 kgf-m, 51.6 ft-lb)
2) Adjust the tooth contact between drive pinion
shaft assembly and the front differential side gear.
<Ref. to 5AT-89, ADJUSTMENT, Drive Pinion
Shaft Assembly.>
3) Join the converter case with the transmission
Case.>
stay.
6) Install the oil charge pipe with O-ring.
mission Assembly.>
AT-01984
AT-01984
5AT-87
C: DISASSEMBLY
1) Flatten the lock nut tab, and then remove the
lock nut while holding the rear spline part of the
shaft using ST1 and ST2. Pull out the drive pinion
collar.
ST1 18667AA010 HOLDER
3) Separate the roller bearing and outer race from
shaft using a press.
4) Separate the front roller bearing from shaft using
a press and ST.
D: ASSEMBLY
1) Measure the dimension A of the drive pinion
shaft.
ST 398643600 GAUGE
2) Using a press, press-fit the new roller bearing
into the specified position.
NOTE:
If excessive force is applied to roller bearing, the
roller bearing will not turn easily.
3) After fitting a new O-ring to the shaft, attach the
drive pinion collar to the shaft.
(A) Outer race
(A) Front roller bearing
AT-00197
ST1
ST3
ST2
AT-00198
(A)
AT-00199
(A)
ST
(B) Roller bearing
A
AT-00200
AT-00201
(B)
(A)
5AT-88
4) Tighten the new lock nuts using ST1, ST2 and
ST3.
Use the calculation below to calculate the tighten-
ing torque.
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:
NOTE:
Attach ST2 to torque wrench as straight as possible.
5) 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, re-
place the roller bearing.
Starting torque:
7.6 38.1 N (0.776 3.88 kgf, 1.7 8.6 lb)
6) Crimp the locknut in 2 locations.
7) Measure the dimension B of the drive pinion
shaft.
ST 398643600 GAUGE
8) Calculate the thickness t (mm) of the drive pin-
ion shim.
t = 6.50.0625 (B A)
9) Select three or less shims from following table.
E: INSPECTION
Make sure that all component parts are free of
scratches, holes and other faults.
Adjust the tooth alignment. <Ref. to 5AT-89, AD-
JUSTMENT, Drive Pinion Shaft Assembly.>
m (in)
Tightening torque
Nm (kgf-m, ft-lb)
0.4 (15.75) 98 (10.0, 72)
0.45 (17.72) 100 (10.2, 73.8)
0.5 (19.69) 101 (10.3, 74.5)
0.55 (21.65) 102 (10.4, 75)
ST1
AT-00202
L1 [m (in)]
L2 [m (in)]
ST2
ST3
AT-00203
Drive pinion shim
31451AA180 0.150 (0.0059)
31451AA190 0.175 (0.0069)
31451AA200 0.200 (0.0079)
31451AA210 0.225 (0.0089)
31451AA220 0.250 (0.0098)
31451AA230 0.275 (0.0108)
B
AT-00204
5AT-89
F: ADJUSTMENT
face completely.
2) Install the converter case to oil pump cover, and
secure them with tightening four bolts evenly.
NOTE:
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
and ST2.
4) Adjust the drive pinion and hypoid driven gear
backlash. <Ref. to 5AT-96, ADJUSTMENT, Front
Differential Assembly.>
5) Apply lead-free red dye evenly to the surfaces of
three or four teeth on hypoid driven gear. Rotate
the drive pinion in the leftward and rightward for
several times. Remove the oil pump cover, and
check the tooth contact pattern.
If the teeth contact is inappropriate, adjust the
backlash or shim thickness. <Ref. to 5AT-96, AD-
JUSTMENT, Front Differential Assembly.>
side.)
Face contact
Contact pattern
Corrective action: Increase thickness of pinion
dures for moving the drive pinion closer to the driv-
en gear.
(A) Toe side
(B) Heel side
AT-01985
ST2 ST1
(A)
(B)
MT-01401
AT-00208
AT-00212
5AT-90
Flank contact
Contact pattern
Corrective action: Reduce thickness of the pinion
dures for moving the drive pinion away from the
driven gear.
Contact pattern
driven gear side.
AT-00209
AT-00213
AT-00210
AT-00213
5AT-91
Contact pattern
dures for moving the drive pinion closer to the driv-
en gear.
6) If tooth contact is correct, mark the retainer posi-
tion and loosen it. After fitting a new O-ring and oil
seal, screw in the retainer to the marked position.
Tighten the lock plate with specified torque.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
(A) Lock plate
AT-00211
AT-00212
AT-01988
(A)
5AT-92
A: REMOVAL
mission Assembly.>
from stay.
Case.>
7) Remove the differential side retainers using ST.
ST 18630AA010 WRENCH COMPL RETAINER
NOTE:
Hold the differential case assembly by hand to
avoid damaging the retainer mounting hole of the
converter case.
8) Remove the differential assembly while being
careful not to damage the attachment part of retainer.
B: INSTALLATION
1) When installing the front differential assembly to
case, be careful not to damage the inside of case
(particularly, the differential side retainer mating
surface).
2) Install the O-ring to left and right side retainer.
3) Using the ST, install the side retainer. <Ref. to
5AT-92, INSTALLATION, Front Differential Assem-
bly.>
4) Adjust the backlash of the front differential. <Ref. to
5AT-96, ADJUSTMENT, Front Differential Assembly.>
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
Case.>
stay.
Pipe.>
(A) Front differential ASSY
AT-01987
(A)
(A) Lock plate
AT-01988
(A)
5AT-93
C: DISASSEMBLY
1) Remove the taper roller bearing using the ST
and a press.
2) Secure the case in a vise, remove the hypoid
driven gear tightening bolts, and then separate the
hypoid driven gear into case (RH) and case (LH).
3) Pull out the straight pin and shaft, and then re-
move the differential bevel gear, washer and differ-
ential bevel pinion.
2. SIDE RETAINER
NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
3) Remove the split pin, and then remove the claw.
AT-00216
(B)
AT-00217
(A)
(C)
AT-00218
(A)
(A) Claw
(B) Split pin
(C) Pin
AT-00219
MT-01454
AT-00221
5AT-94
4) Attach two claws to the outer race, and set the
ST to side retainer.
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 side
retainer, and then remove the bearing outer race.
NOTE:
Replace the bearing inner and outer races as a
single unit.
D: ASSEMBLY
1) Install the washer, differential bevel gear and dif-
ferential bevel pinion in the differential case (RH).
Insert the pinion shaft.
2) Attach the straight pin in the reverse direction.
3) Install the washer and differential bevel gear to
the differential case (LH). Put the differential case
(RH) on the case, and assemble two cases.
4) Install the hypoid driven gear and secure by
tightening the bolt.
Tightening torque:
70 Nm (7.1 kgf-m, 51.6 ft-lb)
(A) Shaft
(B) Claw
(A) Shaft
(B) Side retainer
AT-00222
AT-00223
AT-00218
(A)
(B)
AT-00217
(A)
(C)
5AT-95
5) Measurement of backlash (Selection of washer)
(1) Install the SUBARU genuine axle shaft to
differential case.
(2) Measure the gear backlash using ST1 and
ST2, and then insert the ST2 though the access
window of case.
NOTE:
Measure the backlash by applying a differential
bevel pinion tooth between two differential bevel
gear teeth.
Fix the differential bevel pinion gear in place with
a screwdriver covered with cloth or similar tool
when measuring.
Standard:
0.13 0.18 mm (0.0051 0.0071 in)
(3) If the backlash is not within specification, se-
lect a washer from the table below.
6) Using the ST, install the taper roller bearing.
ST 398487700 DRIFT
2. SIDE RETAINER
NOTE:
Install the oil seal and O-ring of side retainer after
the adjustment of backlash and tooth contact.
1) Install the bearing outer race to side retainer.
2) Install a new oil seal using ST.
SEAL INSTALLER
NOTE:
3) Install a new O-ring.
E: INSPECTION
Check each component for scratches, damage
or other faults.
Measure the backlash, and then adjust it to be
<Ref. to 5AT-96, ADJUSTMENT, Front Differential
Assembly.>
Washer
803038021 0.95 (0.037)
803038022 1.00 (0.039)
803038023 1.05 (0.041)
AT-00224
ST2
ST1
AT-00226
ST
AT-00219
5AT-96
F: ADJUSTMENT
1) Using the ST, screw-in the retainer until resis-
tance is felt.
NOTE:
Screw in the RH side slightly deeper than the LH
side.
face completely.
4) Install the oil pump cover to converter case, and
secure them with tightening four bolts evenly.
NOTE:
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
5) Rotate the drive pinion ten times or more using
ST1 and ST2.
6) Tighten the LH retainer by rotating the shaft until
resistance is felt. Then loosen the retainer RH.
Keep tightening the retainer LH, and loosening the
retainer RH until the pinion shaft no longer be
turned. This is the zero state.
7) After the zero state is established, loosen the
retainer LH by 3 notches and secure it with the lock
plate. Then loosen the retainer RH and retighten
until it stops. Rotate the drive pinion 2 or 3 times.
Tighten the retainer RH further 1-3/4 notches. This
sets the preload. Finally, secure the retainer with its
lock plate.
NOTE:
Turning the retainer by one tooth changes the
backlash approx. 0.05 mm (0.0020 in).
AT-00227
ST
AT-01985
ST2 ST1
(A) Retainer
(A) Lock plate
(A) 0.05 mm (0.0020 in)
AT-01986
(A)
AT-01988
(A)
AT-01989
(A)
5AT-97
8) Turn the drive pinion several times using ST1,
and check to see if the backlash is within the spec-
ification using ST2, ST3, ST4 and ST5.
ST5 498255400 PLATE
Backlash:
0.13 0.18 mm (0.0051 0.0071 in)
9) Adjust the teeth contact of the front differential
and drive shaft. <Ref. to 5AT-89, ADJUSTMENT,
Drive Pinion Shaft Assembly.>
5AT-98
AT Main Case
35.AT Main Case
A: REMOVAL
mission Assembly.>
from stay.
7) Remove the extension case. <Ref. to 5AT-67,
9) Remove the reduction driven gear. <Ref. to 5AT-
73, REMOVAL, Reduction Driven Gear.>
Case.>
11) Remove the control valve body. <Ref. to 5AT-
56, REMOVAL, Control Valve Body.>
<Ref. to 5AT-82, REMOVAL, Oil Pump Cover.>
NOTE:
The input clutch pack assembly and front sun gear
assembly are also removed together.
13) Remove the needle bearing of the middle carri-
er assembly.
14) Remove the middle carrier assembly.
15) Remove the rear carrier assembly.
AT-01990
AT-01991
AT-01992
AT-01993
5AT-99
AT Main Case
16) Remove the middle & rear sun gear assembly.
17) Remove the thrust needle bearing of high & low
reverse clutch.
18) Remove the high & low reverse clutch assembly.
19) Remove the direct clutch assembly.
20) Remove the snap ring of reverse brake.
21) Remove the retaining plate.
22) Remove the leaf spring.
23) Take out the drive plate, driven plate and dish
plate.
AT-01994
AT-01995
AT-01996
(A) Leaf spring
AT-01997
AT-01998
AT-01999
(A)
B' B
(A)
B' B
5AT-100
AT Main Case
24) Remove the snap ring of the reverse brake
spring retainer.
TOOL
25) Remove the spring retainer.
26) Remove the return spring.
27) Apply compressed air.
28) Remove the reverse brake piston.
29) Remove the thrust bearing and the seal ring.
AT-02000
ST3
ST2
ST1
AT-02001
AT-02002
(A) Thrust bearing
(B) Seal ring
AT-02004
AT-02005
(A)
(B)
(A)
(A)
(B)
(A)
AT-04307
5AT-101
AT Main Case
B: INSTALLATION
1) Apply ATF to a new seal ring.
2) Install the thrust bearing and a new seal ring to
the drum support.
3) Install the reverse brake piston.
NOTE:
Apply ATF onto the piston sliding surface.
TOOL
4) Install the return spring.
5) Install the spring retainer and snap ring.
TOOL
6) Install the dish plate.
NOTE:
When installing, make sure that the identification
mark is facing the front side of transmission.
7) Install the drive plate and driven plate.
(A) Thrust bearing
(B) Seal ring
(A)
(B)
(A)
(A)
(B)
(A)
AT-04307
AT-02002
AT-02000
ST3
ST2
ST1
5AT-102
AT Main Case
8) Install the leaf spring.
9) Install the retaining plate.
10) Install the snap ring of the reverse brake.
11) Perform the clearance check of reverse brake.
(1) Measure the clearance between retainer
plate and snap ring using thickness gauge.
Standard:
0.7 1.1 mm (0.028 0.043 in)
(2) If it is out of specification, select a suitable
retainer plate from the following table and as-
semble it.
12) Install the direct clutch assembly.
13) Install the high & low reverse clutch assembly.
14) Install the thrust needle bearing of the high &
low reverse clutch.
(A) Leaf spring
AT-01999
(A)
B' B
(A)
B' B
AT-01998
AT-02372
Retainer plate
31567AB100 4.2 (0.165)
31567AB170 4.4 (0.173)
31567AB180 4.6 (0.181)
31567AB190 4.8 (0.189)
31567AB200 5.0 (0.197)
AT-01997
AT-01996
AT-01995
5AT-103
AT Main Case
15) Install the middle & rear sun gear assembly.
16) Install the rear carrier assembly.
17) Install the middle carrier assembly.
18) Install the thrust needle bearing of middle carri-
er assembly.
19) Measure the total end play, and select the
bearing. <Ref. to 5AT-107, ADJUSTMENT, AT
Main Case.>
20) Install the impact clutch pack assembly to oil
pump cover.
21) Turn the transmission sideways.
AT-01994
AT-01993
(A) Impact clutch pack ASSY
(B) Front sun gear ASSY
AT-01992
AT-01991
AT-02006
(A)
(B)
5AT-104
AT Main Case
(1) Apply ATF to the O-ring of input clutch shaft.
(2) Install the oil pump cover to AT main case
while supporting the input clutch shaft and oil
pump housing with your hand.
(3) Make sure the rear end of drive pinion shaft
is engaged to the spline of reduction driven
gear.
(4) Protect the input clutch shaft with a cloth,
and rotate to engage the spline of the input
clutch and rear carrier using pliers.
NOTE:
Work with pressing the oil pump cover.
(5) Combine the oil pump cover with transmis-
sion main case.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
26) Install the control valve body. <Ref. to 5AT-57,
INSTALLATION, Control Valve Body.>
27) Install the converter case assembly to the
transmission case assembly. <Ref. to 5AT-80, IN-
STALLATION, Converter Case.>
Pipe.>
to 5AT(diag)-23, GENERAL DESCRIPTION,
Learning Control.>
(A) Cloth
AT-01990
AT-02092
(A)
AT-02046
(A)
AT-01976
5AT-105
AT Main Case
C: DISASSEMBLY
1. INPUT CLUTCH PACK ASSEMBLY
1) Remove the front sun gear.
2) Remove the thrust bearing.
3) Remove the snap ring, and then remove the
front carrier.
4) Remove the input clutch assembly from rear in-
ternal gear.
D: ASSEMBLY
1. INPUT CLUTCH PACK ASSEMBLY
1) Assemble the input clutch assembly to rear inter-
nal gear.
2) Install the front carrier, and then install the snap
ring.
3) Install the thrust bearing.
4) Install the front sun gear.
AT-02007
AT-02008
AT-02009
AT-02009
AT-02008
AT-02007
5AT-106
AT Main Case
E: INSPECTION
1. FRONT, MIDDLE & REAR PLANETARY
CARRIER ASSEMBLY
Visually inspect the tooth surface of planetary
gear, and replace with new part if damaged, broken
or excessively worn.
Inspect the planetary carrier body for damage or
breakage.
2. INPUT CLUTCH
Check the clearance of the input clutch. Measure
the clearance L between snap ring and retaining
plate using a thickness gauge. If it is out of specifi-
cation, replace the entire direct clutch assembly.
Check for damage on the drive plate, driven
plate and snap ring, and replace the entire input
clutch assembly if damaged.
Standard:
0.7 1.1 mm (0.028 0.043 in)
3. HIGH & LOW REVERSE CLUTCH ASSY
Check the clearance of the high & low reverse
clutch.
Measure the clearance L between snap ring and
retaining plate using a thickness gauge. If it is out of
specification, replace the entire high & low reverse
clutch assembly.
plate and snap ring, and replace the entire high &
low reverse clutch assembly if damaged.
Standard:
1.8 2.2 mm (0.070 0.087 in)
4. DIRECT CLUTCH ASSEMBLY
Check the clearance of direct clutch.
Measure the clearance L between snap ring and re-
taining plate using a thickness gauge. If it is out of
specification, replace them as direct clutch assembly.
plate and snap ring, and replace the entire direct
clutch assembly if damaged.
Standard:
0.6 1.0 mm (0.024 0.039 in)
5. REVERSE BRAKE
Snap ring for wear, return spring for breakage,
and spring retainer for deformation
Lip seal and D-ring for damage
Piston operation
AT-03259
L
AT-02010
L
AT-02011
L
5AT-107
AT Main Case
F: ADJUSTMENT
1) Using the ST, measure the height A from the
AT main case mating surface to convex surface of
oil pump cover.
ST 499575400 GAUGE
2) Using the ST, measure the depth B from the
convex surface of oil pump cover to thrust bearing
transferring surface.
ST 499575400 GAUGE
3) Calculate the measured value from step 1) and
2), and then set the calculated value as C
Calculation formula: C = A B
4) Using the ST, measure the depth D from the
AT main case mating surface to thrust bearing
transferring surface of front sun gear.
ST 499575400 GAUGE
5) Set the value as E which subtract the thickness of
ST (GAUGE) from the measured value on step 4).
Calculation: E (mm) = D 15
[E (in) = D 0.59]
Select one thrust bearing from the table to adjust clear-
ance within 0.25 0.55 mm (0.0098 0.022 in).
T (mm) = E C + 0.03
[T (in) = E C + 0.0012]
T (mm) = E C + 0.27
[T (in) = E C + 0.012]
T: Thrust bearing thickness
C: Distance from oil pump cover mating surface to
rear end of oil pump cover
E: Depth from mating surface of AT main case to
bearing surface of front sun gear
NOTE:
Calculation formula for T above is applied when
measuring with the ST (499575400 GAUGE). In
the calculation without using ST, substitute the
thickness of collar used to calculate the value E
on step 5).
A Measured value
B Measured value
D Measured value
AT-02012
ST
A
AT-02013
ST B
AT-02014
ST
D
Thrust bearing
806548020 3.2 (0.126)
606548030 3.4 (0.134)
806548040 3.6 (0.142)
806548050 3.8 (0.150)
806548060 4.0 (0.157)
806548070 4.2 (0.165)
5AT-108
36.Transmission Control Device
A: REMOVAL
mission Assembly.>
stay.
5) Wrap vinyl tape around the nipple attached to
the air breather hose.
7) Remove the control valve body assembly. <Ref.
to 5AT-56, REMOVAL, Control Valve Body.>
8) Pull out the straight pin of manual plate.
9) Remove the bolts securing select lever, and then
remove the select lever, manual plate and parking
rod.
NOTE:
Be careful not to damage the lips of press-fitted oil
seal in the case.
10) Remove the detent spring.
(A) Bolt
(C) Manual plate
(D) Parking rod
AT-00305
AT-00306
AT-00307
5AT-109
B: INSTALLATION
1) Install the detent spring to the transmission
case.
Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
2) Insert the select lever, and then tighten the bolt.
Tightening torque:
6 Nm (0.6 kgf-m, 4.4 ft-lb)
3) Insert the manual plate and parking rod.
4) Insert the spring pin to the manual plate.
5) Install the oil pan and the control valve body as-
sembly. <Ref. to 5AT-57, INSTALLATION, Control
Valve Body.>
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
7) Insert the transmission connector to the stay.
8) Install the air breather hose. <Ref. to 5AT-64, IN-
STALLATION, Air Breather Hose.>
C: INSPECTION
Make sure the manual lever and detent spring are
not worn or otherwise damaged.
(A) Bolt
(C) Manual plate
(D) Parking rod
AT-00307
AT-00308
AT-00306
AT-00305
5AT-110
5AT(diag)-2
A: PROCEDURE
Step Check Yes No
5AT(diag)-4, Check List for Interview.>
2) Before performing diagnosis, inspect the fol-
lowing items which may influence AT problems.
General Inspection <Ref. to 5AT(diag)-5,
INSPECTION, General Description.>
Oil leakage
Stall speed test <Ref. to 5AT-32, Stall Test.>
Line pressure test <Ref. to 5AT-34, Line Pres-
sure Test.>
Transfer Clutch Pressure Test <Ref. to 5AT-
36, Transfer Clutch Pressure Test.>
Time Lag Test <Ref. to 5AT-33, Time Lag
Test.>
Road Test <Ref. to 5AT-31, Road Test.>
Inhibitor Switch <Ref. to 5AT-50, Inhibitor
Switch.>
Is the unit that is thought to
influence the AT problem work-
ing properly?
each item.
2 CHECK AT OIL TEMP LIGHT.
After the ignition switch is turned to ON, wait for
at least 2 seconds.
Does the AT OIL TEMP light
illuminate?
2) Check the AT OIL TEMP light. <Ref. to
5AT(diag)-26, INSPECTION, AT Oil Temp
Warning Light Display.>
3) After the ignition switch is turned to ON, wait
for at least 2 seconds.
blink?
4 CHECK DTC.
Read the DTC. <Ref. to 5AT(diag)-20, OPERA-
TION, Read Diagnostic Trouble Code (DTC).>
NOTE:
If the communication function of Subaru Select
Monitor cannot be executed normally, check
the communication circuit. <Ref. to 5AT(diag)-
28, COMMUNICATION FOR INITIALIZING IM-
POSSIBLE, Diagnostic Procedure for Subaru
Select Monitor Communication.>
Is DTC displayed? Go to step 6.
NOTE:
Record all DTC.
Go to step 5.
1) Inspect using Diagnostic Procedure with-
out Diagnostic Trouble Code (DTC). <Ref. to
5AT(diag)-105, Diagnostic Procedure without
4) Display DTC.
Is DTC displayed? Go to step 6. Inspect using
General Diagnos-
tic Table. <Ref. to
5AT(diag)-112,
General Diagnos-
tic Table.>
5AT(diag)-3
1) Inspect using the Diagnostic Procedure
with Diagnostic Trouble Code (DTC). <Ref. to
5AT(diag)-34, Diagnostic Procedure with Diag-
NOTE:
For DTC table, refer to List of Diagnostic Trou-
ble Code (DTC). <Ref. to 5AT(diag)-31, List of
2) Repair the trouble cause.
5) Display DTC.
Is DTC displayed? Inspect using the
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC). <Ref. to
5AT(diag)-34,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
Inspect using
General Diagnos-
tic Table. <Ref. to
5AT(diag)-112,
General Diagnos-
tic Table.>
Step Check Yes No
5AT(diag)-4
A: CHECK
Check the following items when a problem has occurred.
NOTE:
Customers name
Date of purchase
Date of repair
Transmission model Transmission V.I.N.
Odometer reading km (miles)
Symptom No up-shift
No down-shift
No kick down
Vehicle does not move ( Any position Particular position)
Lock-up malfunction
Noise or vibration
Shift shock or slip
Select lever does not move
Others
( )
Frequency Continuous Intermittent ( times a day)
Weather Fine Cloudy Rainy Snowy
Others
( )
Place Highland Suburbs Inner city Uphill Rough road
Others
( )
Ambient air temperature Hot Warm Cool Cold
AT warning light (AT OIL TEMP light) Blinks continuously Not blink
Select lever position P R N D Manual mode
Driving condition Not affected
At racing
While decelerating
At starting
While accelerating
While turning ( RH/
LH)
While idling
While cruising
Manual mode ON OFF
5AT(diag)-5
General Description
A: CAUTION
Supplemental Restraint System Airbag
The airbag system wiring harness is routed near
the TCM.
CAUTION:
connectors are colored yellow. Do not use an
electric test equipment to check these circuits.
wiring harness when performing diagnostics or
servicing the TCM.
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
1. BATTERY
Measure the battery voltage and specific gravity of
the electrolyte.
Standard voltage:
12 V or more
Specific gravity:
1.260 or more
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened
securely.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
3. ATF LEVEL
Make sure that ATF level is the specified amount.
mission Fluid.>
4. FRONT DIFFERENTIAL OIL LEVEL
Make sure the front differential oil level is the spec-
ified amount. <Ref. to 5AT-30, INSPECTION, Dif-
ferential Gear Oil.>
AT-01464
(A) Level gauge
(B) Inspection position when HOT
(C) Upper level
(D) Lower level
(E) Inspection position when COLD
(A) Upper level
(B) Lower level
(A)
PI-00362
C
O
L
DL
F
H
O
T
L
F
(A)
(B)
(D)
(E)
(D)
(C)
(C)
AT-00317
(A)
(B)
L
F
5AT(diag)-6
General Description
5. OPERATION OF SHIFT SELECT LEVER
Make sure there is no noise, dragging or contact
pattern in each select lever range.
WARNING:
Stop the engine while checking operation of the
select lever.
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
AT-02048
MONITOR III KIT
TOOL NAME REMARKS
ST1B021XU0
5AT(diag)-7
A: LOCATION
1. CONTROL MODULE
(1) Engine control module (ECM) (3) Transmission control module
(TCM)
(2) AT OIL TEMP light (AT warning
light)
(5) Body integrated unit
AT-02049
(1)
(3) (4) (2) (5)
5AT(diag)-8
(1)
AT-02051 AT-03759
(2)
AT-02053
(3)
(4)
AT-02052
AT-04405
(5)
5AT(diag)-9
2. SENSOR
(1) Accelerator pedal position sensor (4) Rear vehicle speed sensor (6) ATF temperature sensor
(2) Front vehicle speed sensor (5) Turbine speed sensor 1 (7) Turbine speed sensor 2
(3) Inhibitor switch
(6)
(3),(5),(7) (2) (4)
AT-04263
(1)
5AT(diag)-10
(1)
AT-00375
AT-03281
(2)
AT-04264
(3)
AT-03282
(4)
(5)
AT-04265
(6)
AT-04266
(7)
5AT(diag)-11
3. SOLENOID
(1) High & low reverse clutch linear
solenoid
(3) Front brake linear solenoid (6) Lock-up pressure linear solenoid
(4) Input clutch linear solenoid (7) Transfer linear solenoid
(2) Direct clutch linear solenoid (5) Line pressure linear solenoid (8) Forward brake linear solenoid
AT-04267
(3) (5) (6) (4) (1)
(7)
(2)
(8)
5AT(diag)-12
4. OIL PRESSURE SWITCH
(1) Front brake oil pressure switch (3) High & low reverse clutch oil pres-
sure switch
(4) Direct clutch oil pressure switch
(2) Input clutch oil pressure switch (5) Forward brake oil pressure switch
AT-04303
(3)
(5)
(4)
(1)
(2)
5AT(diag)-13
5. Transmission Control Module (TCM) I/O Signal
NOTE:
The measurement should be performed after warming up.
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
B55 TO TO
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
B54
AT-03733
5AT(diag)-14
Item
Connector
No.
Terminal
No.
Measuring condition Measured value
Resistance
between
terminal and
chassis ground
Remarks
P/L solenoid output B54 6
Engine ON, P range,
accelerator OFF, brake
ON
3.5 7.5 V
3 9 (ATF
temperature
20C (68F))
Drive fre-
quency: 300 Hz
I/C oil pressure
switch input
B54 20
While driving at 1st-3rd
of manual mode
6 V or more
While driving at 4th or
5th of manual mode
Less than 1.5 V
Power GND B54 12 Always Approx. 0 V
CAN communication
line (+)
B55 21
CAN communication
line ()
B55 20
ATF temperature
sensor 1 input
B54 17
Ignition switch ON
ATF oil temperature
20C (68F)
3.5 4.3 V 2.5 7.0 k
When measur-
ing the resis-
tance, be sure
to disconnect
the connector
and perform
the measure-
ment with TCM
alone.
Ignition switch ON
ATF oil temperature
80C (176F)
1 2.2 V 0.3 0.8 k
Backup power
supply
B55 24
Ignition switch ON
8 V or more
Ignition switch OFF
I/C solenoid output B54 3
While driving at 1st-3rd
of manual mode
5 V or more
3 9 (ATF
temperature
20C (68F))
Drive fre-
quency: 300 Hz
While driving at 4th or
5th of manual mode
Less than 1.5 V
H & LR/C solenoid
output
B54 5
While driving at 2nd of
manual mode
5 V or more
3 9 (ATF
temperature
20C (68F))
Drive fre-
quency: 300 Hz
While driving at 1st,
3rd-5th of manual
mode
Less than 1.5 V
Power GND B54 13 Always Approx. 0 V
Analog GND B54 18 Always Approx. 0 V
Fr/B solenoid output B54 4
While driving at other
than 4th of manual
mode
5 V or more
3 9 (ATF
temperature
20C (68F))
Drive fre-
quency: 300 Hz
While driving at 4th of
manual mode
Less than 1.5 V
L/U solenoid output B54 7
When lock-up 3 V or more 3 9 (ATF
temperature
20C (68F))
Drive fre-
quency: 300 Hz
When not lock-up Less than 1 V
D/C solenoid output B54 1
While driving at 1st or
5th of manual mode
5 V or more
3 9 (ATF
temperature
20C (68F))
Drive fre-
quency: 300 Hz
While driving at 2nd-4th
of manual mode
Less than 1.5 V
D/C oil pressure
switch input
B54 22
5th of manual mode
6 V or more
While driving at 2nd-4th
of manual mode
Less than 1.5 V
Subaru Select
Monitor
communication line
B55 8
Ignition switch ON 8 V or more

Ignition switch OFF Less than 1 V
5AT(diag)-15
Sensor GND
(analog)
B54 16 Always Approx. 0 V
H&LR/C oil pressure
switch input
B54 14
While driving at 2nd of
manual mode
6 V or more

While driving at 3rd-5th
of manual mode
Less than 1.5 V
Fwd/B solenoid
output
B54 19
2nd of manual mode
5 V or more
Drive fre-
quency: 300 Hz
of manual mode
Less than 1.5 V
Fwd/B oil pressure
switch input
B54 21
2nd of manual mode
Less than 1.5 V
of manual mode
6 V or more
Front vehicle speed
sensor input
B54 24
While driving at 2nd
and 20 km/h (12 MPH)
of manual mode
Approx.
500 700 rpm

Use the Subaru
Select Monitor.
While driving at 4th and
80 km/h (50 MPH) of
manual mode
Approx.
2,000 2,500 rpm
Use the Subaru
Select Monitor.
Inhibitor switch 1
input
B54 8
Ignition switch ON, P
range
Less than 0.5 V

Ignition switch ON, N
range
5 V or more
Inhibitor switch 2
input
B54 9
range
5 V or more

Ignition switch ON, D
range
Less than 0.5 V
Lateral G sensor
signal
B55 9 Ignition switch ON 2.0 3.0
Ignition power supply B54 27

Rear vehicle speed
sensor input
B54 23
While driving at 2nd
and 20 km/h (12 MPH)
of manual mode
Approx.
500 700 rpm

Use the Subaru
Select Monitor.
While driving at 4th and
80 km/h (50 MPH) of
manual mode
Approx.
2,000 2,500 rpm
Use the Subaru
Select Monitor.
Fr/B oil pressure
switch input
B54 15
While driving at other
than 4th of manual
mode
Less than 1.5 V

While driving at 4th of
manual mode
6 V or more
Turbine speed
sensor 1 input
B54 26
2nd of manual mode,
turbine speed sensor is
2,000 rpm (Read from
Subaru Select Monitor)
Approx. 0 rpm

Use the Subaru
Select Monitor.
4th of manual mode,
Approx.
1,900 2,100 rpm
Use the Subaru
Select Monitor.
Item
Connector
No.
Terminal
No.
Resistance
between
terminal and
chassis ground
Remarks
5AT(diag)-16
Lateral G sensor
power supply output
B55 7
Ignition switch ON
(when lateral G sensor
is in horizontal position)
4.75 5.25
Inhibitor switch 3
input
B54 10
Ignition switch ON, R
range
5 V or more

range
Less than 0.5 V
Control GND1 B55 23
Ignition switch ON
Approx. 0 V
Ignition switch OFF
Control GND2 B55 22
Ignition switch ON
Approx. 0 V
Ignition switch OFF
Inhibitor switch 4
input
B54 11
range
Less than 0.5 V

range
5 V or more
Back-up light relay
output
B55 13
Ignition switch ON, R
range
Less than 1 V
90 110
(ATF tempera-
ture 25C
(77F))
Ignition switch ON,
other than R range
8 V or more
AWD solenoid output B54 2
Engine ON, P range
or N range, accelera-
tor OFF
Less than 1 V
3 9 (ATF
temperature
20C (68F))
Drive fre-
quency: 300 Hz
Engine ON, D range,
accelerator OFF, brake
ON
2 V or more
Turbine speed
sensor 2 input
B54 25
2nd of manual mode,
Approx.
1,200 1,500 rpm

Use the Subaru
Select Monitor.
4th of manual mode,
Approx.
1,900 2,100 rpm

Use the Subaru
Select Monitor.
PN signal output B55 11
Ignition switch ON,
Other than P range or
N range
8 V or more
range or N range
Less than 1 V
Ignition power supply 1 B55 26
Ignition switch ON
8 V or more
Ignition switch OFF
Ignition switch ON
8 V or more
Ignition switch OFF
Item
Connector
No.
Terminal
No.
Resistance
between
terminal and
chassis ground
Remarks
5AT(diag)-17
A: OPERATION
(DTC)
5AT(diag)-6, PREPARATION TOOL, General
Description.>
2) Prepare PC with Subaru Select Monitor installed.
NOTE:
Monitor.
5) Connect the SDI to the data link connector locat-
ed in the lower portion of the instrument panel (on
the drivers side).
CAUTION:
ru Select Monitor.
6) Start the PC.
Monitor.
Check}.
9) On the System Selection Menu, select
{Transmission}.
10) After transmission type information pops up,
select [OK].
11) On the Transmission Diagnosis, select {DTC
Display}.
12) On the Diagnostic Trouble Code screen, se-
lect {Temporary Diagnostic Code(s)} or {Memo-
rized Diagnostic Code(s)}.
Check}.
mission}.
lect [OK].
4) On the Transmission Diagnosis screen, select
{Current Data Display & Save}.
5) Select {Normal sampling} on the Current Data
Display & Save screen.
AT-04371
5AT(diag)-18
Item Display Unit of measure
Battery voltage Battery Voltage V
Accelerator pedal position sensor Acceleration Opening Angle %
Front vehicle speed sensor signal Front Wheel Speed km/h
Gear position Gear Position
Turbine speed sensor signal Turbine Revolution Speed rpm
Rear vehicle speed sensor signal Rear Wheel Speed km/h
Lateral G sensor Lateral G Sensor V
ATF temperature sensor signal ATF Temp. C
Turbine speed sensor 1 signal Turbine Revolution Speed 1 rpm
Turbine speed sensor 2 signal Turbine Revolution Speed 2 rpm
High & low reverse clutch solenoid indicator current H&LR/C Solenoid Current A
Direct clutch solenoid indicator current D/C Solenoid Current A
Front brake solenoid indicator current F/B Solenoid Current A
Input clutch solenoid indicator current I/C Solenoid Current A
Line pressure solenoid indicator current P/L Solenoid Current A
Lock-up solenoid indicator current L/U Solenoid Current A
Transfer solenoid indicator current AWD Solenoid Current A
High & low reverse clutch solenoid target oil pressure H&LR/C Solenoid Target Pressure kPa
Direct clutch solenoid target oil pressure D/C Solenoid Target Pressure kPa
Front brake solenoid target oil pressure F/B Solenoid Target Pressure kPa
Input clutch solenoid target oil pressure I/C Solenoid Target Pressure kPa
Line pressure solenoid target oil pressure P/L Solenoid Target Pressure kPa
Lock-up solenoid target oil pressure L/U Solenoid Target Pressure kPa
Transfer solenoid target oil pressure AWD Solenoid Target Pressure kPa
Ignition switch Ignition Switch ON Input or OFF Input
Tip signal Tiptronic Mode Switch ON or OFF
Cruise control ON signal Cruise Control Signal ON or OFF
Tip down shift signal Down SW ON or OFF
Stop light switch signal Stop Light SW ON or OFF
Tip up shift signal Up SW ON or OFF
Drive range signal D Range Signal ON or OFF
Reverse range signal R Range Signal ON or OFF
Diagnosis light output signal Diagnosis Light ON or OFF
ATF oil temperature light signal ATF Temperature Lamp ON or OFF
Parking range signal P Range Signal ON or OFF
P/N range output signal P/N Signal ON or OFF
Neutral range signal N Range Signal ON or OFF
Inhibitor switch 1 input signal Inhibitor SW1 High or Low
Backup light relay output signal Back-up light relay ON or OFF
High & low reverse clutch oil pressure switch input signal H&LR/C Oil Pressure SW ON or OFF
Direct clutch oil pressure switch input signal D/C Oil Pressure SW ON or OFF
Front brake oil pressure switch input signal Fr/B Oil Pressure SW ON or OFF
Input clutch oil pressure switch input signal I/C Oil Pressure SW ON or OFF
Forward brake indicator current Fwd/B Solenoid Current A
5AT(diag)-19
NOTE:
For details concerning the operation procedure, re-
fer to the help on PC application for Subaru Select
Monitor.
1) Check that the select lever is in P range.
Check}.
3) On the System Selection Menu, select
{Transmission}.
lect [OK].
5) On the Transmission Diagnosis, select {Clear
Memory}.
6) When the Done. Turn ignition switch to OFF
pops up, select [OK].
7) Turn Subaru Select Monitor and ignition switch
to OFF. To turn the ignition switch to ON again, wait
for 10 seconds or more.
NOTE:
To clear the previous DTC, use {Clear Memory},
and to clear the learned value, use {Clear Memory 2}.
refer to the help on PC application for Subaru Se-
lect Monitor.
Forward brake solenoid input signal Fwd/B Solenoid Pressure Kpa
Forward brake oil pressure switch input signal Fwd/B Fluid Pressure ON or OFF
Item Display Unit of measure
5AT(diag)-20
Code (DTC)
A: OPERATION
Refer to Subaru Select Monitor for information about
how to obtain and understand DTC. <Ref. to 5AT(di-
ag)-17, OPERATION, Subaru Select Monitor.>
5AT(diag)-21
Inspection Mode
8. Inspection Mode
A: PROCEDURE
WARNING:
Observe the traffic law when driving on public
roads.
1) Shift the select lever to D range, and then drive
the vehicle with changing the gear from 1st to 5th.
2) When driving the vehicle at 5th speed of D range,
set the gear to manual mode and drive the vehicle by
downshifting using of the select lever from 5th
4th, 4th 3rd, 3rd 2nd, and 2nd 1st.
NOTE:
At shifting down, drive the vehicle at least 10 sec-
onds in each speed.
3) Shift the select lever to R range and drive the
vehicle for 2 seconds or more.
5AT(diag)-22
Clear Memory Mode
A: OPERATION
Use Subaru Select Monitor to clear DTC. <Ref. to
NOTE:
DTC cannot be cleared without using Subaru Se-
lect Monitor.
5AT(diag)-23
Learning Control
10.Learning Control
After performing the following services, perform
the transmission learning operation.
Replacement of TCM/Replacement or disassembly
of transmission assembly/Replacement of control
valve body/Performing Clear Memories 2.
B: PROCEDURE
1. PREPARATION FOR LEARNING
CONTROL
1) Warm-up or cool down until the ATF tempera-
ture displayed on the Subaru Select Monitor reach-
es 60 80C (140 176 F).
CAUTION:
link connector.
6) Turn the ignition switch to ON. (Press push but-
ton ignition switch twice without depressing brake
pedal for push button start.)
8) Select {AT learning mode} on the Learning and
inspection mode related to AT display screen of
2. SIMPLE LEARNING
NOTE:
The simple learning is performed with the vehicle
lifted up, not by driving actually.
CAUTION:
NOTE:
During SHIFT control system learning in progress
and AWD control system learning in progress, AT
OIL TEMP light in the combination meter starts
flashing at 2 Hz and the learning operation starts.
The following message is displayed on the screen
when the AT OIL TEMP light turns off. If operation
ended abnormally during learning, AT OIL TEMP
light flashes at 4 Hz.
5AT(diag)-24
Learning Control
2) AT learning normally ended. is displayed, sim-
ple AT learning is completed.
NOTE:
If communication error occurs during learning,
of the vehicle is displayed during learning, select
[OK] to display the List of Diagnostics Trouble
Code. Retry AT learning mode from the beginning
after repairing the DTC detecting portion.
If AT learning ended abnormally. is displayed,
Monitor.
3. DRIVING CHECK
Drive actually and check for shifting shock or faults.
If shifting shock is felt, perform the learning opera-
tion again.
If reducing of shifting shock is not felt, recheck that
other parts are normal.
AT learning ended abnormally. Fault is detected during AT learning.
The accelerator pedal is depressed during AT learning.
Operation which is not directed is performed during AT learning.
5AT(diag)-25
11.AT Oil Temp Warning Light Display
A: OPERATION
When any on-board diagnostics item is malfunctioning, the AT OIL TEMP light blinks from the time the mal-
function is detected after starting the engine until the ignition switch is turned 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 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.
When the AT OIL TEMP light does not operate normally but no DTC is stored, perform the AT OIL TEMP light
inspection. <Ref. to 5AT(diag)-26, INSPECTION, AT Oil Temp Warning Light Display.>
(A) Ignition switch (engine OFF) (B) Normal (engine ON) (C) Faulty (engine ON)

(1) ON (3) 2 sec. (5) Blink
(2) OFF (4) 0.25 sec.
AT-01750
(4)
(3)
(1)
(2)
(1)
(2)
(1)
(2)
(3)
(5)
(A)
(B)
(C)
5AT(diag)-26
B: INSPECTION
DIAGNOSIS:
AT OIL TEMP light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), AT OIL TEMP light does not illuminate.
WIRING DIAGRAM:
AT-04345
3
2
1
2
2
i10
i84 A: B280 B:
A
2
6
A
2
7
B
2
0
B
3
0
2
1
2
0
TCM B55
AT OIL
TEMP
i10
i84
B280
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
8 7 6 5 4 3 2 1
2223 21 20 19 16 15 14 13 12 11 10 9
3435 33 32
17
30
18
31 29 28 27 26 25 24
8
7 6 5 4 3 2 1
22 23 21
20 19 16 15 14 13 12 11 10 9 17
30
18
29 28 27 26 25 24
A:
B:
B365
i107
i106
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
i107 i106
**
1
*
2
*
1
*
2
*
*
1
*
2
*
*
1 2 3 4
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
5
E
B365
BUZZER
*
B55
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
I / F
I
G
N
I
T
I
O
N
S
W
I
T
C
H
LCD FULL DOT
COMBINATION
METER
MICRO COMPUTER
DRIVE CIRCUIT
CAN TRANSCEIVER
& RECEIVER
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
B
A
T
T
E
R
Y
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
5AT(diag)-27
Step Check Yes No
illuminate?
diagnosis of com-
bination meter.
After the ignition switch is ON, wait for at least 2
seconds.
illuminate?
Start the engine.
Does the AT OIL TEMP light go
off?
Normal. Go back to
Basic Diagnostic
Procedure. <Ref.
to 5AT(diag)-2,
Basic Diagnostic
Procedure.>
Go to step 7.
COMMUNICATION.
link connector.
Is the communication between
TCM normal?
Go to step 5. Check the power
supply ground cir-
cuit of TCM and
Subaru Select
Monitor communi-
cation. <Ref. to
5AT(diag)-28,
Diagnostic Proce-
dure for Subaru
Select Monitor
Communication.>
5 CHECK TCM.
Select Monitor.
signal ON?
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Monitor.>
input signal Illuminate?
Replace the com-
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
Check DTC of
body integrated
unit. <Ref. to
LAN(diag)-12,
OPERATION, Sub-
aru Select Moni-
tor.>
7 CHECK TCM.
2) Display the current data of TCM using Sub-
signal ON?
Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Go to step 8.
Monitor.>
input signal Illuminate?
Check DTC of
body integrated
unit. Perform the
diagnosis accord-
ing to DTC. <Ref.
to LAN(diag)-12,
OPERATION, Sub-
aru Select Moni-
tor.>
Perform the self-
diagnosis of com-
bination meter.
<Ref. to IDI-4,
INSPECTION,
Combination Meter
System.>
5AT(diag)-28
12.Diagnostic Procedure for Subaru Select Monitor Communication
A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
TROUBLE SYMPTOM:
Subaru Select Monitor communication failure
WIRING DIAGRAM:
B55 TCM
B40
M
/
B

N
o
.

1
2
2
4
1
3
8
2
3
8
16
5
7
4
E
E
2
6
2
5
1
1
B40
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
N
o
.
2
1
N
o
.
1
8
SBF-8
No.4
B55
7 2 1 3 4 5 6
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
AT-04346
2
2
B226
10
11
6
5
1
4
2
3
8 9 7
B122
*
*
B226
IG2 RELAY
No.13
9
1
1
7
1
0
B226
MAIN SBF
SBF-6
32
41
B136
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
2 1 3 4
8 7 6 5
B122
*
E
: TERMINAL No.
OPTIONAL
ARRANGEMENT
JOINT
CONNECTOR
BACK-UP
LIGHT RELAY
STARTER SYSTEM BACK-UP LIGHT SYSTEM
INHIBITOR
RELAY
IGNITION
SWITCH
DATA LINK
CONNECTOR
BATTERY
5AT(diag)-29
Step Check Yes No
POWER SUPPLY CIRCUIT.
Measure the voltage between data link connec-
Is the voltage 10 V or more? Go to step 2. Repair harness
connector between
the battery and
data link connec-
tor, and poor con-
tact of the
connector.
GROUND CIRCUIT.
data link connector and chassis ground.
circuit of harness
between data link
connector and
ground terminal,
and poor contact of
connector.
3 CHECK COMMUNICATION OF SUBARU
SELECT MONITOR.
whether communication to the transmission
Is the name of system displayed
on Subaru Select Monitor?
SELECT MONITOR.
2) Disconnect the TCM connector.
4) Check whether communication to engine
SELECT MONITOR.
3) Disconnect the connector from ECM.
5) Check whether communication to transmis-
sion system can be executed normally.
Inspect the ECM. Go to step 6.
CONNECTOR.
2) Disconnect the TCM and ECM connector.
more?
Go to step 7. Check harness and
connector between
each control mod-
ule and data link
connector.
7 CHECK OUTPUT SIGNAL OF TCM.
chassis ground.
Is the voltage 1 V or more? Check harness and
connector between
each control mod-
ule and data link
connector.
Go to step 8.
TCM AND DATA LINK CONNECTOR.
tor and data link connector.
(B55) No. 8 (B40) No. 7:
and connector
between TCM and
9 CHECK INSTALLATION OF TCM CONNECTOR.
Is TCM connector connected to
TCM?
Go to step 10. Connect the TCM
connector to TCM.
5AT(diag)-30
10 CHECK INSTALLATION OF TRANSMISSION
HARNESS CONNECTOR.
Is the transmission harness
connector connected to bulk-
head harness connector?
Go to step 11. Connect the bulk-
head harness con-
nector to
transmission har-
ness connector.
11 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control
module power supply and data
link connector?
Repair the poor
contact.
Go to step 12.
12 CHECK POWER SUPPLY OF TCM.
2) Remove the fuse (No. 12).
(No. 12).
Go to step 14.
14 CHECK HARNESS.
Is the resistance 10 or less? Replace the fuse
(No. 12). If the
replaced fuse (No.
12) blows out eas-
circuit of harness
between fuse (No.
12) and TCM.
Go to step 15.
CUIT.
between TCM connector and chassis ground.
Remove the fuse (No. 21).
(No. 21). If the
replaced fuse (No.
21) blows out eas-
circuit of harness
between fuse (No.
21) and TCM.
Go to step 17.
between TCM and transmission ground.
(B54) No. 22 Transmission ground:
(B54) No. 23 Transmission ground:
more?
Repair the short
circuit of harness
between TCM and
transmission har-
ness connector,
and poor contact of
connector.
Go to step 18.
power supply, ground and data
link connector?
Repair the connector. Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Step Check Yes No
5AT(diag)-31
A: LIST
DTC Item Content of diagnosis Reference target
P0705
Transmission Range
Sensor Circuit (PRNDL
Input)
Inhibitor switch malfunction, open
or short circuit
<Ref. to 5AT(diag)-34, DTC P0705 TRANS-
MISSION RANGE SENSOR CIRCUIT (PRNDL
P0712
Transmission Fluid Tem-
perature Sensor Circuit
Low Input
ATF temperature sensor 1 mal-
function, or open input signal cir-
cuit
MISSION FLUID TEMPERATURE SENSOR
CIRCUIT LOW INPUT, Diagnostic Procedure
P0713
Transmission Fluid Tem-
perature Sensor Circuit
High Input
ATF temperature sensor 1 mal-
function, short input signal circuit
MISSION FLUID TEMPERATURE SENSOR
CIRCUIT HIGH INPUT, Diagnostic Procedure
P0715
Input/Turbine Speed
Sensor Circuit
Turbine speed sensor 1 malfunc-
tion, short input signal circuit
<Ref. to 5AT(diag)-42, DTC P0715 INPUT/
TURBINE SPEED SENSOR CIRCUIT, Diag-
(DTC).>
P0719
Torque Converter/Brake
Brake switch malfunction, open
input signal circuit, body inte-
grated unit malfunction, CAN
communication failure
SWITCH CIRCUIT LOW, Diagnostic Procedure
P0720
Output Speed Sensor
Circuit
Front wheel speed sensor is
faulty or input signal circuit,
ground, power supply is open or
shorted.
<Ref. to 5AT(diag)-48, DTC P0720 OUTPUT
SPEED SENSOR CIRCUIT, Diagnostic Proce-
P0724
Torque Converter/Brake
Brake switch malfunction, short
circuit of input signal, body inte-
grated unit, CAN communication
failure
SWITCH CIRCUIT HIGH, Diagnostic Proce-
P0731 Gear 1 Incorrect Ratio
Vehicle sensor, turbine speed
sensor, control valve malfunction
or shift clutch malfunction
INCORRECT RATIO, Diagnostic Procedure
sensor, control valve malfunction
or shift clutch malfunction
sensor or shift clutch malfunction
P0736 Reverse Incorrect Ratio
P0741
Torque Converter Clutch
Circuit Performance or
Stuck Off
Lock-up clutch is faulty or valve is
stuck.
<Ref. to 5AT(diag)-55, DTC P0741 TORQUE
CONVERTER CLUTCH CIRCUIT PERFOR-
MANCE OR STUCK OFF, Diagnostic Proce-
P0743
Torque Converter Clutch
Circuit Electrical
L/U solenoid circuit malfunction
or L/U solenoid body malfunction
CONVERTER CLUTCH CIRCUIT ELECTRI-
CAL, Diagnostic Procedure with Diagnostic
5AT(diag)-32
P0748
Pressure Control Sole-
noid A Electrical
Line pressure solenoid circuit
malfunction or line pressure sole-
noid body malfunction
<Ref. to 5AT(diag)-59, DTC P0748 PRES-
SURE CONTROL SOLENOID A ELECTRI-
CAL, Diagnostic Procedure with Diagnostic
P0751
Shift Solenoid A Perfor-
mance or Stuck Off
Fr/B Solenoid Function Malfunc-
tion
<Ref. to 5AT(diag)-61, DTC P0751 SHIFT
SOLENOID A PERFORMANCE OR STUCK
OFF, Diagnostic Procedure with Diagnostic
P0753
Shift Solenoid A Elec-
trical
Fr/B solenoid circuit malfunction
or Fr/B solenoid body malfunction
SOLENOID A ELECTRICAL, Diagnostic Pro-
P0756
Shift Solenoid B Perfor-
mance or Stuck Off
Shift Solenoid B Performance
malfunction
SOLENOID B PERFORMANCE OR STUCK
P0758
Shift Solenoid B Elec-
trical
I/C solenoid circuit malfunction or
I/C solenoid body malfunction
SOLENOID B ELECTRICAL, Diagnostic Pro-
P0761
Shift Solenoid C Per-
formance or Stuck Off
H&LR/C solenoid malfunction
SOLENOID C PERFORMANCE OR STUCK
P0763
Shift Solenoid C Elec-
trical
H&LR/C solenoid circuit malfunc-
tion or H&LR/C solenoid body
malfunction
SOLENOID C ELECTRICAL, Diagnostic Pro-
P0766
Shift Solenoid D Per-
formance or Stuck Off
D/C solenoid malfunction
SOLENOID D PERFORMANCE OR STUCK
P0768
Shift Solenoid D Elec-
trical
D/C solenoid circuit malfunction
or D/C solenoid body malfunction
SOLENOID D ELECTRICAL, Diagnostic Pro-
P0771
Shift Solenoid E Perfor-
mance or Stuck Off
Fwd/B solenoid malfunction
SOLENOID E PERFORMANCE OR STUCK
P0773
Shift Solenoid E Elec-
trical
Fwd/B solenoid circuit malfunc-
tion or Fwd/B solenoid body mal-
function
SOLENOID E ELECTRICAL, Diagnostic Pro-
P0801
Reverse Inhibit Control
Circuit
Shift lock solenoid is faulty or
shorted.
Blown out of TCM+B fuse
INHIBIT CONTROL CIRCUIT, Diagnostic Pro-
P0817 Starter Disable Circuit
PN signal output circuit is open
or shorted.
ECM Source Voltage Is Abnor-
mal
Blown out of TCM+B fuse
<Ref. to 5AT(diag)-83, DTC P0817 STARTER
DISABLE CIRCUIT, Diagnostic Procedure with
P0957
Backup Light Relay Cir-
cuit Low
Back-up relay output circuit is
open, shorted or relay OFF mal-
function
<Ref. to 5AT(diag)-85, DTC P0957 BACKUP
LIGHT RELAY CIRCUIT LOW, Diagnostic Pro-
P0958
Backup Light Relay Cir-
cuit High
Back-up relay output circuit is
open, shorted or relay ON mal-
function
<Ref. to 5AT(diag)-87, DTC P0958 BACKUP
LIGHT RELAY CIRCUIT HIGH, Diagnostic Pro-
P1706
AT Vehicle Speed Sen-
sor Circuit Malfunction
(Rear Wheel)
Rear wheel speed sensor is faulty
or input circuit, ground, power
supply is open or shorted.
<Ref. to 5AT(diag)-89, DTC P1706 AT VEHI-
CLE SPEED SENSOR CIRCUIT MALFUNC-
TION (REAR WHEEL), Diagnostic Procedure
5AT(diag)-33
P1707
AT AWD Solenoid Valve
Circuit Malfunction
AWD solenoid circuit malfunction
or AWD solenoid body malfunc-
tion
<Ref. to 5AT(diag)-91, DTC P1707 AT AWD
SOLENOID VALVE CIRCUIT MALFUNCTION,
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1710
Torque Converter Tur-
bine 2 Speed Signal Cir-
cuit 2 Malfunction
Torque converter sensor 2 mal-
function, input circuit, ground,
power open, short circuit
CONVERTER TURBINE 2 SPEED SIGNAL
CIRCUIT 2 MALFUNCTION, Diagnostic Proce-
P1718
AT Can Communication
Circuit
CAN communication line bus-off
open circuit, ECM short circuit,
ABS/VDCCM or integrated CU
malfunction
<Ref. to 5AT(diag)-94, DTC P1718 AT CAN
COMMUNICATION CIRCUIT, Diagnostic Pro-
P1760
Lateral Acceleration
Sensor Performance
Problem
Faulty lateral G sensor
<Ref. to 5AT(diag)-95, DTC P1760 LATERAL
ACCELERATION SENSOR PERFORMANCE
PROBLEM, Diagnostic Procedure with Diag-
P1761
Sensor Circuit Low
Lateral G sensor is faulty, input
signal circuit is open, or CAN
communication failure occurs
ACCELERATION SENSOR CIRCUIT LOW,
Code (DTC).>
P1762
Sensor Circuit High
Lateral G sensor is faulty or input
signal circuit is shorted.
ACCELERATION SENSOR CIRCUIT HIGH,
Code (DTC).>
P1817
SPORT Mode Switch
Circuit (Manual Switch)
Manual mode switch is open,
shorted, or switch malfunction
<Ref. to 5AT(diag)-102, DTC P1817 SPORT
MODE SWITCH CIRCUIT (MANUAL
SWITCH), Diagnostic Procedure with Diagnos-
P1840
Transmission Fluid Pres-
sure Sensor/Switch A
Circuit
Fr/B oil pressure switch is open or
shorted, or switch malfunction
MISSION FLUID PRESSURE SENSOR/
SWITCH A CIRCUIT, Diagnostic Procedure
P1841
sure Sensor/Switch B
Circuit
Fwd/B oil pressure switch is open
or shorted, or switch malfunction
SWITCH B CIRCUIT, Diagnostic Procedure
P1842
sure Sensor/Switch C
Circuit
I/C oil pressure switch is open or
shorted, or switch malfunction.
SWITCH C CIRCUIT, Diagnostic Procedure
P1843
sure Sensor/Switch D
Circuit
D/C oil pressure switch is open or
shorted, or switch malfunction.
SWITCH D CIRCUIT, Diagnostic Procedure
P1844
sure Sensor/Switch E
Circuit
H&LR/C oil pressure switch is
open or shorted, or switch mal-
function.
SWITCH E CIRCUIT, Diagnostic Procedure
5AT(diag)-34
A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT)
The inhibitor switch is open or short.
TROUBLE SYMPTOM:
Shift indicator light does not match with select lever.
Shift indicator light does not illuminate.
N-D, N-R shock occur.
5AT(diag)-35
WIRING DIAGRAM:
AT-04347
3
2
1
2
2
i10
i84 A:
B280 B:
A
2
6
A
2
7
B
2
0
B
3
0
TCM
B55
i10
i84
B280
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
8 7 6 5 4 3 2 1
2223 21 20 19 16 15 14 13 12 11 10 9
3435 33 32
17
30
18
31 29 28 27 26 25 24
8
7 6 5 4 3 2 1
22 23 21
20 19 16 15 14 13 12 11 10 9 17
30
18
29 28 27 26 25 24
A:
B:
B365
i107
i106
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
i107 i106
**
1
*
2
*
1
*
2
*
*
1 2 3 4
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
5
E
B365
*
I / F
A: B54
B:
B
2
1
B
2
0
T14
1 2 3 4
A
1
1
A
1
0
A
9
A
8
6 235
T3
B12
B54 A:
B: B55
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
T14
1 3
4 5 6
2
B12
8 7 6 5
4 3 2 1
1
*
2
*
*
T24
B
A
T
T
E
R
Y
I
G
N
I
T
I
O
N
S
W
I
T
C
H
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
CAN TRANSCEIVER
& RECEIVER
MICRO COMPUTER
DRIVE CIRCUIT COMBINATION
METER
LCD FULL DOT
INHIBITOR SWITCH
CONTROL VALVE BODY
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
5AT(diag)-36
Step Check Yes No
1 CHECK DTC OF TCM. Is DTC of AT CAN communica-
tion circuit displayed?
Perform the diag-
nosis according to
DTC.
Go to step 2.
2) Check input signal of inhibitor SW 1 4
monitor using Subaru Select Monitor.
Is all displayed High? Go to step 4. Go to step 3.
transmission.
nector and chassis ground about the item which
indicated Low on step 2.
more?
circuit of harness
between TCM con-
nector and chassis
ground.
2) Check input signal of inhibitor SW 1 4
monitor using Subaru Select Monitor.
Is all displayed Low? Go to step 6. Go to step 5.
transmission.
TCM and transmission connector about the
item which indicated High on step 4.
(B54) No. 8 (B12) No. 4:
(B54) No. 9 (B12) No. 3:
(B54) No. 10 (B12) No. 2:
(B54) No. 11 (B12) No. 1:
circuit of harness
between TCM con-
nector and trans-
mission connector.
CIRCUIT TESTER.
2) Disconnect the transmission connector
(B12).
5) Measure the voltage between TCM terminals.
(B54) No. 8 (+) (B55) No. 23 ():
(B54) No. 9 (+) (B55) No. 23 ():
(B54) No. 10 (+) (B55) No. 23 ():
(B54) No. 11 (+) (B55) No. 23 ():
Is the voltage of inhibitor SW
1 4 between 4 6 V?
7 CHECK TCM I/O SIGNAL.
Check the power supply and ground I/O sig-
nals.
<Ref. to 5AT(diag)-13, ELECTRICAL SPECIFI-
CATION, Transmission Control Module (TCM) I/
O Signal.>
Is TCM I/O signal OK? Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Repair the open or
short circuit for
power supply and
ground.
5AT(diag)-37
TRANSMISSION AND CONTROL VALVE
BODY.
2) Disconnect the connector from transmission.
bracket.
NOTE:
Raise all wheels off the floor.
5) Drain the ATF.
CAUTION:
connector from control valve body connector.
sion connector and control valve body connector.
(T3) No. 4 (T14) No. 2:
(T3) No. 3 (T14) No. 3:
(T3) No. 2 (T14) No. 5:
(T3) No. 1 (T14) No. 6:
circuit of harness
between control
valve body con-
nector and trans-
mission connector.
BODY.
ground and control valve body connector.
more?
circuit of harness
between control
valve body con-
nector and trans-
mission connector.
10 CHECK POOR CONTACT. Is there any poor contact in inhib-
itor SW 1 4 monitor circuit?
Repair the poor
contact.
Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Step Check Yes No
5AT(diag)-38
B: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW
INPUT
Input signal circuit to ATF temperature sensor is open.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
Step Check Yes No
transmission.
(B54) No. 17 (B11) No. 5:
(B54) No. 18 (B11) No. 12:
circuit of harness
between TCM and
transmission
connector.
2 CHECK ATF OIL TEMPERATURE SENSOR.
TCM.
engine.
NOTE:
ating temperature.
sion.
(T4) No. 5 (T4) No. 12:
300 800 ?
TCM
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
1
8
B54
B11
T10
T4
1
2
B54
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
CONTROL VALVE BODY
T10
1 2 3 4
6 7 8 9
5
10
1
7
5
4 3
T20
A
T
F

T
E
M
P
E
R
A
T
U
R
E

S
E
N
S
O
R
AT-04348
5AT(diag)-39
(T4) No. 5 (T4) No. 12:
ature decreases?
3) Read the ATF temperature using Subaru
Select Monitor.
gradually decrease?
Even if the AT OIL
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the poor
contact of harness
between ATF oil
temperature sen-
sor and transmis-
sion connector.
Go to step 6.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 12 (T10) No. 4:
(T4) No. 5 (T10) No. 3:
Is the resistance less than 1 ? Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Repair the open
circuit of harness
between transmis-
sion connector and
control valve body
connector.
6 CHECK POOR CONTACT. Is there poor contact in ATF oil
Repair the poor
contact.
Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Step Check Yes No
5AT(diag)-40
C: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH
INPUT
Input signal circuit to ATF oil temperature sensor is shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
Step Check Yes No
transmission.
more?
circuit of harness
between TCM and
transmission
connector.
TCM.
engine.
NOTE:
ating temperature.
sion.
(T4) No. 5 (T4) No. 12:
300 800 ?
TCM
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
1
8
B54
B11
T10
T4
1
2
B54
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
CONTROL VALVE BODY
T10
1 2 3 4
6 7 8 9
5
10
1
7
5
4 3
T20
A
T
F

T
E
M
P
E
R
A
T
U
R
E

S
E
N
S
O
R
AT-04348
5AT(diag)-41
(T4) No. 5 (T4) No. 12:
ature decreases?
3) Read the ATF temperature using Subaru
Select Monitor.
gradually decrease?
Even if the AT OIL
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the poor
contact of harness
between ATF oil
temperature sen-
sor and transmis-
sion connector.
Go to step 6.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
7) Measure the resistance between chassis
more?
Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Repair the short
circuit of harness
between transmis-
sion connector and
control valve body
connector.
6 CHECK POOR CONTACT. Is there poor contact in ATF oil
Repair the poor
contact.
Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Step Check Yes No
5AT(diag)-42
D: DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT
TROUBLE SYMPTOM:
Does not shift to 5th
WIRING DIAGRAM:
Step Check Yes No
nals.
O Signal.>
Is TCM I/O signal OK? Go to step 2. Repair the open or
short circuit for
power supply and
ground.
2 CHECK TCM AND TRANSMISSION
HARNESS CONNECTOR.
transmission.
(B54) No. 16 (B11) No. 2:
(B54) No. 26 (B12) No. 7:
(B54) No. 27 (B11) No. 7:
circuit of harness
between TCM and
transmission
connector.
HARNESS CONNECTOR.
Is the resistance less than 1 M? Go to step 4. Repair the short
circuit of harness
between TCM and
transmission
connector.
AT-04349
AT1
1 2 3
1 2 3 4
5 6 7 8
B11
B12
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
B54
2
6
7
B12
T3
B11
T4
TCM
1
6
2
2
7
AT1
B54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
7
2 13
TURBINE SPEED SENSOR 1
5AT(diag)-43
4 CHECK TCM POWER SUPPLY OUTPUT.
1) Connect the connector to the TCM. (Trans-
mission connector is disconnected)
3) Measure the voltage between transmission
Is the voltage 10 13 V? Go to step 5. Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
5 CHECK INPUT CIRCUIT OF TCM TURBINE
SPEED SENSOR.
Measure the voltage between TCM connector
terminals.
(B12) No. 7 (+) (B11) No. 2 ():
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
6 CHECK HARNESS ASSEMBLY
(TURBINE SPEED SENSOR GROUND).
Check the installing condition of ground con-
necting harness of harness assembly (used for
both of turbine speed sensor 1, rear vehicle
speed sensor).
Is the ground connecting har-
ness installed securely to the
transmission body? Is there
any serious damage in the har-
ness and terminal?
Go to step 7. When poor instal-
lation of ground
occurs, install it
securely. Replace
the transmission
assembly if the
harness or termi-
nal is damaged.
<Ref. to 5AT-38,
Automatic Trans-
mission Assem-
bly.>
7 CHECK HARNESS ASSEMBLY.
3) Disconnect the connector from turbine
speed sensor 1.
4) Measure the resistance between transmission
connector and turbine speed sensor 1 connector.
(T3) No. 7 (AT1) No. 2:
(T4) No. 7 (AT1) No. 3:
(T4) No. 2 (AT1) No. 1:
(AT1) No. 1 Chassis ground:
cuit of harness
between TCM and
transmission con-
nector, or poor con-
tact of connector.
8 CHECK HARNESS ASSEMBLY.
more?
circuit of harness
between TCM and
transmission
connector.
Step Check Yes No
5AT(diag)-44
NOTE:
3) Start the engine, and set the vehicle in 4th
speed driving condition of manual mode.
NOTE:
Turbine speed sensor 1 signal can be mea-
sured only on 4th speed.
4) Read the current data of turbine speed sen-
sor 1 using the Subaru Select Monitor. <Ref. to
5AT(diag)-17, READ CURRENT DATA, OPER-
NOTE:
VDC memory clearance procedure of on-board
diagnostics system. <Ref. to VDC(diag)-23,
Clear Memory Mode.>
Does the value of the turbine
speed sensor 1 change
depending on the acceleration,
deceleration and shifting range
of the vehicle?
Even if the AT OIL
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the poor
contact of harness
between ATF tem-
perature sensor
and transmission
connector.
Replace the tur-
bine speed sensor
1. <Ref. to 5AT-55,
Turbine Speed
Sensor 1.>
Step Check Yes No
5AT(diag)-45
E: DTC P0719 BRAKE SWITCH CIRCUIT LOW
Stop light switch malfunction, open input signal circuit
TROUBLE SYMPTOM:
Brake down control does not operate at S# mode.
WIRING DIAGRAM:
B280 B:
B281 C:
C
2
3
B
2
0
B
3
0
B159
2 1 3 4
8 9 7 6 5
B280
8
7 6 5 4 3 2 1
22 23 21
20 19 16 15 14 13 12 11 10 9 17
30
18
29 28 27 26 25 24
B281
8
7 6 5 4 3 2 1
21 22 20
19 16 15 14 13 12 11 10 9 1718
28 27 26 25 24 23
2
1
2
0
B55
C:
B:
B65
1 2
3 4
TCM
9
5
B65
B225
7
.
5
A
4
3
AT-04350
B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
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
B365
B365
1
*
2
*
1
*
2
*
S
B
F
-
2
E
FUSE
(RELAY BLOCK)
3
2
B225
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
RELAY BLOCK
FUSE & RELAY
BOX (F/B)
B159
STOP LIGHT
SWITCH
B
A
T
T
E
R
Y
M
A
I
N

S
B
F
N
o
.
8
:
:
1
*
2
*
ARRANGEMENT
AMONG 1, 2 ,3,11,12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
CAN
JOINT
CONNECTOR
5AT(diag)-46
Step Check Yes No
1 CHECK DTC. Is any of following DTC dis-
played? / AT CAN Communica-
tion Circuit / Output Speed
Sensor Circuit / AT Vehicle
Speed Sensor Circuit Malfunc-
tion (Rear Wheel)
Perform the diag-
nosis according to
DTC.
Go to step 2.
2 CHECK FUSE (RELAY BLOCK).
Remove the fuse (7.5A) in the relay block.
Is the fuse (7.5A) blown out? Replace the fuse
(7.5A). If the
replaced fuse
(7.5A) has blown
out easily, repair
ness between fuse
(7.5A) and body
integrated unit.
Go to step 3.
4) Turn the Subaru Select Monitor switch to
ON.
6) Read the data of "Stop Light Switch" using
4 CHECK TCM.
Read the data of "Stop Light Switch" using Sub-
Is ON displayed? A temporary poor
contact of connec-
tor or harness may
be the cause.
Check the poor
contact.
Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
SIGNAL.
grated unit.
grated unit connector and chassis ground.
SWITCH.
switch.
(B281) No. 23 (B65) No. 3:
circuit of harness
between body inte-
grated unit and
stop light switch.
SWITCH.
body integrated unit connector and stop light
switch.
more?
circuit of harness
between body inte-
grated unit and
stop light switch.
5AT(diag)-47
Repair the poor
contact.
Check the body
integrated unit.
Step Check Yes No
5AT(diag)-48
F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT
AT vehicle speed signal is abnormal.
The harness connector between TCM and front vehicle speed sensor is shorted or open.
TROUBLE SYMPTOM:
Shifting quality malfunction
Driving performance is poor.
WIRING DIAGRAM:
AT-04414
T15
1 2 3
B11
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
B54
B11
T4
TCM
1
6
2
7
B54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
7
2
4
CONTROL
VALVE BODY
T15
FRONT VEHICLE
SPEED SENSOR
2
12
T10
3
41
T14
2
1 2 3
4 5 6
T14 T10
1 2 3 4
6 7 8 9
5
10
1
5AT(diag)-49
Step Check Yes No
nals.
O Signal.>
short circuit for
power supply and
ground.
HARNESS CONNECTOR.
transmission.
(B54) No. 24 (B11) No. 1:
(B54) No. 16 (B11) No. 2:
(B54) No. 27 (B11) No. 7:
circuit of harness
between TCM and
transmission
connector.
HARNESS CONNECTOR.
circuit of harness
between TCM and
transmission
connector.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
SPEED SENSOR.
Measure the voltage variation between TCM
(B11) No. 1 (+) (B11) No. 2 ():
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
NOTE:
3) Start the engine, and drive it.
4) Read the current data of front wheel speed
5AT(diag)-17, READ CURRENT DATA, OPER-
NOTE:
CLEAR MEMORY MODE, OPERATION, Sub-
aru Select Monitor.>
Does the value of the front
wheel speed change depend-
ing on the acceleration and
deceleration of the vehicle?
Even if the AT OIL
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the poor
contact of harness
between ATF tem-
perature sensor
and transmission
connector.
Go to step 7.
5AT(diag)-50
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 1 (T10) No. 2:
circuit of harness
between control
valve body con-
nector and trans-
mission connector.
BODY.
more?
circuit of harness
between transmis-
sion connector and
transmission
ground.
CONTROL VALVE BODY AND FRONT
VEHICLE SPEED SENSOR.
1) Disconnect the connector from front vehicle
speed sensor.
control valve body connector and vehicle speed
sensor connector.
(T14) No. 4 (T15) No. 1:
(T10) No. 2 (T15) No. 2:
(T14) No. 1 (T15) No. 3:
Is the resistance less than 1 ? Go to step 10. Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
CONTROL VALVE BODY AND FRONT
VEHICLE SPEED SENSOR.
control valve body connector and transmission
ground.
more?
Replace the front
vehicle speed
sensor.
Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Step Check Yes No
5AT(diag)-51
G: DTC P0724 BRAKE SWITCH CIRCUIT HIGH
Stop light switch malfunction, open input signal circuit
TROUBLE SYMPTOM:
Gear is not shifted down when climbing a hill.
WIRING DIAGRAM:
B280 B:
B281 C:
C
2
3
B
2
0
B
3
0
B159
2 1 3 4
8 9 7 6 5
B280
8
7 6 5 4 3 2 1
22 23 21
20 19 16 15 14 13 12 11 10 9 17
30
18
29 28 27 26 25 24
B281
8
7 6 5 4 3 2 1
21 22 20
19 16 15 14 13 12 11 10 9 1718
28 27 26 25 24 23
2
1
2
0
B55
C:
B:
B65
1 2
3 4
TCM
9
5
B65
B225
7
.
5
A
4
3
AT-04350
B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
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
B365
B365
1
*
2
*
1
*
2
*
S
B
F
-
2
E
FUSE
(RELAY BLOCK)
3
2
B225
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
RELAY BLOCK
FUSE & RELAY
BOX (F/B)
B159
STOP LIGHT
SWITCH
B
A
T
T
E
R
Y
M
A
I
N

S
B
F
N
o
.
8
:
:
1
*
2
*
ARRANGEMENT
AMONG 1, 2 ,3,11,12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
CAN
JOINT
CONNECTOR
5AT(diag)-52
Step Check Yes No
1 CHECK DTC. Is any of following DTC
detected? / AT CAN Communi-
cation Circuit / Output Speed
Sensor Circuit / AT Vehicle
Speed Sensor Circuit Malfunc-
tion (Rear Wheel)
Perform the diag-
nosis according to
DTC.
Go to step 2.
ON.
5) Read the data of "Stop Light Switch" using
3 CHECK TCM.
Read the data of "Stop Light Switch" using Sub-
Is OFF displayed? A temporary poor
contact of connec-
tor or harness may
be the cause.
Check the poor
contact.
Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
SIGNAL.
grated unit.
grated unit connector and chassis ground.
switch.
stop light switch connectors.
(B65) No. 3 (B65) No. 2:
more?
light switch.
SWITCH.
body integrated unit connector and chassis
ground.
circuit of harness
between TCM and
stop light switch.
Repair the poor
contact.
Check the body
integrated unit.
5AT(diag)-53
H: DTC P0731 GEAR 1 INCORRECT RATIO
NOTE:
I: DTC P0732 GEAR 2 INCORRECT RATIO
NOTE:
J: DTC P0733 GEAR 3 INCORRECT RATIO
NOTE:
K: DTC P0734 GEAR 4 INCORRECT RATIO
NOTE:
L: DTC P0735 GEAR 5 INCORRECT RATIO
NOTE:
5AT(diag)-54
M: DTC P0736 REVERSE INCORRECT RATIO
Target gear ratio and actual gear ratio do not match.
TROUBLE SYMPTOM:
Shift point is too high or too low.
Gear is not changed.
The vehicle does not move in D or R range with the engine running at high speed.
Step Check Yes No
1 CHECK DTC OF TCM. Is any DTC of the followings
detected? P0715, P0720,
P0753, P0758, P0763, P0768,
P0773, P0751, P0756, P0761,
P0766, P0771, P1706, P1710,
P1718
Perform the diag-
nosis according to
DTC.
Go to step 2.
2 CHECK TURBINE SPEED SENSOR USING
NOTE:
2) Start the engine, and drive it.
3) Read the current data of torque converter
turbine speed using Subaru Select Monitor.
NOTE:
Does the displayed value of the
Subaru Select Monitor change
according to engine speed and
shifting?
Go to step 3. Perform the diag-
nosis according to
DTC P0715,
P1710.
3 CHECK FRONT AND REAR VEHICLE
SPEED SENSORS.
Do the values displayed for
each of the Subaru Select Mon-
itor and the speedometer sub-
stantially match?
nosis according to
DTC P0720,
P1706.
4 CHECK INHIBITOR SWITCH. Do the values displayed for the
Subaru Select Monitor and the
meter indicator match?
nosis according to
DTC P0705.
5 DRIVING CHECK.
2) After restarting the engine, check that the
AT OIL TEMP light is not blinking, and perform a
drive check based on the Inspection Mode.
<Ref. to 5AT(diag)-21, PROCEDURE, Inspec-
tion Mode.>
Is DTC displayed again? Check the DTC.
Then, when pro-
ceeded again to
step 5, go to step 6.
Go to step 6.
6 CHECK AFTER REPAIR. Is the trouble symptom unre-
peatable (malfunction in shift-
ing such as excessive shift
shock, engine speed increases
excessively when shifting)?
Replace the trans-
mission assembly.
Temporary poor
contact occurs.
Check that the har-
ness connector is
not faulty.
5AT(diag)-55
N: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR
STUCK OFF
Defective lock-up clutch or torque converter assembly
Defective control valve
Defective turbine speed sensor 1 or 2
TROUBLE SYMPTOM:
Step Check Yes No
1 CHECK DTC OF TCM. Is any DTC of the followings
detected? P0715, P0720,
P0753, P0758, P0763, P0768,
P0773, P0751, P0756, P0761,
P0766, P0771, P1710, P1718
Perform the diag-
nosis according to
each DTC.
Go to step 2.
2 DRIVING CHECK FOR LOCK-UP CONDITION.
1) Perform a drive check based on the Inspec-
tion Mode with the following conditions. <Ref. to
5AT(diag)-21, PROCEDURE, Inspection
Mode.>
(1) Read the current data of throttle opening
angle using Subaru Select Monitor. <Ref. to
5AT(diag)-17, READ CURRENT DATA,
(2) Keep the same vehicle speed at 60 km/h
with 10% or less throttle opening angle
which is read currently on Subaru Select
Monitor. <Ref. to 5AT(diag)-17, READ CUR-
RENT DATA, OPERATION, Subaru Select
Monitor.>
(3) Read the current data of L/U solenoid
target pressure using Subaru Select Moni-
tor. <Ref. to 5AT(diag)-17, READ CUR-
Monitor.>
(4) Check the engine speed and turbine
speed when the L/U solenoid target value
displayed on Subaru Select Monitor is 500
kPa or more.
Are the engine speed and tur-
bine speed almost the same?
Temporary poor
contact or open cir-
cuit occurs.
Recheck that the
harness connector
has no faulty.
Go to step 3.
5AT(diag)-56
3 DRIVING CHECK FOR LOCK-UP CONDITION.
1) Clear the memory. <Ref. to 5AT(diag)-19,
2) Perform a drive check based on the Inspec-
tion Mode with the following conditions. <Ref. to
5AT(diag)-21, PROCEDURE, Inspection
Mode.>
(1) Read the current data of throttle opening
angle using Subaru Select Monitor. <Ref. to
5AT(diag)-17, READ CURRENT DATA,
(2) Keep the same vehicle speed at 60 km/h
with 10% or less throttle opening angle
which is read currently on Subaru Select
Monitor. <Ref. to 5AT(diag)-17, READ CUR-
Monitor.>
(3) Read the current data of L/U solenoid
target pressure using Subaru Select Moni-
tor. <Ref. to 5AT(diag)-17, READ CUR-
Monitor.>
(4) Drive the vehicle continuously for one
minutes or more with the L/U solenoid target
value displayed on Subaru Select Monitor at
500 kPa or more.
4) Turn the ignition switch to ON. (engine ON)
5) Perform the step 2) again.
Does the AT OIL TEMP light blink
and is DTC P0741 displayed?
Replace the trans-
mission assembly
when DTC P0741
is displayed.
When DTC other
than P0741 is dis-
played, perform
the diagnosis cor-
responding to the
DTC.
Temporary poor
cuit occurs.
Recheck that the
harness connector
has no faulty.
Step Check Yes No
5AT(diag)-57
O: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL
Output signal circuit of lock-up pressure linear solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT-04352
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
A
7
B11
T11
2
0
5
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
CONTROL VALVE BODY
1 2 3 4
5 6 7 8
T11
T4
LOCK-UP PRESSURE
LINEAR SOLENOID
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TCM B54 A: B55 B:
B
2
2
B
2
3
E
B54 A:
B55 B:
5AT(diag)-58
Step Check Yes No
transmission.
(B54) No. 7 (B11) No. 20:
circuit of harness
between TCM con-
nector and trans-
mission connector.
more?
circuit of harness
between TCM con-
nector and trans-
mission connector.
BODY.
bracket.
NOTE:
5) Drain the ATF.
NOTE:
(T4) No. 20 (T11) No. 5:
circuit of harness
between transmis-
sion connector and
control valve body
connector.
BODY.
Measure the resistance between chassis
more?
circuit of harness
between control
valve body con-
nector and trans-
mission ground.
5 CHECK LOCK-UP PRESSURE LINEAR
SOLENOID.
Is the resistance between 3 9 ? Go to step 6. Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Check that there are no poor contact in TCM
connector, transmission connector and control
valve body connector.
Is there any loosing terminal,
entering foreign matter, damag-
ing connector body?
Repair the poor
contact.
Go to step 7.
7 CHECK AFTER REPAIR.
2) Drive for a while, read the DTC, and check
that there is no faulty.
Is DTC displayed? Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Temporary poor
cuit occurs.
Recheck that the
harness connector
has no faulty.
5AT(diag)-59
P: DTC P0748 PRESSURE CONTROL SOLENOID A ELECTRICAL
Output signal circuit of line pressure linear solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT-04353
A
6
B11
T4
1
9
1
CONTROL VALVE BODY
T11
LINE PRESSURE
LINEAR SOLENOID
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
1 2 3 4
5 6 7 8
T11
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TCM B54 A: B55 B:
B
2
2
B
2
3
E
B54 A:
B55 B:
5AT(diag)-60
Step Check Yes No
transmission.
(B54) No. 6 (B11) No. 19:
circuit of harness
between TCM con-
nector and trans-
mission connector.
more?
circuit of harness
between TCM con-
nector and trans-
mission connector.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 19 (T11) No. 1:
circuit of harness
between transmis-
sion connector and
control valve body
connector.
BODY.
more?
circuit of harness
between control
valve body con-
nector and trans-
mission ground.
NOID.
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
ing connector body?
Repair the poor
contact.
Go to step 7.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Temporary poor
cuit occurs.
Recheck that the
harness connector
has no faulty.
5AT(diag)-61
Q: DTC P0751 SHIFT SOLENOID A PERFORMANCE OR STUCK OFF
Output signal value of front brake linear solenoid does not match the oil pressure.
TROUBLE SYMPTOM:
Locked to 1st gear.
WIRING DIAGRAM:
Step Check Yes No
transmission.
(B54) No. 15 (B11) No. 3:
(B54) No. 4 (B11) No. 17:
circuit of harness
between TCM and
transmission
connector.
more?
circuit of harness
between TCM and
transmission
connector.
3) Check input signal of "Fr/B oil pressure
SW".
AT-04354
B11
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
T11
1 2 3 4
5 6 7 8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
T10
1 2 3 4
6 7 8 9
5
10
A
1
5
7
A
4
8
B11
T4
CONTROL VALVE BODY
1
7
3
T10 T11
FRONT BRAKE
LINEAR
SOLENOID
FRONT BRAKE
OIL PRESSURE
SWITCH
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TCM B54 A: B55 B:
B
2
2
B
2
3
E
B54 A:
B55 B:
5AT(diag)-62
3) Shift to 1st speed while checking the current
gear position using Subaru Select Monitor.
4) Check input signal of "Fr/B oil pressure
SW".
Is ON displayed? Even if the AT OIL
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the poor
contact of harness
in the solenoid out-
put and oil pres-
sure SW input.
Go to step 5.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(B11) No. 17 (T11) No. 8:
(B11) No. 3 (T10) No. 7:
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Replace the trans-
mission harness
assembly.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
sion ground and control valve body connector.
more?
Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Replace the trans-
mission harness
assembly.
Step Check Yes No
5AT(diag)-63
R: DTC P0753 SHIFT SOLENOID A ELECTRICAL
Output signal circuit of front brake linear solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 1st gear.
WIRING DIAGRAM:
AT-04355

A
4
8
B11
T4
CONTROL VALVE BODY
1
7
T11
FRONT BRAKE
LINEAR
SOLENOID
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
1 2 3 4
5 6 7 8
T11
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TCM B54 A: B55 B:
B
2
2
B
2
3
E
B54 A:
B55 B:
5AT(diag)-64
Step Check Yes No
transmission.
(B54) No. 4 (B11) No. 17:
circuit of harness
between TCM con-
nector and trans-
mission connector.
more?
circuit of harness
between TCM con-
nector and trans-
mission connector.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 17 (T11) No. 8:
circuit of harness
between transmis-
sion connector and
control valve body
connector.
BODY.
more?
circuit of harness
between control
valve body and
transmission con-
nector.
5 CHECK FRONT BRAKE LINEAR SOLENOID.
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
ing connector body?
Repair the poor
contact.
Go to step 7.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Temporary poor
cuit occurs.
Recheck that the
harness connector
has no faulty.
5AT(diag)-65
S: DTC P0756 SHIFT SOLENOID B PERFORMANCE OR STUCK OFF
Output signal value of input clutch linear solenoid does not match the oil pressure.
TROUBLE SYMPTOM:
Locked to 1st or 4th gear.
WIRING DIAGRAM:
Step Check Yes No
transmission.
(B54) No. 3 (B11) No. 18:
(B54) No. 20 (B11) No. 11:
circuit of harness
between TCM and
transmission
connector.
more?
circuit of harness
between TCM and
transmission
connector.
3) Check input signal of "I/C oil pressure SW".
AT-04356
A
2
0

A
3
B11
T4
CONTROL VALVE BODY
83 T10 T11
1
1
1
8
INPUT CLUTCH
LINEAR
SOLENOID
INPUT CLUTCH
OIL PRESSURE
SWITCH
TCM B54 A: B55 B:
B11
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
T11
1 2 3 4
5 6 7 8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
T10
1 2 3 4
6 7 8 9
5
10
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
B
2
2
B
2
3
E
B54 A:
B55 B:
5AT(diag)-66
3) Drive the vehicle on 4th speed of D range
with checking current gear position using Sub-
aru Select Monitor.
4) Check input signal of "I/C oil pressure SW".
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the poor
contact of harness
put and oil pres-
sure SW input.
Go to step 5.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 18 (T11) No. 3:
(T4) No. 11 (T10) No. 8:
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Replace the trans-
mission harness
assembly.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
7) Check the insulation of transmission harness
assembly.
more?
Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Replace the trans-
mission harness
assembly.
Step Check Yes No
5AT(diag)-67
T: DTC P0758 SHIFT SOLENOID B ELECTRICAL
Output signal circuit of input clutch linear solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT-04357
A
3
B11
T11
T4
1
8
3
CONTROL VALVE BODY
INPUT CLUTCH
LINEAR
SOLENOID
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
1 2 3 4
5 6 7 8
T11
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TCM B54 A: B55 B:
B
2
2
B
2
3
E
B54 A:
B55 B:
5AT(diag)-68
Step Check Yes No
transmission.
(B54) No. 3 (B11) No. 18:
circuit of harness
between TCM and
transmission
connector.
TCM AND BODY HARNESS.
TCM connector and body harness.
more?
circuit of harness
between TCM and
transmission
connector.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 18 (T11) No. 3:
circuit of harness
between transmis-
sion connector and
control valve body
connector.
BODY.
more?
circuit of harness
between transmis-
sion connector and
control valve body
connector.
5 CHECK INPUT CLUTCH LINEAR SOLENOID.
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
ing connector body?
Repair the poor
contact.
Go to step 7.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Temporary poor
cuit occurs.
Recheck that the
harness connector
has no faulty.
5AT(diag)-69
U: DTC P0761 SHIFT SOLENOID C PERFORMANCE OR STUCK OFF
Output signal value of high & low reverse clutch linear solenoid does not match the oil pressure.
TROUBLE SYMPTOM:
Locked to 1st gear.
WIRING DIAGRAM:
Step Check Yes No
transmission.
(B54) No. 5 (B11) No. 15:
(B54) No. 14 (B11) No. 4:
circuit of harness
between TCM and
transmission
connector.
more?
circuit of harness
between TCM and
transmission
connector.
3) Check the input signal of the "H&LR/C oil
pressure SW".
A
1
4

A
5
B11
T4
62
T10 T11
1
5
4
B11
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
T11
1 2 3 4
5 6 7 8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
T10
1 2 3 4
6 7 8 9
5
10
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TCM B54 A: B55 B:
B
2
2
B
2
3
E
B54 A:
B55 B:
AT-04358
CONTROL VALVE BODY
HIGH & LOW
REVERSE
CLUTCH
LINEAR
SOLENOID
HIGH & LOW
REVERSE
CLUTCH
OIL PRESSURE
SWITCH
5AT(diag)-70
3) Shift to D range and brake ON (1st) with
checking current gear position using Subaru
Select Monitor.
4) Check the input signal of the "H&LR/C oil
pressure SW".
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the poor
contact of harness
put and oil pres-
sure SW input.
Go to step 5.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 15 (T11) No. 2:
(T4) No. 4 (T10) No. 6:
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Replace the trans-
mission harness
assembly.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
assembly.
more?
Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Replace the trans-
mission harness
assembly.
Step Check Yes No
5AT(diag)-71
V: DTC P0763 SHIFT SOLENOID C ELECTRICAL
Output signal circuit of high & low reverse clutch linear solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 1st gear.
WIRING DIAGRAM:

A
5
2
B11
T4
1
5
T11
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
1 2 3 4
5 6 7 8
T11
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TCM B54 A: B55 B:
B
2
2
B
2
3
E
B54 A:
B55 B:
AT-04359
CONTROL VALVE BODY
HIGH & LOW
REVERSE CLUTCH
LINEAR SOLENOID
5AT(diag)-72
Step Check Yes No
transmission.
(B54) No. 5 (B11) No. 15:
circuit of harness
between TCM con-
nector and trans-
mission connector.
more?
circuit of harness
between TCM con-
nector and trans-
mission connector.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 15 (T11) No. 2:
circuit of harness
between transmis-
sion connector and
control valve body
connector.
BODY.
between control valve body connector and
chassis ground.
more?
Go to step 5. Repair the open
circuit of harness
between control
valve body con-
nector and trans-
mission ground.
5 CHECK HIGH & LOW REVERSE CLUTCH
LINEAR SOLENOID.
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
ing connector body?
Repair the poor
contact.
Go to step 7.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Temporary poor
cuit occurs.
Recheck that the
harness connector
has no faulty.
5AT(diag)-73
W: DTC P0766 SHIFT SOLENOID D PERFORMANCE OR STUCK OFF
Output signal value of direct clutch linear solenoid does not match the oil pressure.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
Step Check Yes No
transmission.
(B54) No. 1 (B11) No. 16:
(B54) No. 22 (B11) No. 10:
circuit of harness
between TCM and
transmission
connector.
more?
circuit of harness
between TCM and
transmission
connector.
3) Check input signal of "D/C oil pressure SW".
AT-04360
A
2
2

A
1
CONTROL VALVE BODY
B11
T4
94 T10
T11
1
6
1
0
DIRECT CLUTCH
OIL PRESSURE
SWITCH
DIRECT CLUTCH
LINEAR
SOLENOID
B11
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
T11
1 2 3 4
5 6 7 8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
T10
1 2 3 4
6 7 8 9
5
10
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TCM B54 A: B55 B:
B
2
2
B
2
3
E
B54 A:
B55 B:
5AT(diag)-74
3) Shift to 2nd speed of manual mode and
brake ON with checking current gear position
4) Check input signal of "D/C oil pressure SW".
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the poor
contact of harness
put and oil pres-
sure SW input.
Go to step 5.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 16 (T11) No. 4:
(T4) No. 10 (T10) No. 9:
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Replace the trans-
mission harness
assembly.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
assembly.
more?
Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Replace the trans-
mission harness
assembly.
Step Check Yes No
5AT(diag)-75
X: DTC P0768 SHIFT SOLENOID D ELECTRICAL
The output signal circuit of direct clutch linear solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT-04361
A
1
B11
T11
T4
1
6
4
CONTROL VALVE BODY
DIRECT CLUTCH
LINEAR SOLENOID
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
1 2 3 4
5 6 7 8
T11
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TCM B54 A: B55 B:
B
2
2
B
2
3
E
B54 A:
B55 B:
5AT(diag)-76
Step Check Yes No
transmission.
(B54) No. 1 (B11) No. 16:
circuit of harness
between TCM con-
nector and trans-
mission connector.
more?
circuit of harness
between TCM con-
nector and trans-
mission connector.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 16 (T11) No. 4:
circuit of harness
between transmis-
sion connector and
control valve body
connector.
BODY.
more?
circuit of harness
between control
valve body con-
nector and trans-
mission ground.
5 CHECK DIRECT CLUTCH LINEAR SOLE-
NOID.
transmission ground.
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
ing connector body?
Repair the poor
contact.
Go to step 7.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Temporary poor
cuit occurs.
Recheck that the
harness connector
has no faulty.
5AT(diag)-77
Y: DTC P0771 SHIFT SOLENOID E PERFORMANCE OR STUCK OFF
Output signal of forward brake linear solenoid does not match the oil pressure.
TROUBLE SYMPTOM:
Locked to 2nd, 3rd, 4th gear.
WIRING DIAGRAM:
Step Check Yes No
transmission.
(B54) No. 19 (B11) No. 13:
(B54) No. 21 (B11) No. 9:
circuit of harness
between TCM and
transmission
connector.
more?
circuit of harness
between TCM and
transmission
connector.
3) Check input signal of "Fwd/B oil pressure
SW".
AT-04362
A
2
1

A
1
9
CONTROL VALVE BODY
B11
T4
7 T10 T11
9
1
3
1
0
FORWARD
BRAKE
OIL PRESSURE
SWITCH
FORWARD
BRAKE
LINEAR
SOLENOID
B11
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
T11
1 2 3 4
5 6 7 8
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
T10
1 2 3 4
6 7 8 9
5
10
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TCM B54 A: B55 B:
B
2
2
B
2
3
E
B54 A:
B55 B:
5AT(diag)-78
3) Drive the vehicle on 2nd speed of manual
mode 15 km/h (9 MPH) with checking current
gear position using Subaru Select Monitor.
4) Check input signal of "Fwd/B oil pressure
SW".
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the poor
contact of harness
put and oil pres-
sure SW input.
Go to step 5.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 13 (T11) No. 7:
(T4) No. 9 (T10) No. 10:
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Replace the trans-
mission harness
assembly.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
assembly.
more?
Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Repair the short
circuit of harness
between transmis-
sion connector and
control valve body
connector.
Step Check Yes No
5AT(diag)-79
Z: DTC P0773 SHIFT SOLENOID E ELECTRICAL
Output signal circuit of forward brake linear solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 2nd, 3rd, 4th gear.
WIRING DIAGRAM:
AT-04363
A
1
9
B11
T11
T4
1
3
7
CONTROL VALVE BODY
FORWARD BRAKE
LINEAR SOLENOID
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
1 2 3 4
5 6 7 8
T11
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TCM B54 A: B55 B:
B
2
2
B
2
3
E
B54 A:
B55 B:
5AT(diag)-80
Step Check Yes No
transmission.
(B54) No. 19 (B11) No. 13:
circuit of harness
between TCM con-
nector and trans-
mission connector.
more?
circuit of harness
between TCM con-
nector and trans-
mission connector.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 13 (T11) No. 7:
circuit of harness
between transmis-
sion connector and
control valve body
connector.
BODY.
more?
circuit of harness
between control
valve body con-
nector and trans-
mission ground.
5 CHECK FORWARD BRAKE LINEAR SOLENOID.
transmission ground.
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
ing connector body?
Repair the poor
contact.
Go to step 7.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Temporary poor
contact occurs.
Recheck that the
harness connector
has no faulty.
5AT(diag)-81
AA: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 R range during driving at 20 km/h (12 MPH) or more.
Gear can not be shifted from N range to R range though the vehicle is parked.
WIRING DIAGRAM:
Step Check Yes No
1) Start the integrated unit by force, and check
the operation of shift lock solenoid.(<Ref. to
LAN(diag)-12, READ DIAGNOSTIC TROUBLE
Monitor.>)
2) Operate AT select lever without depressing
the brake pedal.
Does the AT select lever operate? Go to step 2. Go to step 3.
2 CHECK OUTPUT SIGNAL OF INTEGRATED
UNIT.
1) Display the following items using Subaru
Select Monitor.
Key warning SW
Shift position
P SW
Stop light switch
2) Step on the brake and shift the AT select
lever to P range.
Do the units of measure of
items displayed change?
Go to step 3. Check the circuits
of the items whose
values do not
change.
BODY INTEGRATED UNIT AND SHIFT LOCK
SOLENOID.
Measure the harness resistance between the
body integrated unit and chassis ground.
more?
circuit of harness
between body inte-
grated unit and
shift lock solenoid
connector.
6
E
B116
B116
3
4
B280
B280
1 2 3 4 5
6 7 8 9 10 11 12
5 4 6 7
8
2 1
9
3
10
22 23
11 12 13 14 15
24 25 26 27
16 17 18
28 29
19 20
21 30
AT-04340
SHIFT LOCK
SOLENOID
5AT(diag)-82
4 CHECK HARNESS BETWEEN SHIFT LOCK
SOLENOID AND CHASSIS GROUND
TERMINAL.
shift lock solenoid and chassis ground.
circuit of harness
between chassis
ground and shift
lock solenoid
connector.
terminals.
(B116) No. 3 No. 4:
Is the resistance between 7 21 ? Go to step 6. Replace the shift
lock solenoid.
6 CHECK OUTPUT SIGNAL OF BODY
INTEGRATED UNIT.
3) With the brake pedal depressed, shift the AT
select lever to D range.
7 CHECK OUTPUT SIGNAL OF BODY
INTEGRATED UNIT.
NOTE:
3) Shift the AT select lever to D range and
slowly increase vehicle speed to exceed 20 km/h
(12 MPH).
NOTE:
Is the voltage less than 1 V? Even if the AT OIL
TEMP light illumi-
nates, the circuit is
in normal condi-
tion. A temporary
poor contact of
connector or har-
ness may be the
cause. Repair the
harness or con-
nector in the
reverse inhibitor
control circuit.
Go to step 8.
reverse inhibitor control circuit?
Repair the poor
contact.
Replace the body
integrated unit.
<Ref. to SL-55,
Body Integrated
Unit.>
Step Check Yes No
5AT(diag)-83
AB:DTC P0817 STARTER DISABLE CIRCUIT
Open or short in P/N signal output circuit
TROUBLE SYMPTOM:
Engine can be started on other than P or N range
Engine can not be started on P or N range.
WIRING DIAGRAM:
AT-04364
B136
B55
3
1
1
1
ECM
TCM
B136
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
5AT(diag)-84
Step Check Yes No
1 CHECK DTC OF TCM. Is DTC of Transmission Range
Sensor Circuit (PRNDL Input)
detected?
Perform the diag-
nosis according to
DTC.
Go to step 2.
2 CHECK ECM. Is the communication between
ECM normal?
nosis according to
DTC concerning
ECM.
2) Remove the fuse.
(No. 32). If the
replaced fuse (No.
32) blows out eas-
circuit of harness
between fuse (No.
32) and TCM.
Go to step 4.
TCM AND ECM.
transmission.
(B55) No. 11 (B136) No. 31
cuit of harness
between TCM and
transmission con-
tact of connector.
TCM AND ECM.
more?
circuit of harness
between transmis-
sion connector and
chassis ground.
6 CHECK TCM OUTPUT SIGNAL.
1) Connect the TCM and ECM connector.
Is the voltage 1 V or less? Go to step 7. Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
8 CHECK POOR CONTACT. Is there any open or poor con-
tact of connector (loosing termi-
nal, entering foreign matter,
damaging connector body)?
Repair the poor
contact.
Check the neutral
switch of ECM.
5AT(diag)-85
AC:DTC P0957 BACKUP LIGHT RELAY CIRCUIT LOW
Output circuit of the back-up light relay is open or shorted
TROUBLE SYMPTOM:
Back-up light does not illuminate in R range.
WIRING DIAGRAM:
1
3
B55
B226
TCM
IG2 RELAY
N
o
.
1
8
E
1 3
2 4
B226
B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
10
11
6
5
1
4
2
3
8 9 7
MAIN SBF
SBF-8
B
A
T
T
E
R
Y
BACK-UP LIGHT RELAY
BACK-UP LIGHT SYSTEM
AT-04365
5AT(diag)-86
Step Check Yes No
detected?
Perform the diag-
nosis according to
DTC.
Go to step 2.
TCM AND BACK-UP LIGHT RELAY.
back-up light relay.
TCM connector and back-up light relay connector.
(B55) No. 13 (B226) No. 4:
circuit of harness
between TCM and
transmission con-
nector, or poor
contact of
connector.
more?
circuit of harness
between TCM and
transmission
connector.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
1) Set the select lever to R range.
2) Is the voltage 1 V or less?
Is the voltage less than 1 V? Go to step 6. Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
6 CHECK INPUT VOLTAGE FOR BACK-UP
LIGHT RELAY.
Measure the voltage between back-up light
relay and chassis ground.
Is the voltage 10 13 V? Replace the back-
up light relay.
Check open or
ness between fuse
(No. 18) and back-
up light relay.
5AT(diag)-87
AD:DTC P0958 BACKUP LIGHT RELAY CIRCUIT HIGH
Output circuit of the back-up light relay is open or shorted
TROUBLE SYMPTOM:
Back-up light does not illuminate in R range.
WIRING DIAGRAM:
1
3
B55
B226
TCM
IG2 RELAY
N
o
.
1
8
E
1 3
2 4
B226
B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
10
11
6
5
1
4
2
3
8 9 7
MAIN SBF
SBF-8
B
A
T
T
E
R
Y
BACK-UP LIGHT RELAY
BACK-UP LIGHT SYSTEM
AT-04365
5AT(diag)-88
Step Check Yes No
detected?
Perform the diag-
nosis according to
DTC.
Go to step 2.
TCM AND BACK-UP LIGHT RELAY.
back-up light relay.
TCM connector and back-up light relay connector.
(B55) No. 13 (B226) No. 4:
circuit of harness
between TCM and
transmission con-
nector, or poor
contact of
connector.
more?
circuit of harness
between TCM and
transmission
connector.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
1) Set the select lever to R range.
Is the voltage 1 V or less? Go to step 6. Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
6 CHECK INPUT VOLTAGE FOR BACK-UP
LIGHT RELAY.
Measure the voltage between back-up light
relay and chassis ground.
Is the voltage 10 13 V? Replace the back-
up light relay.
Check open or
ness between fuse
(No. 18) and back-
up light relay.
5AT(diag)-89
AE:DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION
(REAR WHEEL)
TROUBLE SYMPTOM:
Shifting quality malfunction
WIRING DIAGRAM:
Step Check Yes No
Check the power supply and ground I/O signal.
O Signal.>
short circuit for
power supply and
ground.
HARNESS CONNECTOR.
transmission.
(B54) No. 23 (B12) No. 5:
(B54) No. 27 (B11) No. 7:
(B54) No. 16 (B11) No. 2:
circuit of harness
between TCM and
transmission
connector.
HARNESS CONNECTOR.
more?
circuit of harness
between TCM and
transmission
connector.
AT-04366
B54
2
7
7
AT4
TCM
1
6
2
B11
2
3
5
1 2
5 6 7 8
13 14 15 16
9 10 11 12
3 4
17 18 19 20
AT4
1
3 12
B54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
B11
T4
B12
T3
B12
8 7 6 5
4 3 2 1
2 3
REAR VEHICLE SPEED SENSOR
5AT(diag)-90
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
SPEED SENSOR.
Measure the voltage variation between TCM
(B12) No. 5 (+) (B11) No. 2 ():
6 CHECK HARNESS ASSEMBLY
(TURBINE SPEED SENSOR GROUND).
Check the installing condition of ground con-
necting harness (used for both of turbine speed
sensor 1, rear vehicle speed sensor).
Is the ground connecting har-
ness installed to transmission
body correctly, or the harness
and connector terminals not
damaged?
Go to step 7. When the poor
installation of
ground connecting
harness, install it
securely.
Replace the trans-
mission assembly
when the harness
is damaged. <Ref.
to 5AT-38, Auto-
matic Transmis-
sion Assembly.>
NOTE:
3) Start the engine, and drive the vehicle.
4) Read the current data of rear wheel speed
5AT(diag)-17, OPERATION, Subaru Select
Monitor.>
NOTE:
Does the value of the rear
wheel speed depending on the
acceleration and deceleration
of the vehicle?
Even if the AT OIL
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Repair poor con-
tact of harness in
ATF temperature
sensor and trans-
mission connector.
Replace the trans-
mission harness.
Step Check Yes No
5AT(diag)-91
AF:DTC P1707 AT AWD SOLENOID VALVE CIRCUIT MALFUNCTION
Output signal circuit of transfer linear solenoid is open or shorted.
TROUBLE SYMPTOM:
Drivability getting worse.
WIRING DIAGRAM:
AT-04367
TCM
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
A
2
B54
B11
T11
T4
8
6
B54
5 6
7 8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16
17 18 19 20 21
33 34 29 32 30 31 35
CONTROL VALVE BODY
1 2 3 4
5 6 7 8
T11
B11
B
2
2
B
2
3
A: B55 B:
E
B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
TRANSFER
LINEAR
SOLENOID
5AT(diag)-92
Step Check Yes No
transmission.
(B54) No. 2 (B11) No. 8:
circuit of harness
between TCM con-
nector and trans-
mission connector.
more?
circuit of harness
between TCM con-
nector and trans-
mission connector.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 8 (T11) No. 6:
circuit of harness
between transmis-
sion connector and
control valve body
connector.
BODY.
more?
circuit of harness
between control
valve body con-
nector and trans-
mission ground.
5 CHECK TRANSFER LINEAR SOLENOID.
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
ing connector body?
Repair the poor
contact.
Go to step 7.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Temporary poor
cuit occurs.
Recheck that the
harness connector
has no faulty.
5AT(diag)-93
AG:DTC P1710 TORQUE CONVERTER TURBINE 2 SPEED SIGNAL CIRCUIT 2
MALFUNCTION
TROUBLE SYMPTOM:
Does not shift to 5th
WIRING DIAGRAM:
Step Check Yes No
Check the power supply and ground I/O signal.
O Signal.>
short circuit for
power supply and
ground.
HARNESS CONNECTOR.
transmission.
(B54) No. 25 (B12) No. 6:
(B54) No. 16 (B11) No. 2:
(B54) No. 27 (B11) No. 7:
circuit of harness
between TCM and
transmission
connector.
HARNESS CONNECTOR.
circuit of harness
between TCM and
transmission
connector.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
AT-04368
B54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
T10
1 2 3 4
6 7 8 9
5
10
2
7
1
TCM B54
B12
T3
CONTROL VALVE BODY
6
TURBINE SPEED
SENSOR 2
B12
8 7 6 5
4 3 2 1
B11
T4
7
2
5
1
6
2
T14 T10
1 4
1 2 3
4 5 6
T14
B11
1 2 3 4
5 6 7 8
9
13 14 15
20 19 17
16
10 11 12
18
5AT(diag)-94
AH:DTC P1718 AT CAN COMMUNICATION CIRCUIT
NOTE:
DTC P1718 AT CAN communication circuit, refer to LAN System. <Ref. to LAN(diag)-12, READ DIAGNOS-
TIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.>
SPEED SENSOR 2.
Measure the voltage between TCM connector
terminals.
(B12) No. 6 (+) (B11) No. 2 ():
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
NOTE:
3) Start the engine, and set the vehicle in 1st
speed driving condition of manual mode.
4) Read the current data of torque converter
turbine speed 2 using Subaru Select Monitor.
<Ref. to 5AT(diag)-17, OPERATION, Subaru
Select Monitor.>
NOTE:
Does the value of the turbine
speed sensor 2 change
depending on the acceleration,
deceleration and shifting gear
of the vehicle?
Even if the AT OIL
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Repair the poor
contact of harness
of turbine speed
sensor 2 and trans-
mission connector.
Go to step 7.
BODY.
bracket.
NOTE:
5) Drain the ATF.
CAUTION:
(T3) No. 6 (T10) No. 1:
circuit of harness
between transmis-
sion connector and
control valve body
connector.
BODY.
more?
Replace the con-
trol valve body.
<Ref. to 5AT-56,
Control Valve
Body.>
Repair the short
circuit of harness
between transmis-
sion connector and
transmission
ground.
Step Check Yes No
5AT(diag)-95
AI: DTC P1760 LATERAL ACCELERATION SENSOR PERFORMANCE PROBLEM
Lateral G sensor output voltage fault
WIRING DIAGRAM:
Step Check Yes No
1 CHECK VEHICLE CONDITION. Is the vehicle a model with
VDC, which has the VDC OFF
switch on the instrument panel?
tion detected?
Perform the diag-
nosis according to
DTC.
Go to step 3.
3 CHECK DTC OF ABS. Is DTC of ABS detected? Perform the diag-
nosis according to
DTC of ABS.
Temporary poor
contact occurs.
Recheck for defec-
tive parts in har-
ness and
connectors.
4 CHECK OUTPUT OF LATERAL G SENSOR
USING SUBARU SELECT MONITOR.
Read the value of Lateral G Sensor using
Is the reading indicated on
monitor display 2.3 2.7 V?
2) Remove the console box.
3) Remove the lateral G sensor from vehicle.
(Do not disconnect the connector.)
5) Read the value of Lateral G Sensor using
Is the value on the display 3.3
4.3 V with the lateral G sen-
sor inclined 90 to right?
Go to step 6. Replace the lateral
G sensor. <Ref. to
5AT-60, Lateral G
Sensor.>
Is the value on the display 0.7
1.7 V with the lateral G sen-
sor inclined 90 to left?
G sensor. <Ref. to
5AT-60, Lateral G
Sensor.>
7 CHECK POOR CONTACT IN CONNECTOR.
Is there poor contact in connec-
tor between TCM and lateral G
sensor?
Repair the connector. Go to step 8.
AT-04479
21 3
B359
B
7
B
9
B55 B: TCM
B359
1 2 3
B: B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
A: B54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
LATERAL G SENSOR
A: B54
A
1
8
5AT(diag)-96
8 CHECK ABSCM&H/U.
3) Perform the Inspection Mode.
4) Read the DTC.
Is the same DTC displayed? Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Go to step 9.
9 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag-
nosis according to
DTC.
Temporary poor
contact occurs.
10 CHECK OPEN CIRCUIT IN LATERAL G
SENSOR OUTPUT HARNESS AND GROUND
HARNESS.
nector terminals.
(B54) No. 18 (B55) No. 7:
Is the resistance 5.0 6.0 k? Go to step 11. Repair the harness
between lateral G
sensor and TCM.
11 CHECK LATERAL G SENSOR.
3) Connect the connector to lateral G sensor.
4) Connect the connector to ABSCM&H/U.
6) Measure the voltage between lateral G sen-
sor connector terminals.
(B359) No. 3 (+) No. 2 ():
Is the voltage 2.3 2.7 V when
lateral G sensor is in horizontal
position?
G sensor. <Ref. to
5AT-60, Lateral G
Sensor.>
Measure the voltage between lateral G sensor
(B359) No. 3 (+) No. 2 ():
lateral G sensor is inclined 90
to right?
G sensor. <Ref. to
5AT-60, Lateral G
Sensor.>
(B359) No. 3 (+) No. 2 ():
to left?
G sensor. <Ref. to
5AT-60, Lateral G
Sensor.>
14 CHECK ABSCM&H/U.
5) Read the DTC.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Go to step 15.
nosis according to
DTC.
Temporary poor
contact occurs.
Step Check Yes No
5AT(diag)-97
AJ:DTC P1761 LATERAL ACCELERATION SENSOR CIRCUIT LOW
Lateral G sensor open circuit or output voltage fault (Model without VDC)
CAN communication malfunction (Model with VDC)
WIRING DIAGRAM:
Step Check Yes No
tion detected?
Perform the diag-
nosis according to
DTC.
Go to step 3.
nosis according to
DTC of ABS.
Temporary poor
contact occurs.
Recheck for defec-
tive parts in har-
ness and
connectors.
monitor display 2.3 2.7 V
when lateral G sensor is level?
sensor?
6 CHECK ABSCM&H/U.
4) Read the DTC.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Go to step 7.
nosis according to
DTC.
Temporary poor
contact occurs.
AT-04479
21 3
B359
B
7
B
9
B55 B: TCM
B359
1 2 3
B: B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
A: B54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
LATERAL G SENSOR
A: B54
A
1
8
5AT(diag)-98
HARNESS.
nector terminals.
(B54) No. 18 (B55) No. 7:
between lateral G
sensor and TCM.
9 CHECK GROUND SHORT OF HARNESS.
more?
Go to step 10. Repair the harness
between lateral G
sensor and TCM.
Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
(B359) No. 3 (+) No. 2 ():
position?
G sensor. <Ref. to
5AT-60, Lateral G
Sensor.>
(B359) No. 3 (+) No. 2 ():
to right?
G sensor. <Ref. to
5AT-60, Lateral G
Sensor.>
(B359) No. 3 (+) No. 2 ():
to left?
G sensor. <Ref. to
5AT-60, Lateral G
Sensor.>
13 CHECK TCM.
5) Read the DTC.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Go to step 14.
nosis according to
DTC.
Temporary poor
contact occurs.
Step Check Yes No
5AT(diag)-99
AK:DTC P1762 LATERAL ACCELERATION SENSOR CIRCUIT HIGH
Lateral G sensor output voltage fault
WIRING DIAGRAM:
AT-04479
21 3
B359
B
7
B
9
B55 B: TCM
B359
1 2 3
B: B55
5 6 7 2 1 3 4
29
10 11 12 13 14 15
25 24
16
30
9 8 17 18 19
20
28
21 22 23
32 31
26 27
33 34 35
A: B54
16 10 11 12 13 14 15
25 24
30
9 8 7
17 18 19 20
28
21 22 23
29 32 31
1 2 3 4 5 6
27 26
33 34 35
LATERAL G SENSOR
A: B54
A
1
8
5AT(diag)-100
Step Check Yes No
tion detected?
Perform the diag-
nosis according to
DTC.
Go to step 3.
nosis according to
DTC of ABS.
Temporary poor
contact occurs.
Recheck for defec-
tive parts in har-
ness and
connectors.
monitor display 2.3 2.7 V
when lateral G sensor is level?
5 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in connec-
sensor?
6 CHECK ABSCM&H/U.
4) Read the DTC.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Go to step 7.
nosis according to
DTC.
Temporary poor
contact occurs.
8 CHECK INFORMATION STORED IN FREEZE
FRAME DATA.
Is the reading on monitor 4.65 V
or more?
HARNESS.
nector terminals.
(B55) No. 9 (B54) No. 18:
connector between
the lateral G sen-
sor and
ABSCM&H/U.
10 CHECK BATTERY SHORT OF HARNESS.
3) Disconnect the connector from the lateral G
sensor.
Is the voltage less than 1 V? Go to step 11. Repair the harness
between lateral G
sensor and TCM.
11 CHECK BATTERY SHORT OF HARNESS.
between lateral G
sensor and TCM.
sensor?
5AT(diag)-101
13 CHECK TCM.
4) Read the DTC.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Go to step 14.
nosis according to
DTC.
Temporary poor
contact occurs.
15 CHECK LATERAL G SENSOR INPUT VOLTAGE.
(B359) No. 1 (+) No. 2 ():
between lateral G
sensor and TCM.
HARNESS.
nector terminals.
(B55) No. 9 No. 7:
between lateral G
sensor and TCM.
(B359) No. 3 (+) No. 2 ():
position?
G sensor. <Ref. to
5AT-60, Lateral G
Sensor.>
(B359) No. 3 (+) No. 2 ():
to right?
G sensor. <Ref. to
5AT-60, Lateral G
Sensor.>
(B359) No. 3 (+) No. 2 ():
to left?
G sensor. <Ref. to
5AT-60, Lateral G
Sensor.>
sensor?
Repair the connec-
tor.
Go to step 21.
21 CHECK ABSCM&H/U.
4) Read the DTC.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Go to step 22.
nosis according to
DTC.
Temporary poor
contact occurs.
Step Check Yes No
5AT(diag)-102
AL:DTC P1817 SPORT MODE SWITCH CIRCUIT (MANUAL SWITCH)
TROUBLE SYMPTOM:
When shifting to N D, the SPORT shift indicator light illuminates.
WIRING DIAGRAM:
3
2
1
2
2
i10
i84 A: B280 B:
A
2
6
A
2
7
B
2
0
B
3
0
2
1
2
0
TCM
B55
AT OIL
TEMP
i10
i84
B280
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
8 7 6 5 4 3 2 1
2223 21 20 19 16 15 14 13 12 11 10 9
3435 33 32
17
30
18
31 29 28 27 26 25 24
8
7 6 5 4 3 2 1
22 23 21
20 19 16 15 14 13 12 11 10 9 17
30
18
29 28 27 26 25 24
A:
B:
B365
i107
i106
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
i107 i106
**
1
*
2
*
1
*
2
*
*
1 2 3 4
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
5
E
B365
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
COMBINATION
METER
*
B55
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
C
2
6
B116
8
9
E
AT
SELECT LEVER
:
:
1
*
2
*
:
*
ARRANGEMENT
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
I
G
N
I
T
I
O
N
S
W
I
T
C
H
B
A
T
T
E
R
Y
BODY INTEGRATED
UNIT
B116
1 2 3 4 5
6 7 8 9 10 11 12
B281 C:
B281
8
7 6 5 4 3 2 1
2223 21 20
19 16 15 14 13 12 11 10 9 1718
28 27 26 25 24
C:
AT-04369
5AT(diag)-103
Step Check Yes No
nosis according to
DTC.
Go to step 2.
SIGNAL.
2) Read the "TIP mode SW" data of body inte-
Monitor.>
SIGNAL.
range.
Monitor.>
OFF?
Go to step 4. Replace the select
lever assembly.
<Ref. to CS-23,
Select Lever.>
SIGNAL.
1) Shift the AT select lever to manual mode.
2) Shift the AT select lever to other than D
range.
Monitor.>
Is OFF displayed? Go to step 5. Replace the select
lever assembly.
<Ref. to CS-23,
Select Lever.>
and AT CAN communication
circuit displayed?
Perform the diag-
nosis according to
each DTC.
Go to step 6.
6 CHECK INPUT SIGNAL FROM TCM.
range.
2) Read the "TIP mode SW" data of TCM using
OFF?
Even if the AT OIL
TEMP light blinks,
the system is in
normal condition.
A temporary poor
contact of connec-
tor or harness may
be the cause.
Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
GRATED UNIT AND MANUAL MODE
SWITCH.
2) Disconnect harness connector from body
integrated unit and select lever.
3) Measure the harness resistance between
more?
circuit of harness
between body inte-
grated unit and
manual mode.
5AT(diag)-104
AM:DTC P1840 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH A CIRCUIT
Front brake oil pressure switch malfunction
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0751 for diagnostic procedure. <Ref. to 5AT(diag)-61, DTC P0751 SHIFT SOLENOID A
PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AN:DTC P1841 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH B CIRCUIT
Forward brake oil pressure switch malfunction
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0771 for diagnostic procedure. <Ref. to 5AT(diag)-77, DTC P0771 SHIFT SOLENOID E
AO:DTC P1842 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH C CIRCUIT
Input clutch oil pressure switch is malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0756 for diagnostic procedure. <Ref. to 5AT(diag)-65, DTC P0756 SHIFT SOLENOID B
AP:DTC P1843 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH D CIRCUIT
Direct clutch oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0766 for diagnostic procedure. <Ref. to 5AT(diag)-73, DTC P0766 SHIFT SOLENOID D
AQ:DTC P1844 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH E CIRCUIT
High & low reverse clutch oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0761 for diagnostic procedure. <Ref. to 5AT(diag)-69, DTC P0761 SHIFT SOLENOID C
8 CHECK MANUAL MODE SWITCH.
2) Measure the resistance between harness
connector terminals of SPORT/manual mode
switch.
Terminals
(B116) No. 9 No. 8
more?
Check the body
integrated unit.
Replace the select
lever assembly.
<Ref. to CS-23,
Select Lever.>
Step Check Yes No
5AT(diag)-105
A: CHECK MANUAL MODE SWITCH
DIAGNOSIS:
TROUBLE SYMPTOM:
Does not shift on manual mode.
WIRING DIAGRAM:
Step Check Yes No
1) Perform ON/OFF operation on the SPORT/
manual mode switch.
2) Read the data of TIP mode SW using Sub-
aru Select Monitor.
Is the ON/OFF normally
detected?
2 CHECK DTC OF BODY INTEGRATED UNIT. Is DTC of CAN detected? Perform the diag-
nosis according to
DTC.
Go to step 3.
3 CHECK TCM.
1) Perform ON/OFF operation on the SPORT/
manual mode switch.
2) Read the data of TIP mode SW using Sub-
aru Select Monitor.
Is the ON/OFF normally
detected?
4 CHECK SPORT SHIFT INDICATOR OF
COMBINATION METER.
Is the SPORT shift indicator
light OK?
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
AT-04370
1
*
2
*
1
*
2
*
B281 C:
B280 B:
B
2
0
B
3
0
C
2
5
C
1
5
2
1
2
0
B116
TCM B55
1
0
1
1
6
7
B280
B281
8
7 6 5 4 3 2 1
22 23 21
20 19 16 15 14 13 12 11 10 9 17
30
18
29 28 27 26 25 24
8
7 6 5 4 3 2 1
2223 21 20
19 16 15 14 13 12 11 10 9 1718
28 27 26 25 24
B116
B:
C:
B365
B365
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
AT
SELECT LEVER
U
P
D
O
W
N
B227
U
P
D
O
W
N
1
2
3
B227
1 2 3
B55
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
:
:
1
*
2
*
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
JOINT
CONNECTOR
PADDLE SHIFT
SWITCH
C
2
6
S
P
O
R
T
/
M
A
N
U
A
L

M
O
D
E
S
W
I
T
C
H
9
8
5AT(diag)-106
5 CHECK DTC OF TCM. Is DTC of CAN detected? Perform the diag-
nosis according to
DTC.
Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
6 CHECK DTC OF METER. Is DTC of CAN detected? Perform the diag-
nosis according to
DTC.
Replace the meter.
7 CHECK GROUND CIRCUIT OF
SPORT/MANUAL MODE SWITCH.
manual mode switch.
chassis ground.
circuit of harness
between SPORT/
manual mode
switch and chassis
ground.
(B116) No. 6 No. 7:
(B116) No. 10 No. 11:
more?
plate assembly.
1) Move the select lever to manual mode.
(B116) No. 6 No. 7:
(B116) No. 10 No. 11:
Is the resistance less than 1 ? Go to step 10. Replace the guide
plate assembly.
MANUAL MODE SWITCH.
grated unit.
(B116) No. 7 (B281) No. 15:
(B116) No. 11 (B281) No. 25:
cuit of harness
between the
SPORT/manual
mode switch con-
nector and body
integrated unit con-
tact of connector.
MANUAL MODE SWITCH.
grated unit.
chassis ground.
more?
Go to step 12. Repair the short cir-
cuit of harness
between SPORT/
manual mode
switch connector
and body integrated
unit connector.
Step Check Yes No
5AT(diag)-107
12 CHECK INPUT SIGNAL TO BODY
INTEGRATED UNIT.
unit.
Is the voltage 9 V or more? Go to step 13. Replace the body
integrated unit.
<Ref. to SL-55,
Body Integrated
Unit.>
13 CHECK INPUT SIGNAL TO BODY
INTEGRATED UNIT.
1) Shift and hold the AT select lever to shift up
side.
unit.
integrated unit.
<Ref. to SL-55,
Body Integrated
Unit.>
14 CHECK PADDLE SHIFT SWITCH GROUND
CIRCUIT.
2) Disconnect the connector from paddle shift
switch.
paddle shift switch connector and chassis
ground.
circuit of harness
between paddle
shift switch and
chassis ground.
15 CHECK PADDLE SHIFT SWITCH.
Measure the resistance between paddle shift
(B227) No. 2 (B227) No. 3:
more?
Go to step 16. Replace the paddle
shift switch connector
or paddle shift switch.
Or repair the poor
contact of connector.
16 CHECK PADDLE SHIFT SWITCH.
1) Press and hold the + side of paddle shift
switch.
2) Measure the resistance between paddle
shift switch connector terminals.
(B227) No. 2 (B227) No. 3:
Is the resistance less than 1 ? Go to step 17. Replace the paddle
shift switch connector
or paddle shift switch.
Or repair the poor
contact of connector.
circuit?
Repair the poor
contact.
Temporary poor con-
tact of the SPORT/
manual mode switch
circuit connector or
harness.
Step Check Yes No
5AT(diag)-108
B: CHECK SPORT SHIFT INDICATOR LIGHT
DIAGNOSIS:
Output signal circuit of SPORT shift indicator light is open or shorted.
TROUBLE SYMPTOM:
SPORT shift indicator light does not illuminate or remains illuminated.
SPORT shift indicator light display does not change.
WIRING DIAGRAM:
AT-04345
3
2
1
2
2
i10
i84 A: B280 B:
A
2
6
A
2
7
B
2
0
B
3
0
2
1
2
0
TCM B55
AT OIL
TEMP
i10
i84
B280
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
8 7 6 5 4 3 2 1
2223 21 20 19 16 15 14 13 12 11 10 9
3435 33 32
17
30
18
31 29 28 27 26 25 24
8
7 6 5 4 3 2 1
22 23 21
20 19 16 15 14 13 12 11 10 9 17
30
18
29 28 27 26 25 24
A:
B:
B365
i107
i106
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
i107 i106
**
1
*
2
*
1
*
2
*
*
1
*
2
*
*
1 2 3 4
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
5
E
B365
BUZZER
*
B55
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
I / F
I
G
N
I
T
I
O
N
S
W
I
T
C
H
LCD FULL DOT
COMBINATION
METER
MICRO COMPUTER
DRIVE CIRCUIT
CAN TRANSCEIVER
& RECEIVER
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
B
A
T
T
E
R
Y
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
5AT(diag)-109
Step Check Yes No
Check DTC of the body integrated unit.
Is DTC of AT CAN communica-
Perform the diag-
nosis according to
DTC.
Go to step 2.
2 CHECK TCM.
Check DTC of TCM.
Is DTC of AT CAN communica-
Perform the diag-
nosis according to
DTC.
Go to step 3.
3 CHECK TCM.
ON.
5) Shift the AT select lever to manual mode
side, and shift down the AT select lever.
6) Read the indicator.
Is the gear position at 1 and
displayed?
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
4 CHECK TCM.
1) Shift up the AT select lever.
2) Read the indicator.
Is the gear position at 2 and
displayed?
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Read the gear position data using Subaru
Select Monitor.
Is the SPORT shift gear posi-
tion 2?
Go to step 6. Check the body
integrated unit.
<Ref. to SL-55,
Body Integrated
Unit.>
6 CHECK COMBINATION METER. Is the SPORT shift indicator
OK?
Refer to Symptom
Related Diagnos-
tic. <Ref. to
5AT(diag)-112,
General Diagnos-
tic Table.>
Replace the com-
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
5AT(diag)-110
C: CHECK BUZZER
DIAGNOSIS:
Output signal circuit of buzzer is open or shorted.
TROUBLE SYMPTOM:
Buzzer remains beeping.
WIRING DIAGRAM:
AT-04345
3
2
1
2
2
i10
i84 A: B280 B:
A
2
6
A
2
7
B
2
0
B
3
0
2
1
2
0
TCM B55
AT OIL
TEMP
i10
i84
B280
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
8 7 6 5 4 3 2 1
2223 21 20 19 16 15 14 13 12 11 10 9
3435 33 32
17
30
18
31 29 28 27 26 25 24
8
7 6 5 4 3 2 1
22 23 21
20 19 16 15 14 13 12 11 10 9 17
30
18
29 28 27 26 25 24
A:
B:
B365
i107
i106
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
i107 i106
**
1
*
2
*
1
*
2
*
*
1
*
2
*
*
1 2 3 4
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
5
E
B365
BUZZER
*
B55
5 6 7
8
2 1
9
4 3
10
24 22 23 25
11 12 13 14 15
26 27
28
16 17 18 19
20 21
29 30 31 32 33 34 35
I / F
I
G
N
I
T
I
O
N
S
W
I
T
C
H
LCD FULL DOT
COMBINATION
METER
MICRO COMPUTER
DRIVE CIRCUIT
CAN TRANSCEIVER
& RECEIVER
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
CAN
JOINT
CONNECTOR
B
A
T
T
E
R
Y
ARRANGEMENT
AMONG 1, 2, 3, 11, 12 AND 13
ARRANGEMENT
ARRANGEMENT
AMONG 8, 9, 10, 18, 19 AND 20
5AT(diag)-111
Step Check Yes No
Check DTC of the body integrated unit.
displayed?
Perform the diag-
nosis according to
DTC.
Go to step 2.
2 CHECK TCM.
Check DTC of TCM.
displayed?
Perform the diag-
nosis according to
DTC.
Go to step 3.
3 CHECK BUZZER STOP.
Disconnect the connector (B55).
Does the buzzer stop? Replace the TCM.
<Ref. to 5AT-59,
Transmission Con-
trol Module
(TCM).>
Go to step 4.
ON.
5) Read the data of SPORT shift buzzer using
Is the SPORT shift buzzer dis-
play ON?
Replace the body
integrated unit.
<Ref. to SL-55,
Body Integrated
Unit.>
Go to step 5.
5 CHECK COMBINATION METER. <Ref. to IDI-
4, SELF-DIAGNOSIS, INSPECTION, Combi-
nation Meter System.>.
Is the buzzer OK? Refer to Symptom
Related Diagnos-
tic. <Ref. to
5AT(diag)-112,
General Diagnos-
tic Table.>
Replace the com-
bination meter
assembly. <Ref. to
IDI-19, Combina-
tion Meter.>
5AT(diag)-112
A: INSPECTION
Symptoms Problem parts
Shifting vehicle speed is low on D range.
Vehicle speed sensor 1 and vehicle speed sensor 2
Throttle position sensor
CAN communication signal
Shifting vehicle speed is high on D range.
Brake switch signal
Lateral G sensor
Excessive shift shock (N D range)
Engine idle speed
Engine speed signal
Control cable adjustment
Oil pressure switch 1 and front brake solenoid valve
Fluid level and condition
TCM power supply
Excessive shift shock on 1st of D range 2nd of D range or
1st of manual mode 2nd of manual mode.
Oil pressure switch 4 and direct clutch solenoid valve
Engine speed signal
Turbine speed sensor 1 and turbine speed sensor 2
Excessive shift shock on 2nd of D range 3rd of D range or
2nd of manual mode 3rd of manual mode.
Oil pressure switch 5 and high & low reverse clutch solenoid
valve
Engine speed signal
Excessive shift shock on 3rd of D range 4th of D range or
3rd of manual mode 4th of manual mode.
Oil pressure switch 3 and input clutch solenoid valve
Engine speed signal
5AT(diag)-113
Excessive shift shock on 4th of D range 5th of D range or
4th of manual mode 5th of manual mode.
Engine speed signal
Excessive shock at kick down.
Engine speed signal
Excessive shock at shift up.
Engine speed signal
Excessive shock at lock up.
Engine speed signal
Lock up solenoid valve
Excessive shock at engine brake.
Line pressure
Forward brake solenoid valve
Judder is occurred at lock up.
Engine speed signal
Noise at R, N and D range.
Engine speed signal
Hold at D range or 1st on manual mode.
Direct clutch solenoid valve
Line pressure
Up switch signal
5AT(diag)-114
Hold at D range or 2nd on manual mode.
Line pressure
Up switch signal
Down switch signal
Hold at D range or 3rd on manual mode.
Line pressure
Up switch signal
Down switch signal
Hold at D range or 4th on manual mode.
valve
Front brake solenoid valve
Line pressure
Up switch signal
Down switch signal
TCM power supply
Hold at D range or 5th on manual mode.
Line pressure
Down switch signal
Gear does not shift 1st of D range 2nd of D range or 1st
of manual mode 2nd of manual mode.
Line pressure
Up switch
Gear does not shift 2nd of D range 3rd of D range or 2nd
of manual mode 3rd of manual mode.
valve
Line pressure
Up switch signal
Gear does not shift 3rd of D range 4th of D range or 3rd
of manual mode 4th of manual mode.
Line pressure
Up switch signal
5AT(diag)-115
Gear does not shift 4th of D range 5th of D range or 4th
of manual mode 5th of manual mode.
Line pressure
Up switch signal
Gear does not shift down to 4th on D range or manual mode.
Line pressure
Down switch signal
Gear does not shift down to 3rd on D range or manual mode.
Line pressure
Down switch signal
TCM power supply
Gear does not shift down to 2nd on D range or manual mode.
Line pressure
Down switch signal
Gear does not shift down to 1st on D range or manual mode.
Line pressure
Down switch signal
No lock-up occurs.
Line pressure
Engine speed signal
Brake switch signal
Range signal
No shift shock occurred when shifting 1st of D range 2nd of
D range or 1st of manual mode 2nd of manual mode. Or
clutch slipping occurred.
Line pressure
5AT(diag)-116
No shift shock occurred when shifting 2nd of D range 3rd of
D range or 2nd of manual mode 3rd of manual mode. Or
valve
Line pressure
No shift shock occurred when shifting 3rd of D range 4th of
D range or 3rd of manual mode 4th of manual mode. Or
Line pressure
No shift shock occurred when shifting 4th of D range 5th of
D range or 4th of manual mode 5th of manual mode. Or
Line pressure
Engine skids when shifting 5th of D range 4th of D range
or 5th of manual mode 4th of manual mode. Or slipping
occurred.
Line pressure
Engine skids when shifting 4th of D range 3rd of D range
or 4th of manual mode 3rd of manual mode. Or slipping
occurred.
Line pressure
Engine skids when shifting 3rd of D range 2nd of D range
or 3rd of manual mode 2nd of manual mode. Or slipping
occurred.
valve
Line pressure
Engine skids when shifting 2nd of D range 1st of D range
or 2nd of manual mode 1st of manual mode. Or slipping
occurred.
Line pressure
Engine brake does not function at 5th 4th of manual mode.
Inhibitor switch
Manual mode switch
Oil pressure switch 1
Down switch signal
Engine brake does not function at 4th 3rd of manual mode.
Inhibitor switch
Manual mode switch
Oil pressure switch 1 and oil pressure switch 3
Down switch signal
5AT(diag)-117
Engine brake does not function at 3rd 2nd of manual mode.
Inhibitor switch
Manual mode switch
Engine brake does not function at 2nd 1st of manual mode.
Inhibitor switch
Manual mode switch
Excessive acceleration failure on D range.
Line pressure
Inhibitor switch
Vehicle speed sensor 1, 2
Excessive acceleration failure in R range.
Line pressure
valve
Inhibitor switch
Vehicle speed sensor 1, 2
Engine skids when start driving (1st) the vehicle. Or slipping
occurred.
Line pressure
Engine skids when driving at 2nd. Or slipping occurred.
Line pressure
Engine skids when driving at 3rd. Or slipping occurred.
Line pressure
valve
Engine skids when driving at 4th. Or slipping occurred.
Line pressure
5AT(diag)-118
Engine skids when driving at 5th. Or slipping occurred.
Line pressure
Slip at lock up.
Line pressure
Engine speed signal
Maximum vehicle speed is low.
Line pressure
Direct clutch solenoid valve
Vehicle speed sensor 1 and 2
There is completely no creep.
Engine speed signal
Line pressure
Excessive large creep.
Engine speed signal
Vehicle cannot be parking condition on P range. Parking con-
dition is not released though shifting to other ranges.
Inhibitor switch
Vehicle can drive on P range.
Inhibitor switch
Line pressure
Vehicle can drive on N range.
Inhibitor switch
Line pressure
Vehicle cannot drive at any range.
Line pressure
Inhibitor switch
Loosing or damaging of propeller shaft.
Loosing or damaging of drive shaft.
Vehicle cannot drive on D range.
Line pressure
Inhibitor switch
Vehicle cannot drive on R range.
Line pressure
Inhibitor switch
5AT(diag)-119
Engine cannot start on N or P range
Push engine switch and starter
Inhibitor switch
CAN communication line
TCM
Engine start other than N or P range
Push engine switch and starter
Inhibitor switch
TCM
Engine stalls.
Engine speed signal
Line pressure
Engine stalls when shifting to N D and R range.
Engine speed signal
Line pressure
5AT(diag)-120
5MT-2
General Description
MANUAL TRANSMISSION AND DIFFERENTIAL
A: SPECIFICATION
1. MANUAL TRANSMISSION AND DIFFERENTIAL
Model
2.5 L non-turbo model 2.5 L turbo model
Except for
OUTBACK
OUTBACK
Except for
OUTBACK
OUTBACK
Type 5-forward speeds and 1-reverse
Transmission gear ratio
1st 3.454 3.166
2nd 2.062 1.882
3rd 1.448 1.296
4th 1.088 0.972
5th 0.780 0.825 0.738
Reverse 3.333
Front reduction gear Final
Type of gear Hypoid
Gear ratio 3.900 4.111 3.900 4.444
Rear reduction gear
Transfer
Type of gear Helical
Gear ratio 1.000
Final
Type of gear Hypoid
Gear ratio 3.900 4.111 3.900 4.444
Front differential Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differential Type and number of gear Straight bevel gear (Bevel pinion: 2, bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Transmission gear oil capacity
Single-range
model
3.5 2 (3.7 US qt, 3.1 Imp qt)
5MT-3
General Description
2. TRANSMISSION GEAR OIL
Recommended oil:
GL-5 (75W-90) or equivalent
3. TRANSMISSION CASE ASSEMBLY
Drive pinion shim adjustment
Hypoid gear backlash:
0.13 0.18 mm (0.0051 0.0071 in)
Selection of main shaft rear plate
4. DRIVE PINION ASSEMBLY
Preload adjustment of thrust bearing
Starting torque:
0.3 0.8 Nm (0.03 0.08 kgf-m, 0.2 0.6 ft-lb)
5. REVERSE IDLER GEAR
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)
After installing a suitable reverse shifter lever, ad-
just the clearance using washers.
Reverse idler gear to transmission case wall
clearance:
0 0.5 mm (0 0.020 in)
Drive pinion shim
Part number
Thickness
mm (in)
Part number
Thickness
mm (in)
32295AA031
0.150
(0.0059)
32295AA071
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)
Main shaft rear plate
Dimension A mm (in) Part number Mark
4.00 4.13
(0.1575 0.1626)
32294AA041 1
3.87 4.00
(0.1524 0.1575)
32294AA051 2
Adjusting washer No. 1
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
Reverse shifter lever
Part number Mark Remarks
32820AA070 7 Further from case wall
32820AA080 8 Standard
32820AA090 9 Closer to the case wall
Washer (20.5 26 t)
Part number
Thickness
mm (in)
Part number
Thickness
mm (in)
803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059)
5MT-4
General Description
6. SHIFTER FORK AND ROD
Select a suitable shifter fork so that both the cou-
pling sleeve and reverse driven gear are positioned
in the center of their synchromesh mechanisms.
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)
7. TRANSFER CASE
Neutral position adjustment
Reverse check plate adjustment
1st-2nd shifter fork
32804AA060 1
Approaches 1st gear
by 0.2 mm (0.008 in).
32804AA070 No mark Standard
32804AA080 3
Approaches 2nd gear
by 0.2 mm (0.008 in).
3rd-4th shifter fork
32810AA061 1
Approaches 4th gear
by 0.2 mm (0.008 in).
32810AA101 3
Approaches 3rd gear
by 0.2 mm (0.008 in).
5th shifter fork (Non-turbo model), Identification paint (pink)
32812AA201 7
Approaches 5th gear
by 0.2 mm (0.008 in).
32812AA221 9
Moves away from 5th
gear by 0.2 mm
(0.008 in).
5th shifter fork (Turbo model), Identification paint (blue)
32812AA231 7
Approaches 5th gear
by 0.2 mm (0.008 in).
32812AA251 9
Moves away from 5th
gear by 0.2 mm
(0.008 in).
Adjusting shim
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
32188AA130 S
Neutral position is
closer to 1st.
32188AA140 T Standard
32188AA150 U
Neutral position is
closer to reverse gear.
Reverse check plate
Part number Mark Angle Remarks
32189AA001 0 28
Arm stops closer to 5th
gear.
32189AA011 1 31
gear.
33189AA021 2 34 Arm stops in the center.
32189AA031 3 37
Arm stops closer to
reverse gear.
32189AA041 4 40
Arm stops closer to
reverse gear.
5MT-5
General Description
8. EXTENSION ASSEMBLY
Preload of the taper roller bearing
(amount of standard protrusion):
0.15 0.25 mm (0.006 0.010 in)
NOTE:
Be sure that the amount of preload is within the
standard value.
Thrust washer to center differential side
clearance:
0.15 0.35 mm (0.0059 0.0138 in)
9. FRONT DIFFERENTIAL
Bevel gear to pinion backlash:
0.13 0.18 mm (0.0051 0.0071 in)
10.TRANSFER DRIVE GEAR
Snap ring (Outer-30) to ball bearing clearance:
0.01 0.15 mm (0.0004 0.0059 in)
Thrust washer (50 61 t)
803050060 0.50 (0.0197)
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256)
803050064 0.70 (0.0276)
803050065 0.75 (0.0295)
803050066 0.80 (0.0315)
803050067 0.85 (0.0335)
803050068 0.90 (0.0354)
803050069 0.95 (0.0374)
803050070 1.00 (0.0394)
803050071 1.05 (0.0413)
803050072 1.10 (0.0433)
803050073 1.15 (0.0453)
803050074 1.20 (0.0472)
803050075 1.25 (0.0492)
803050076 1.30 (0.0512)
803050077 1.35 (0.0531)
803050078 1.40 (0.0551)
803050079 1.45 (0.0571)
Thrust washer
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051)
803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
Washer (38.1 50 t)
Part number
Thickness
mm (in)
Part number
Thickness
mm (in)
803038021
0.925
0.950
(0.0364
0.0374)
803038023
1.025
1.050
(0.0404
0.0413)
803038022
0.975
1.000
(0.0384
0.0394)

Snap ring (Outer-30)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
5MT-6
General Description
B: COMPONENT
1. TRANSMISSION CASE
(1) Transmission case ASSY (6) Clamp Tightening torque:Nm (kgf-m, ft-lb)
(2) Gasket (7) Pitching stopper bracket T1: 44 (4.5, 32.5) (Aluminum gasket)
(3) Drain plug (8) Oil level gauge (Non-turbo model) 70 (7.1, 51.6) (Copper gasket)
(4) Harness bracket (Non-turbo
model)
(9) Oil level gauge (Turbo model) T2: 60 (6.1, 43.7)
(10) Gasket
(5) Harness bracket (Turbo model) (11) Plug
MT-01403
T1
(3)
(1)
(2)
(4)
(5)
(9)
(8)
(7)
(6)
(11)
(10)
T2
5MT-7
General Description
Transmission case tightening torque
Bolt No.
Bolt size
mm
Tightening torque: Nm (kgf-m, ft-lb)
(5) (15) 8 25 (2.5, 18.4)
(1) (4)
(16) (17)
10 39 (4.0, 28.9)
MT-00003
(9)
(5) (7)
(16)
(17)
(3)
(4)
(11)
(1)
(2)
(6) (8) (10) (12)
(14)
(13)
(15)
5MT-8
General Description
2. DRIVE PINION ASSEMBLY
(1) Drive pinion shaft (15) 1st-2nd synchronizer hub (30) Thrust bearing
(2) Roller bearing (16) Ball detent (31) Differential bevel gear sleeve
(3) Washer (17) Reverse driven gear (32) Washer
(4) Thrust bearing (18) Outer baulk ring (33) Lock washer
(5) Needle bearing (19) Synchro cone (34) Lock nut
(6) Driven shaft (20) Inner baulk ring (35) Inner baulk ring
(7) Key (21) 2nd driven gear (36) Synchro cone
(8) Woodruff key (22) 2nd driven gear bushing (37) Outer baulk ring
(9) Drive pinion collar (23) 3rd-4th driven gear
(10) Needle bearing (24) Driven pinion shim Tightening torque:Nm (kgf-m, ft-lb)
(11) Snap ring (outer) (2.5 L non-turbo
model)
(25) Roller bearing T1: 30 (3.1, 22.1)
(26) 5th driven gear T2: 120 (12.2, 88.5)
(12) Washer (2.5 L non-turbo model) (27) Lock washer T3: 260 (26.5, 191.8)
(13) Sub gear (2.5 L non-turbo model) (28) Lock nut
(14) 1st driven gear (29) Washer
(5)
(4)
(1)
(24)
(25)
(26)
(27)
(28)
(20)
(21)
(22)
(30)
(29)
(31)
(32)
(33)
(23)
(19)
(17)
(18)
(6)
(3)
(2)
(12)
(11)
(10)
(9)
(8)
(7)
(13)
(16)
(14)
T1
T3
(34)
T2
(29)
(35)
(36)
(37)
(15)
MT-01631
5MT-9
General Description
3. MAIN SHAFT FOR SINGLE-RANGE
MT-01572
T
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(31)
(30)
(33)
(34)
(3)
(10)
(4)
(5)
(2)
(1)
(6)
(8)
(7)
(9)
(11)
(13)
(12)
(21)
(14)
(15)
(16)
(17)
(18)
(20) (19)
(32)
5MT-10
General Description
(1) Oil seal (15) Needle bearing (25) 5th baulk ring
(2) Needle bearing (16) 4th gear thrust washer (26) Baulk lever
(3) Transmission main shaft (17) Ball bearing (Non-turbo model) (27) 5th hub & sleeve No. 2
(4) Needle bearing (18) Taper roller bearing (Turbo model) (28) Lock washer
(5) 3rd drive gear (19) 5th needle bearing race (Turbo
model)
(29) Lock nut
(6) Inner baulk ring (30) Straight pin
(7) 3rd synchro cone (20) 5th gear thrust washer (Non-turbo
model)
(31) Reverse idler gear shaft
(8) Outer baulk ring (32) Washer
(9) 3rd-4th coupling sleeve (21) 5th needle bearing race (Non-
turbo model)
(33) Reverse idler gear
(10) 3rd-4th synchronizer hub (34) Washer
(11) 3rd-4th shifting insert key (22) Needle bearing
(12) 4th baulk ring (23) Main shaft rear plate Tightening torque:Nm (kgf-m, ft-lb)
(13) 4th drive gear (24) 5th drive gear T: 120 (12.2, 88.5)
(14) 4th needle bearing race
5MT-11
General Description
4. SHIFTER FORK AND SHIFTER ROD
(1) Shifter arm (8) Ball (15) Spring
(2) 5th shifter fork (9) 3rd-4th fork rod (16) Snap ring (Outer)
(3) Straight pin (10) Interlock plunger (17) Reverse fork rod arm
(4) Reverse fork rod (11) 1st-2nd fork rod (18) Reverse shifter lever
(5) Checking ball plug (12) 3rd-4th shifter fork
(6) Gasket (13) 1st-2nd shifter fork Tightening torque:Nm (kgf-m, ft-lb)
(7) Checking ball spring (14) Ball T: 20 (2.0, 14.8)
MT-00007
T
T
T
(1)
(2)
(3)
(3)
(3)
(4)
(5)
(5)
(5)
(6)
(6)
(6)
(7)
(7)
(7)
(8)
(8)
(8)
(9)
(10)
(10)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
5MT-12
General Description
5. TRANSFER CASE AND EXTENSION
(1) Oil guide (16) Return spring (31) Transfer drive gear
(2) Gasket (17) O-ring (32) Ball bearing
(3) Transfer case (18) Adjusting select shim (33) Extension case
(4) Ball (19) Reverse check sleeve (34) Oil seal
(5) Reverse accent spring (20) Gasket (35) Dust cover
(6) Gasket (21) Neutral position switch (36) Shift bracket
(7) Plug (22) Gasket (37) Snap ring
(8) Oil seal (23) Back-up light switch
(9) Snap ring (Inner) (24) Roller bearing Tightening torque:Nm (kgf-m, ft-lb)
(10) Reverse check plate (25) Transfer driven gear T1: 6.4 (0.65, 4.7)
(11) Reverse check spring (26) Roller bearing T2: 9.75 (1.0, 7.2)
(12) Reverse return spring (27) Adjusting washer T3: 24.5 (2.5, 18.1)
(13) Reverse check cam (28) Ball bearing T4: 26 (2.7, 19.2)
(14) Reverse accent shaft (29) Center differential T5: 32.3 (3.3, 23.8)
(15) Return spring cap (30) Adjusting washer T6: 40 (4.1, 29.5)
(2)
(7)
(6)
(21)
(8)
(5)
(4)
(3)
(1)
T3
T2
T5
T5
T1
T1
(20)
(9)
(11)
(13)
(15)
(10)
(12)
(17)
(16)
(19)
(22)
(23)
(14)
(18)
T3
T6
T4
(34)
(36)
(35)
(33)
(27)
(31)
(30)
(29)
(28)
(37)
(32)
(24)
(25)
(26)
T3
T6
MT-01562
5MT-13
General Description
6. FRONT DIFFERENTIAL
(1) Drive pinion shaft (7) Differential bevel pinion (13) Retainer lock plate
(2) Hypoid driven gear (8) Roller bearing
(3) Pinion shaft (9) Differential case Tightening torque:Nm (kgf-m, ft-lb)
(4) Straight pin (10) Oil seal T1: 25 (2.5, 18.4)
(5) Washer (11) Differential side retainer T2: 62 (6.3, 45.6)
(6) Differential bevel gear (12) O-ring
MT-01365
(12)
(10)
(1)
(2)
T1
T2
(5)
(5)
(6)
(9)
(7)
(7)
(12)
(8)
(8)
(13)
(13)
(11)
(11)
(10)
T1
(4)
(3)
5MT-14
General Description
7. TRANSMISSION MOUNTING
(1) Pitching stopper (7) Rear crossmember Tightening torque:Nm (kgf-m, ft-lb)
(2) Spacer (8) Upper cushion rubber T1: 7.5 (0.76, 5.5)
(3) Lower cushion rubber (9) Center crossmember T2: 35 (3.6, 25.8)
(4) Front plate (10) Rear plate T3: 50 (5.1, 36.9)
(5) Dynamic damper (11) Front crossmember T4: 58 (5.9, 42.8)
(6) Transmission cushion rubber T5: 70 (7.1, 51.6)
T6: 75 (7.6, 55.3)
T7: 140 (14.3, 103.3)
MT-01626
(1)
T4
T6
T5
T5
T2
T7
T2
T3
(2)
(4)
(6)
(8)
(9)
(8)
(3)
(2)
(10)
(7)
(3)
(11)
T1
(5)
5MT-15
General Description
C: CAUTION
forming any work.
loy parts, use a plastic hammer to force it apart. Do
not pry apart with screwdrivers or other tools.
points.
new parts.
cient amount of gear oil to avoid damage and defor-
mation.
move the liquid gasket.
5MT-16
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
399411700 ACCENT BALL
INSTALLER
Used for installing reverse shifter rail arm.
899524100 PULLER SET Used for removing and installing the roller bear-
ing (Differential).
(1) Puller
(2) Cap
399780104 WEIGHT Used for measuring preload on the roller bear-
ing.
498077000 REMOVER Used for removing the roller bearing of the drive
pinion shaft.
ST-399411700
ST-899524100
(1)
(2)
ST-399780104
ST-498077000
5MT-17
General Description
498077300 CENTER DIFFER-
ENTIAL BEARING
REMOVER
Used for removing the center differential cover
ball bearing.
498147001 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.
(498247100).
498247100 DIAL GAUGE Used for measuring backlash between the
side gear and pinion, and the hypoid gear.
(498247001).
498427100 STOPPER Used for securing the drive pinion shaft assem-
bly and the driven gear assembly when removing
the drive pinion shaft assembly lock nut.
ST-498077300
ST-498147001
ST-498247001
ST-498247100
ST-498427100
5MT-18
General Description
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).
RETAINER
tial side retainer.
be used.
ST-498937000
ST-499277100
ST-499277200
ST-499757002
ST18630AA010
5MT-19
General Description
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 the REMOVER
(899714110).
499917500 DRIVE PINION
GAUGE ASSY
Used for adjusting the drive pinion shim.
499927100 HANDLE Used for fitting the transmission main shaft.
ST-499827000
ST-499857000
ST-499877000
ST-499917500
ST-499927100
5MT-20
General Description
499937100 TRANSMISSION
STAND SET
Used for disassembling and assembling the
transmission.
499987003 SOCKET WRENCH
(35)
Used for removing and installing the driven pin-
ion lock nut and main shaft lock nut.
(50)
Used for removing and installing the driven gear
assembly lock nut.
899714110 REMOVER Used for fixing the transmission main shaft, drive
pinion and rear drive shaft.
899864100 REMOVER Used for removing transmission main shaft and
drive pinion parts.
ST-499937100
ST-499987003
ST-499987300
ST-899714110
ST-899864100
5MT-21
General Description
899884100 HOLDER Used for tightening the lock nut on the sleeve.
899904100 REMOVER Used for removing and installing the straight pin.
(27)
Used for removing and installing the drive pinion
lock nut.
398497701 ADAPTER Used for installing roller bearing onto the differ-
ential case.
(499277100).
499587000 INSTALLER Used for installing the driven gears to the driven
shaft.
ST-899884100
ST-899904100
ST-899988608
ST-398497701
ST-499587000
5MT-22
General Description
498255400 PLATE Used for measuring backlash.
498077400 SYNCHRONIZER
CONE REMOVER
Used for removing the synchronizer cone of
the main shaft.
Used for removing 5th driven gear of the drive
pinion shaft.
41099AC000 ENGINE SUPPORT
ASSY
Used for supporting the engine.
bearing.
ST-498057300
ST-498255400
ST-498077400
ST41099AC000
ST-398527700
5MT-23
General Description
398177700 INSTALLER Used for installing the bearing cone of transfer
driven gear (transfer case side).
Used for installing the ball bearing of the trans-
fer drive gear.
28399SA010 FRONT DRIVE
SHAFT OIL SEAL
PROTECTOR
Used for protecting the oil seal from damage
when inserting the front drive shaft.
SIDE OIL SEAL
INSTALLER
seal.
398791700 STRAIGHT PIN
REMOVER
Used for installing and removing the straight pin.
ST-398643600
ST-398177700
ST28399SA010
ST18675AA000
ST-398791700
5MT-24
General Description
2. GENERAL TOOL
TOOL NAME REMARKS
TORX
BIT T70 Used for installing and removing the differential gear oil drain
plug.
5MT-25
2. Transmission Gear Oil
A: INSPECTION
2) Turn the ignition switch to OFF, and wait until the
engine cools.
that the oil level gauge is correctly inserted in the
proper direction.
5) Pull out the oil level gauge again, and check the
oil level. If it is at the lower level or less, add oil
through the oil level gauge hole to bring the level up
to the upper level.
B: REPLACEMENT
1) Pull out the oil level gauge.
3) Using the TORX
BIT T70, remove the drain

plug, and drain the transmission gear oil completely.
CAUTION:
Immediately after the engine has been run-
ning, the transmission gear oil is hot. Be careful
not to burn yourself.
Be careful not to spill the transmission gear
oil on the exhaust pipe, to prevent emission of
smoke or causing a fire. If differential gear oil is
pletely.
4) Using the TORX
BIT T70, tighten the transmis-

sion gear oil drain plug.
NOTE:
Tighten the drain plug of the transmission gear
oil after draining the transmission gear oil.
Use a new gasket.
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)
6) Pour gear oil through the oil level gauge hole.
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 oil level gauge into trans-
mission, align the protrusion on the top part of
the oil level gauge with the notch in the oil level
gauge hole.
(A) Oil level gauge
(B) Upper level
(C) Lower level
PM-00030
(B)
(C)
(A)
MT-01548
5MT-26
Manual Transmission Assembly
3. Manual Transmission
Assembly
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.>
5) Remove the air intake chamber and intake boot.
(Non-turbo model) <Ref. to IN(H4SO)-7, REMOV-
AL, Air Intake Chamber.>
6) Remove the air intake chamber stay. (Non-turbo
model)
8) Disconnect the connector back-up light switch
& neutral position switch.
Non-turbo model
Turbo model
MOVAL, Starter.>
10) Remove the operating cylinder from the trans-
mission, and suspend on a wire.
12) Set the ST.
(Non-turbo model) <Ref. to EX(H4SO)-4, REMOV-
AL, Front Exhaust Pipe.>
(A) Neutral position switch connector (Brown)
(B) Back-up light switch connector (Gray)
MT-00062
MT-00104
(A)
(B)
MT-00105
MT-01220
MT-01556
MT-01226
ST
MT-01524
5MT-27
16) Remove the center exhaust pipe. (Turbo mod-
el) <Ref. to EX(H4DOTC)-9, REMOVAL, Center
Exhaust Pipe.>
Non-turbo model
fler.>
Turbo model
AL, Muffler.>
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
18) Remove the heat shield cover. (If equipped)
20) 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 trans-
mission.
21) Disconnect the stabilizer link from the front
arm.
22) Remove the bolt securing the ball joint of the
front arm to the housing, then separate the front
arms and the housing.
23) Using a crowbar, remove the left and right front
drive shaft from the transmission.
(A) Stay
(B) Gear shift rod
MT-00075
(A)
(B) (B)
MT-00988
(A) Front arm
(B) Ball joint
(C) Stabilizer link
(A) Bar
MT-00987
(A)
(C)
(B)
MT-01017
(A)
MT-00077
5MT-28
sion.
CAUTION:
Always support the transmission case with a
transmission jack.
26) Remove the front crossmember and rear cross-
member from the vehicle.
27) Tighten the turnbuckle of the ST while lowering
the transmission jack to tilt the engine assembly to-
wards the back.
NOTE:
Move the transmission jack towards the rear until
the main shaft is withdrawn from the clutch disc.
29) Separate the transmission assembly from the
transmission cushion rubber.
B: INSTALLATION
1) Replace the differential side retainer oil seal.
<Ref. to 5MT-34, REPLACEMENT, Differential
Side Retainer Oil Seal.>
SEAL INSTALLER
NOTE:
Be sure to replace the differential side retainer oil
seal after the removing the front drive shaft.
2) Install the transmission cushion rubber to the
transmission assembly.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
(1) Lift up the transmission gradually using a
transmission jack.
(2) Engage at the spline section.
NOTE:
Be careful not to hit the main shaft against the
clutch housing cover.
4) Loosen the turnbuckle of the ST while raising the
transmission jack to return the engine to its original
position.
5) Install the front crossmember and rear cross-
member.
Tightening torque:
T1: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
T2: 140 Nm (14.3 kgf-m, 103.3 ft-lb)
MT-00078
MT-00079
ST
MT-00103
MT-00081
T 2 T 2
T 1
T 1
5MT-29
6) Take out the transmission jack.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
8) Connect the transmission to the engine.
(1) Install the starter.
<Ref. to SC(H4SO)-6, INSTALLATION, Start-
er.>
(2) Tighten the bolts which hold the upper side
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
9) Remove the ST.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
12) Install the front drive shaft into the transmis-
sion.
ST 28399SA010 FRONT DRIVE SHAFT OIL
SEAL PROTECTOR
13) Insert the ball joints of the front arm into the
housing, then tighten the installing bolts.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
MT-00077
MT-01524
MT-01226
ST
(A) Front arm
(B) Ball joint
(C) Stabilizer link
MT-01557
T2
T1
AT-00110
ST
MT-00987
(A)
(C)
(B)
5MT-30
14) Attach the stabilizer link to the front arm.
Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
15) Attach the gear shift rod and stay.
(1) Attach the gear shift rod to the transmission.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(2) Attach the stay to the transmission.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
17) Install the heat shield cover. (If equipped)
Non-turbo model
TION, Muffler.>
Turbo model
19) Install the front and center exhaust pipe. (Non-
turbo model)
haust Pipe.>
20) Install the center exhaust pipe. (Turbo model)
Exhaust Pipe.>
21) Install the operating cylinder.
Tightening torque:
37 Nm (3.8 kgf-m, 27.5 ft-lb)
(1) Transmission ground cable
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
(2) Neutral position switch connector
(3) Back-up light switch connector
23) Fill transmission gear oil through the transmis-
sion oil level gauge hole.
(Non-turbo model)
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
25) Install the air intake chamber and intake boot.
(Non-turbo model) <Ref. to IN(H4SO)-7, INSTAL-
LATION, Air Intake Chamber.>
tery.
28) Take off the vehicle from lift arms.
(A) Stay
(B) Gear shift rod
MT-00988
MT-00089
(A)
(B) (B)
MT-01220
5MT-31
4. Transmission Mounting System
A: REMOVAL
1. PITCHING STOPPER
2. CROSSMEMBER AND CUSHION RUBBER
4) Remove the center exhaust pipe. (Turbo model)
haust Pipe.>
Non-turbo model
fler.>
Turbo model
AL, Muffler.>
7) Set the transmission jack under the transmission
body.
CAUTION:
transmission jack.
8) Remove the front crossmember and the rear
crossmember.
9) Remove the transmission cushion rubber.
MT-01556
MT-00079
5MT-32
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, 42.8 ft-lb)
cooler.>
2. CROSSMEMBERAND CUSHION RUBBER
1) Install the transmission cushion rubber.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
member.
Tightening torque:
T1: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
T2: 140 Nm (14.3 kgf-m, 103.3 ft-lb)
turbo model)
haust Pipe.>
6) Install the center exhaust pipe. (Turbo model)
Exhaust Pipe.>
Non-turbo model
TION, Muffler.>
Turbo model
C: INSPECTION
Perform the following inspection procedures and
repair or replace faulty parts.
1. PITCHING STOPPER
Check the pitching stopper for bends or damage.
Check that the rubber is not stiff, cracked or other-
wise damaged.
that the cushion rubber is not stiff, cracked, or oth-
erwise damaged.
MT-01557
T2
T1
MT-00081
T 2 T 2
T 1
T 1
5MT-33
Oil Seal
5. Oil Seal
A: INSPECTION
Check for leakage of gear oil from the oil seal. If
there is oil leakage, replace the oil seal with the
new part and check the propeller shaft.
B: REPLACEMENT
2) Using the TORX
BIT T70, remove the drain

plug, and drain the transmission gear oil completely.
3) Using the TORX

NOTE:
Use a new gasket.
Tightening torque:
Non-turbo model
fler.>
Turbo model
AL, Muffler.>
Non-turbo model
TION, Muffler.>
Turbo model
12) Pour in the transmission gear oil and check the
oil level. <Ref. to 5MT-25, Transmission Gear Oil.>
(A) Oil seal
MT-01548
MT-00098
(A)
ST
MT-01299
ST
5MT-34
6. Differential Side Retainer Oil
Seal
A: INSPECTION
Check for leakage of gear oil from the differential
side retainer oil seal. If there is oil leakage, replace
the oil seal with the new part and check the drive
shaft.
B: REPLACEMENT
TORX

bit T70, and drain the differential gear oil
completely.
3) Replace the gasket with a new part and tighten
the differential gear oil drain plug using the
TORX
bit T70.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)(Aluminum gasket)
5) Remove the center exhaust pipe. (Turbo model)
haust Pipe.>
Shaft.>
7) Remove the differential side retainer oil seal.
NOTE:
Be sure to replace the differential side retainer oil
seal after the procedure of removing front drive
shaft from transmission.
To remove the oil seal, use ST 398527700
PULLER ASSY. When removing the part by using
a flat tip screwdriver, be careful not to scratch the
differential side retainer.
oil seal by lightly tapping with a plastic hammer.
SEAL INSTALLER
NOTE:
turbo model) <Ref. to EX(H4SO)-5, INSTALLA-
TION, Front Exhaust Pipe.>
haust Pipe.>
13) Fill the transmission gear oil through the oil lev-
el gauge hole. <Ref. to 5MT-25, REPLACEMENT,
Transmission Gear Oil.>
MT-01548
MT-01548
ST
MT-00103
5MT-35
Switches and Harness
7. Switches and Harness
A: REMOVAL
1. BACK-UP LIGHT SWITCH
& NEUTRAL POSITION SWITCH
4) Disconnect the connector back-up light switch
Non-turbo model
Turbo model
6) Remove the back-up light switch & neutral posi-
tion switch with the harness.
(A) Neutral position switch connector (Brown)
(B) Back-up light switch connector (Gray)
MT-00104
(A)
(B)
MT-00105
(A) Neutral position switch
(B) Back-up light switch
MT-00106
(A)
(B)
5MT-36
Switches and Harness
B: INSTALLATION
& NEUTRAL POSITION SWITCH
1) Install the back-up light switch & neutral position
switch with the harness.
Tightening torque:
32.3 Nm (3.3 kgf-m, 23.8 ft-lb)
2) Connect the connectors of back-up light switch
cooler.>
C: INSPECTION
Check the back-up light switch. <Ref. to LI-8, IN-
SPECTION, Back-up Light System.>
2. NEUTRAL POSITION SWITCH
2) Disconnect the connector of neutral position switch.
3) Measure the resistance between neutral posi-
tion switch terminals.
Non-turbo model
Turbo model
4) Replace faulty parts.
(A) Neutral position switch
(B) Back-up light switch
MT-00106
(A)
(B)
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 2
Less than 1
Other positions 1 M or more
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 3
Less than 1
MT-00110
1 2
MT-00111
1 2
3 4
5MT-37
8. Preparation for Overhaul
A: PROCEDURE
1) Clean oil, grease, dirt and dust from the trans-
mission.
2) Using the TORX
BIT T70, remove the trans-

mission gear oil drain plug, and drain the transmis-
sion gear oil completely.
3) Using the TORX

NOTE:
Use a new gasket.
Tightening torque:
4) Attach the transmission to the ST.
ST 499937100 TRANSMISSION STAND
5) Apply oil to rotating parts before assembly.
6) All disassembled parts, if to be reused, should
be reinstalled in the original positions and direc-
tions.
7) Gaskets, lock washers and lock nuts must be re-
placed with new parts.
8) Apply liquid gasket to the specified areas to pre-
vent leakage.
MT-01548
MT-00115
ST
5MT-38
Transfer Case and Extension Case Assembly
9. Transfer Case and Extension
Case Assembly
A: REMOVAL
from the vehicle. <Ref. to 5MT-26, REMOVAL,
Manual Transmission Assembly.>
tion switch. <Ref. to 5MT-35, REMOVAL, Switches
and Harness.>
3) Remove the transfer case together with the ex-
tension case assembly.
4) Remove the shifter arm.
5) Remove the extension case assembly.
B: INSTALLATION
1) Install the center differential and transfer driven
gear into the transfer case.
2) Remove the bearing outer race from the exten-
sion case.
3) While holding the bearing outer race horizontal-
ly, 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
MT-00117
(A) Bearing outer race
(B) Extension case
MT-00118
MT-00119
(B)
(A)
MT-00120
W
5MT-39
5) Measure depth X on bearing insertion part of
the extension case.
NOTE:
Measure with bearing outer race and thrust washer
removed.
6) Calculate the thickness t of the thrust washer
using following calculation.
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.
Preload of the taper roller bearing (amount of
standard protrusion):
0.15 0.25 mm (0.006 0.010 in)
NOTE:
Be sure that the amount of preload is within the
standard value.
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
11) Measure the height T between the extension
case and transfer drive gear.
ST 398643600 GAUGE
NOTE:
ST thickness [15 mm (0.59 in)]
12) Calculate the thickness U of the thrust washer
using following calculation.
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)
14) Fit the thrust washer onto the center differen-
tial.
803050060 0.50 (0.0197)
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256)
803050064 0.70 (0.0276)
803050065 0.75 (0.0295)
803050066 0.80 (0.0315)
803050067 0.85 (0.0335)
803050068 0.90 (0.0354)
803050069 0.95 (0.0374)
803050070 1.00 (0.0394)
803050071 1.05 (0.0413)
803050072 1.10 (0.0433)
803050073 1.15 (0.0453)
803050074 1.20 (0.0472)
803050075 1.25 (0.0492)
803050076 1.30 (0.0512)
803050077 1.35 (0.0531)
803050078 1.40 (0.0551)
803050079 1.45 (0.0571)
MT-00121
X
Thrust washer
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051)
803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
MT-00122
ST
S
MT-00123
T
ST
5MT-40
15) Apply a proper amount of liquid gasket to the
transfer case mating surface.
Liquid gasket:
equivalent
16) Install the extension assembly into the transfer
case.
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
17) Attach the shifter arm to transfer case.
18) Hang the shifter arm on 3rd-4th fork rod.
19) Install the extension case assembly along with
the transfer case to the transmission case.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
MT-00124
MT-00117
MT-00126
(A) Shifter arm
(B) 3rd-4th fork rod
MT-00127
(A)
(B)
MT-00116
5MT-41
C: DISASSEMBLY
1. TRANSFER CASE
1) Remove the reverse check assembly. <Ref. to
5MT-47, REMOVAL, Reverse Check Sleeve.>
2) Remove the oil guide.
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. <Ref.
to 5MT-42, REMOVAL, Transfer Drive Gear.>
2) Remove the shift bracket.
<Ref. to 5MT-33, Oil Seal.>
D: ASSEMBLY
1. EXTENSION CASE
1) Using the ST, install the oil seal to the extension
case. <Ref. to 5MT-33, Oil Seal.>
NOTE:
Use a new oil seal.
2) Install the shift bracket to extension case.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
3) Install the transfer drive gear to the extension
case. <Ref. to 5MT-42, 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)
NOTE:
2) Install the reverse check sleeve assembly to the
transfer case. <Ref. to 5MT-47, INSTALLATION,
Reverse Check Sleeve.>
MT-01563
MT-00130
MT-00130
MT-01563
5MT-42
Transfer Drive Gear
10.Transfer Drive Gear
A: REMOVAL
1) Remove the manual transmission assembly from
the vehicle. <Ref. to 5MT-26, REMOVAL, Manual
and Harness.>
tension case assembly. <Ref. to 5MT-38, REMOV-
AL, Transfer Case and Extension Case Assembly.>
5) Remove the transfer driven gear.
6) Remove the transfer drive gear.
B: INSTALLATION
1) Install the transfer drive gear.
Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
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-38, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
5) Install the back-up light switch and the neutral
position switch. <Ref. to 5MT-36, INSTALLATION,
Switches and Harness.>
6) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-28, INSTALLATION, Manual
C: DISASSEMBLY
2) Remove the ball bearing.
D: ASSEMBLY
1) Set the ST against the inner race of the bearing,
and install the drive shaft.
CAUTION:
Do not apply a load in excess of 10 kN
(1 ton, 1.1 US ton, 1.0 Imp ton).
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-43, INSPECTION,
Transfer Drive Gear.>
MT-00133
MT-00133
MT-00135
MT-00136
MT-00137
ST
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
When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
2) Drive gear
If the drive gear tooth surface and shaft are exces-
sively broken or damaged, replace the drive gear.
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)
If the measurement is not within specification, se-
lect a suitable snap ring and replace it.
Snap ring (Outer-30)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
MT-00138
5MT-44
Transfer Driven Gear
11.Transfer Driven Gear
A: REMOVAL
and Harness.>
6) Remove bearing outer races from the extension
case and transfer case.
B: INSTALLATION
1) Install the bearing outer races to extension case
and transfer case.
3) Install the transfer case and the extension case
assembly. <Ref. to 5MT-38, INSTALLATION,
Transfer Case and Extension Case Assembly.>
(A) Bearing outer race (Transfer case side)
(B) Bearing outer race (Extension case side)
MT-00118
MT-00140
(B)
(A)
(A) Bearing outer race
(B) Bearing outer race
(C) Transfer case
(D) Extension case
MT-00141
(C)
(A)
(D)
(B)
MT-00118
5MT-45
C: DISASSEMBLY
1) Using the ST, remove the roller bearing
(extension case side).
2) Using ST1 and ST2, remove the roller bearing
(transfer case side).
ST1 498077000 REMOVER
D: ASSEMBLY
1) Using the ST, install the roller bearing
CAUTION:
2) Using ST, install the roller bearing
(transfer case side).
CAUTION:
E: INSPECTION
1) Bearing
2) Driven gear
If the driven gear tooth surface and shaft are exces-
sively broken or damaged, replace the driven gear.
(A) Roller bearing
(A) Roller bearing
MT-00143
(A)
ST
MT-00144
(A)
ST1
ST2
(A) Roller bearing
(A) Roller bearing
MT-00145
(A)
ST1
ST2
MT-00146
(A)
ST
5MT-46
Center Differential
12.Center Differential
A: REMOVAL
3) Remove the extension case assembly. <Ref. to
5MT-38, REMOVAL, Transfer Case and Extension
Case Assembly.>
4) Remove the transfer driven gear. <Ref. to 5MT-
44, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential.
B: INSTALLATION
1) Install the center differential into transfer case.
2) Install the transfer driven gear. <Ref. to 5MT-44,
INSTALLATION, Transfer Driven Gear.>
3) Install the extension case assembly. <Ref. to
5MT-38, INSTALLATION, Transfer Case and Ex-
tension Case Assembly.>
4) Install the transfer case together with the extension
case assembly. <Ref. to 5MT-38, INSTALLATION,
C: DISASSEMBLY
NOTE:
Center differential is a non-disassembled part
which should not be disassembled.
Remove the ball bearing using ST.
NOTE:
Do not reuse the ball bearing.
ST 498077300 CENTER DIFFERENTIAL
BEARING REMOVER
D: ASSEMBLY
Install the ball bearing into the center differential
assembly.
CAUTION:
E: INSPECTION
1) Bearing
When bearing has other defects.
2) Center differential
Replace the center differential case assembly if
worn or damaged.
MT-00147
ST
(A) Ball bearing
MT-00148
(A)
5MT-47
Reverse Check Sleeve
13.Reverse Check Sleeve
A: REMOVAL
3) Remove the shifter arm.
4) Remove the plug, gasket, reverse accent spring,
and reverse check ball.
5) Remove the reverse check sleeve.
B: INSTALLATION
1) Install the reverse check sleeve.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
2) Reverse check ball, reverse accent spring, gas-
ket and plug to the transfer case.
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
3) Attach the shifter arm to the transfer case as-
sembly.
MT-00149
MT-00150
MT-00150
MT-00149
5MT-48
C: DISASSEMBLY
1) Cover the reverse check sleeve with a rag, and
remove the snap ring using a screwdriver.
NOTE:
Replace the snap ring with a new part if it is de-
formed or spring force is weakened.
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).
NOTE:
Visually check the O-ring. Replace if faulty.
Be careful not to damage the adjusting shim be-
tween reverse check sleeve assembly and the
case.
D: ASSEMBLY
1) Install the return spring (1st-2nd), return spring
cap, reverse accent shaft, reverse check cam, re-
turn spring (5th-Rev) and reverse check spring to
the reverse check sleeve.
NOTE:
Be sure to position the bent section of reverse
check spring to fit in the groove of the check cam.
2) Hook the curved section of the reverse check
spring over the reverse check plate.
3) Rotate the cam so that the protrusion of the re-
verse check cam comes to the opening of the plate.
4) With cam held in that position, install the reverse
check 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.
(A) Snap ring
(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)
MT-00153
(A)
MT-00154
(B)
(C)
(D)
(E)
(F)
(G)
(A)
(A) Reverse check plate
(B) Reverse check spring
(C) Return spring (5th-Rev)
(E) Reverse accent shaft
(F) Return spring cap
(G) Return spring (1st-2nd)
MT-00154
(B)
(C)
(D)
(E)
(F)
(G)
(A)
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 rota-
tion.
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 re-
verse 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.
Select a suitable reverse accent shaft and re-
verse check plate. <Ref. to 5MT-49, ADJUST-
MENT, Reverse Check Sleeve.>
F: ADJUSTMENT
1. NEUTRAL POSITION ADJUSTMENT
1) Shift the gear into 3rd gear position.
2) Because of the return spring, until the arm con-
tacts 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 (re-
verse 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 adjust-
ment shim between the sleeve assembly and the
case to adjust the clearance.
CAUTION:
Be careful not to damage the O-ring when plac-
ing shims.
NOTE:
When the shim is removed, the neutral position
will move closer to reverse, when the shim is add-
ed, the neutral position will move closer to 1st gear.
If it is not possible to adjust the clearance with
only shims, replace the reverse accent shaft and
re-adjust.
(A) Snap ring
(B) Reverse check plate
(C) Reverse check spring
MT-00156
(A)
(D)
(B)
(C)
Adjusting shim
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
Reverse accent shaft
32188AA130 S
Neutral position is
closer to 1st.
32188AA140 T Standard
32188AA150 U
Neutral position is
closer to reverse gear.
5MT-50
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.
Reverse check plate
Part number (A): No. Angle Remarks
32189AA001 0 28
gear.
32189AA011 1 31
gear.
32189AA021 2 34 Arm stops in the center.
32189AA031 3 37
Arm stops closer to
reverse gear.
32189AA041 4 40
Arm stops closer to
reverse gear.
MT-00157
(A)
5MT-51
Transmission Case
14.Transmission Case
A: REMOVAL
2) Remove the clutch release lever. <Ref. to CL-
18, REMOVAL, Release Bearing and Lever.>
4) Remove the bearing mounting bolt.
5) Remove the main shaft rear plate.
6) Separate the transmission case into the right
and left cases by loosening the coupling bolts and
nuts.
7) Remove the drive pinion shaft assembly from
the left side of the transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
8) Remove the main shaft assembly for single-
range.
9) Remove the front differential assembly.
NOTE:
Do not confuse the right and left roller bearing
outer races.
Be careful not to damage the oil seal of retainer.
(A) Main shaft rear plate
MT-01514
(A)
MT-01515
MT-00160
(A) Main shaft ASSY for single-range
(B) Drive pinion shaft ASSY
MT-00161
( A)
( B)
MT-00162
5MT-52
Transmission Case
B: INSTALLATION
1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with cleaning solvent.
2) Install the front differential assembly.
3) Install the main shaft assembly for single-range.
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 roll-
er bearing knock pin hole.
5) Apply liquid gasket, then join the right side and
left side of the case together.
Liquid gasket:
equivalent
6) With brackets and clips as shown in the figure,
tighten the seventeen bolts.
NOTE:
Insert the 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
between cases.
Tightening torque:
8 mm bolt
25 Nm (2.5 kgf-m, 18.4 ft-lb)
10 mm bolt
39 Nm (4.0 kgf-m, 28.9 ft-lb)
7) Tighten the ball bearing mounting bolts.
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
8) Perform backlash adjustment of the hypoid gear
and preload measurement of the roller bearing:
NOTE:
Attach the ST on drive pinion assembly.
ST 498427100 STOPPER
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 transmis-
sion 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 sev-
eral times to ensure the contact point.
ST1 399780104 WEIGHT
ST2 18630AA010 WRENCH COMPL RETAIN-
ER
ST3 499927100 HANDLE
MT-00172
(9)
(7)
(5)
(1)
(2)
(16)
(17)
(11)
(3)
(4)
(12) (8)
(6)
(10)
(14)
(15)
(13)
MT-01514
ST
MT-01516
MT-00175
ST3
ST2
ST1
5MT-53
Transmission Case
11) Remove the weight, and screw in the retainer
without the O-ring on the upper side, and stop at
the point where a slight resistance is felt.
NOTE:
In this condition, the backlash between hypoid gear
and drive pinion shaft is zero.
12) Loosen the retainer on the lower side by
3 notches and turn the retainer on the upper side by
the same amount in order to apply backlash.
13) Rotate the retainer of the upper side additional-
ly by 1 notch in order to apply preload on taper roll-
er bearing.
14) Tighten temporarily 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 install the lock plates, reverse the
sides and install them.
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-72, INSPECTION,
Front Differential Assembly.>
17) After checking the tooth contact of the hypoid
gears, remove the lock plate. Then loosen the re-
tainer until the O-ring groove appears. Fit the O-
ring into the groove and tighten the retainer into the
position where retainer was tightened previously.
Install the lock plate.
NOTE:
Count number of turns while loosening retainer
and record it.
Perform this for both upper and lower retainers.
Tightening torque:
T: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
18) Select the main shaft rear plate. <Ref. to 5MT-
58, ADJUSTMENT, Main Shaft Assembly for Sin-
gle-range.>
19) Install the clutch release lever and bearing.
<Ref. to CL-18, INSTALLATION, Release Bearing
and Lever.>
20) Install the transfer case together with the exten-
sion case assembly. <Ref. to 5MT-38, INSTALLA-
TION, Transfer Case and Extension Case
Assembly.>
C: INSPECTION
Check the transmission case for cracks, damage,
or oil leaks.
MT-00176
ST
MT-00177
T
5MT-54
Main Shaft Assembly for Single-range
15.Main Shaft Assembly for
Single-range
A: REMOVAL
3) Remove the transmission case. <Ref. to 5MT-
51, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly. <Ref.
to 5MT-59, REMOVAL, Drive Pinion Shaft Assem-
bly.>
range.
B: INSTALLATION
1) Install the needle bearing and oil seal to the front of
the transmission single-range main shaft assembly.
NOTE:
Wrap the clutch splined section with vinyl tape to
prevent damage to the oil seal.
Apply UNILUBE #2 (or equivalent) to the sealing
lip of the oil seal.
Use a new oil seal.
2) Install the transmission case knock pin into the
knock pin hole of the needle bearing outer race.
NOTE:
Align the end face of the seal with surface (A) when
installing the oil seal.
3) Install the drive pinion shaft assembly. <Ref. to
5MT-59, INSTALLATION, Drive Pinion Shaft As-
sembly.>
4) Install the transmission case. <Ref. to 5MT-52,
INSTALLATION, Transmission Case.>
C: DISASSEMBLY
1) Put vinyl tape around main shaft spline 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 for single range.
NOTE:
Flatten the lock nut tab before removing the lock nut.
3) Remove the 5th hub & sleeve No. 2, baulk lever,
baulk ring, 5th drive gear & needle bearing.
MT-00185
(A)
(A) 5th hub & sleeve No. 2
(B) Baulk ring
(C) 5th drive gear
ST2 ST1
MT-01517
( A)
( B)
( C)
MT-01518
5MT-55
4) Using ST1 and ST2, remove the rest of the
parts.
NOTE:
When replacing the sleeve & hub, replace them
as a set.
Do not disassemble the sleeve & hub; the align-
ing position is pre-matched.
If it is necessary to disassemble, mark the en-
gaging points on the splines beforehand.
D: ASSEMBLY
1) When the sleeve & hub assemblies have been
disassembled, reassemble by aligning the align-
ment marks.
NOTE:
Position the open ends of the spring 120 apart.
(A) Press
MT-00190
(A)
ST2
ST1
(A) 3rd-4th hub ASSY
(B) 3rd gear side
(C) 5th hub & sleeve No. 2
(D) 5th gear side
(D)
(C)
(B)
(A)
MT-01523
5MT-56
2) Install the 3rd drive gear, outer baulk ring, syn-
chro cone, inner baulk ring, sleeve & hub assembly
for the 3rd needle bearing, on the transmission
main shaft.
NOTE:
Align the groove in baulk ring with the shifting in-
sert.
3) Install the 4th needle bearing race onto trans-
mission main shaft using ST1, ST2 and press.
CAUTION:
ST2 499877000 RACE 4-5 INSTALLER
4) Install the baulk ring, needle bearing, 4th drive
gear and 4th gear thrust washer to the transmission
main shaft.
NOTE:
Align the baulk ring and gear & hub assembly with
the key groove.
5) Press-fit the ball bearing into the rear section of
transmission main shaft using ST1, ST2 and a
press.
CAUTION:
(A) 3rd needle bearing
(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve & hub ASSY
(A) 4th needle bearing race
MT-01318
(A)
(B) (C)
(D) (E)
(F)
MT-00192
(A)
ST1
ST2
(A) Groove
(B) Face this surface to the 4th gear side.
MT-00193
(A)
(B)
MT-00194
ST1
ST2
5MT-57
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.
CAUTION:
NOTE:
Make sure the thrust washer is oriented in the cor-
rect direction.
7) Install rest of the parts to the rear section of the
transmission main shaft.
CAUTION:
Install the baulk lever so that the concave
side faces toward the 5th hub.
Fit the convex portions of baulk ring with the
gaps between baulk levers.
8) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
9) Crimp lock nuts in two locations after tightening.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
(A) Face this surface to the 5th gear side.
(A) Baulk lever
(B) 5th hub
MT-00195
(A)
(A)
(B)
MT-01522
(A) Baulk ring
(B) Baulk lever
(C) 5th hub
(A) Needle bearing
(B) 5th drive gear
(C) Baulk ring
(D) 5th hub & sleeve No. 2
(E) Lock washer
(F) Lock nut
(G) Baulk lever
MT-01531
(A) (B)
(C)
(B)
MT-01627
(D) (A) (B) (C)
(E)
(F)
(G)
5MT-58
E: INSPECTION
Disassembled parts should be washed clean first
with cleaning solvent and then inspected carefully.
1) Bearing
When the bearing balls, outer races and inner
races are broken or rusty.
When the bearing is worn.
2) Bushing (each gear)
Replace the bushing in following cases.
When the sliding surface is damaged or abnor-
mally worn.
When the inner wall is abnormally worn.
3) Gear
Replace gears in the following cases.
Replace 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 rings in the following cases.
When the inner surface and end face are dam-
aged.
When the ring inner surface is abnormally or par-
tially worn down.
When the contact surface of synchronizer ring in-
sert is cracked or abnormally worn.
5) Shifting insert key
Replace the insert key if deformed, excessively
worn or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, worn or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent or defective in any way.
F: ADJUSTMENT
Selection of main shaft rear plate:
Using the ST, measure the protrusion amount (A)
of ball bearing from transmission main case sur-
face, and select a suitable plate in the following ta-
ble.
NOTE:
Before measuring, tap the end of main shaft with a
plastic hammer lightly in order to make the clear-
ance zero between the main case surface and
moving flange of bearing.
ST 498147001 DEPTH GAUGE
MT-01213
Dimension (A)
mm (in)
Part number Mark
4.00 4.13
(0.1575 0.1626)
32294AA041 1
3.87 4.00
(0.1524 0.1575)
32294AA051 2
MT-00209
(A)
5MT-59
A: REMOVAL
4) Remove the drive pinion shaft assembly.
NOTE:
Use a hammer handle, etc. to remove if too tight.
B: INSTALLATION
2) Alignment marks/numbers on hypoid gear set:
The number (A) on top of the drive pinion, and the
number on the hypoid driven gear are set numbers
for the two gears. Use a pair having the same num-
bers.
The figure (B) below shows a number for shim ad-
justment. If no number is shown, the value is zero.
3) Place the drive pinion shaft assembly on trans-
mission main case RH without shim and tighten the
bearing mounting bolts.
4) Perform inspection and adjustment of ST.
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
5) Position the ST by inserting the knock pin of ST
into the knock hole of transmission case.
(A) Main shaft ASSY for single-range
(B) Drive pinion shaft ASSY
MT-00161
( A)
( B)
(A) Set number
(B) Number for shim adjustment
(A) Plate
(B) Scale
MT-00990
(A)
(B)
(A)
+
0
.
1
MT-00242
(A)
(B)
ST
5MT-60
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.
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 .)
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.
9) Install the front differential assembly. <Ref. to
5MT-68, INSTALLATION, Front Differential As-
sembly.>
10) Set the transmission main shaft assembly for
single range and drive pinion shaft assembly in the
install location. (When doing so, there will be no
clearance between the two when moved all the way
to the front). Inspect a suitable 1st-2nd, 3rd-4th and
5th shifter fork so that the coupling sleeve and re-
verse driven gear are positioned in the center of the
synchronizing mechanism. <Ref. to 5MT-65, IN-
SPECTION, Drive Pinion Shaft Assembly.>
C: DISASSEMBLY
NOTE:
Attach a cloth to the end of driven shaft (on the fric-
tional side of the thrust needle bearing) to prevent
damage during disassembly or reassembly.
1) Flatten the tab of the axle nut. Remove the lock
nut with ST1, ST2 and ST3.
ST2 498427100 STOPPER
2) Draw out the drive pinion from driven shaft.
Remove the differential bevel gear sleeve, adjust-
ing washer No. 1, adjusting washer No. 2, thrust
bearing, needle bearing and drive pinion collar.
(A) Adjust the clearance to zero without shim.
Drive pinion shim
32295AA031 0.150 (0.0059)
32295AA041 0.175 (0.0069)
32295AA051 0.200 (0.0079)
32295AA061 0.225 (0.0089)
32295AA071 0.250 (0.0098)
32295AA081 0.275 (0.0108)
32295AA091 0.300 (0.0118)
32295AA101 0.500 (0.0197)
MT-00243
(A)
ST
(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)
MT-00244
ST1
ST2
ST3
MT-00245
( B)
( D)
( C)
( A)
( F )
( H)
( G)
( E)
5MT-61
3) Remove the roller bearing and washer using ST
and a press.
NOTE:
Do not reuse the roller bearing.
4) Flatten the tab of the axle nut. Remove the lock
nut using ST1 and ST2.
5) Remove the 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOVER
6) Remove the woodruff key.
7) Remove the roller bearing and 3rd-4th driven
gear using ST1 and ST2.
8) Remove the key.
9) Remove the 2nd driven gear, inner baulk ring,
synchro cone and outer baulk ring.
MT-00246
ST
MT-00247
ST1
ST2
MT-00248
ST
(A) 2nd driven gear
(B) Inner baulk ring
(C) Synchro cone
(D) Outer baulk ring
MT-00249
ST1
ST2
(A)
(B) (C)
(D)
MT-01633
5MT-62
10) Remove the 1st driven gear, inner baulk ring,
synchro cone, outer baulk ring, 2nd gear bushing,
gear and hub using ST1 and ST2.
NOTE:
If necessary, use the new gear & hub assembly,
when replacing the gear or hub assembly. Because
these must engage at the specified point, avoid dis-
assembly as much as possible. If it must be disas-
sembled, mark the engaging point on the spline
beforehand.
11) Remove the sub gear, washer, and snap ring
(outer) for the 1st driven gear. (2.5 L non-turbo
model)
D: ASSEMBLY
1) Install the sleeve and gear & hub assembly by
matching alignment marks.
NOTE:
After installation, make sure there is no significant
gap at both sides of the ball detent.
NOTE:
Use the new gear & hub assembly, if replacing the
gear or hub.
2) Install the washer, snap ring (outer) and sub
gear onto the 1st driven gear. (2.5 L non-turbo
model)
(A) 1st driven gear
(C) Synchro cone
(D)
(C) (B)
(A)
MT-01634
MT-00251
ST1
ST2
(A) Ball detent
(B) 1st-2nd synchronizer hub
(C) Reverse driven gear
(D) There is no significant gap at these points.
(A) 1st gear side
(B) 2nd gear side
(C) Flush surface
(D) Stepped surface
MT-01639
(A)
(D)
(B)
(C)
MT-00252
( B)
( A)
( C)
( D)
5MT-63
3) Install the 1st driven gear, inner baulk ring, syn-
chro cone, outer baulk ring, gear & hub assembly
onto driven shaft.
NOTE:
Take care to install the gear & hub assembly in
proper direction.
Align the baulk ring and gear & hub assembly
with the key groove.
4) Install the 2nd driven gear bushing onto the driv-
en shaft using ST1, ST2 and a press.
CAUTION:
NOTE:
Attach a cloth to the end of the driven shaft to
prevent damage.
When press fitting, align the oil holes of the shaft
and bushing
5) Install the 2nd driven gear, inner baulk ring, syn-
chro cone and outer baulk ring, and insert them
onto driven shaft.
6) After installing key on driven shaft, install the
3rd-4th driven gear using an ST and a press.
CAUTION:
NOTE:
Align the groove in baulk ring with the insert.
7) Install a set of roller bearings onto the driven
shaft using the ST and a press.
CAUTION:
(A) 1st driven gear
(C) Synchro cone
(D)
(C) (B)
(A)
MT-01634
MT-00253
ST1
ST2
(A) 2nd driven gear
(C) Synchro cone
(A)
(B) (C)
(D)
MT-01633
MT-00255
ST
MT-00256
ST
5MT-64
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:
9) Install the lock washer. Install the lock nut and
tighten to the specified torque using the ST.
ST 499987300 SOCKET WRENCH (50)
Tightening torque:
260 Nm (26.5 kgf-m, 191.8 ft-lb)
NOTE:
Crimp the locknut in 2 locations.
Using a spring scale, check that starting torque
of the roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf,
0.02 to 0.33 Ibf).
10) Install the roller bearing onto drive pinion.
NOTE:
When installing the roller bearing, note its direc-
tions (front and rear) because the knock pin hole of
outer race is offset.
11) Install the washer using ST1, ST2 and a press.
CAUTION:
ST1 499277100 BUSHING 1-2 INSTALLER
12) Install the thrust bearing and needle bearing.
Install the driven shaft assembly.
MT-00257
ST
MT-00258
ST
MT-00259
(A) Roller bearing
(B) Knock pin hole
(A) Washer
MT-00260
(A)
(B)
MT-00261
(A)
ST1
ST2
MT-00262
5MT-65
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.
NOTE:
Be careful to install the spacer in the proper direc-
tion.
14) Adjust the thrust bearing preload. <Ref. to
5MT-66, THRUST BEARING PRELOAD, AD-
JUSTMENT, Drive Pinion Shaft Assembly.>
E: INSPECTION
1) Bearing
When the bearing balls, outer races and inner
races are broken or rusty.
When the bearing is worn.
The ball bearing on the rear side of the drive pin-
ion shaft should be checked for smooth rotation be-
fore the drive pinion assembly is disassembled. In
this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging
unlike other bearings.
When the sliding surface is damaged or abnor-
mally worn.
When the inner wall is abnormally worn.
3) Gear
Replace 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.
(A) Driven shaft
(B) Drive shaft
(C) Drive pinion collar
(D) Needle bearing (25 30 20)
(E) Adjusting washer No. 2 (25 36 4)
(F) Thrust bearing (25 37.5 3)
(G) Adjusting washer No. 1 (25 36 t)
(H) Differential bevel gear sleeve
MT-00263
(A) (B)
(C) (D) (E) (F) (G) (H)
(B) Ball bearing
MT-00264
(A)
(B)
5MT-66
4) Baulk ring
Replace the ring in following cases:
When the inner surface and end face are dam-
aged.
When the ring inner surface is abnormally or par-
tially worn down.
If the gap between the end faces of the ring and
the gear splined part is excessively small, check
the clearance (A) while pressing the ring against
the cone.
Clearance (A):
0.5 1.0 mm (0.020 0.040 in)
When the contact surface of synchronizer ring in-
sert is scratched or abnormally worn.
5) Ball detent
Replace the ball detent if deformed, excessively
worn or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, worn or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn or defective in any way.
F: ADJUSTMENT
1. THRUST BEARING PRELOAD
1) Select a suitable adjusting washer No. 1 to so
that dimension (H) will be zero in a visual check.
Position the washer (18.3 30 4) and lock wash-
er (18 30 2) and install lock nut.(18 13.5)
2) Using the ST1, ST2 and ST3, tighten the new
lock nut to the specified torque.
ST2 498427100 STOPPER
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
(A) Ball detent
MT-00265
(A)
MT-01640
(A)
MT-00267
(H)
MT-00268
ST1
ST2
ST3
5MT-67
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 ft-lb)
4) If the starting torque is not within the specified
limit, select new adjusting washer No. 1 and re-
check starting torque.
5) When the specified starting torque cannot be ob-
tained by adjusting washer No. 1, select adjusting
washer No. 2 from the following table. Repeat pro-
cedures 1) through 4) to adjust starting torque.
6) Recheck that the starting torque is within the
specified range, then crimp the lock nut at four po-
sitions.
(A) Adjusting washer No. 1
(B) Adjusting washer No. 2
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
MT-00269
ST1
ST3
MT-00270
( A)
( B)
(A) Adjusting washer No. 1
(B) Adjusting washer No. 2
Starting torque Dimension H Adjusting washer No. 2
Low Small Select thicker one.
High Large Select thinner one.
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
MT-00270
( A)
( B)
5MT-68
A: REMOVAL
bly.>
range. <Ref. to 5MT-54, REMOVAL, Main Shaft
Assembly for Single-range.>
NOTE:
Do not confuse the right and left roller bearing
outer races.
Be careful not to damage the oil seal of retainer.
7) Remove the differential side retainers using ST.
8) Remove the bearing outer race from the trans-
mission case.
B: INSTALLATION
1) Install the differential side retainers using ST.
2) Install the bearing outer race to the transmission
case.
3) Install the front differential assembly.
NOTE:
Be careful not to fold the sealing lip of oil seal.
<Ref. to 5MT-54, INSTALLATION, Main Shaft As-
sembly for Single-range.>
sembly.>
MT-00162
MT-00176
ST
MT-00162
5MT-69
C: DISASSEMBLY
1) Loosen the twelve bolts and remove hypoid driv-
en gear.
2) Drive out the straight pin from differential assem-
bly toward hypoid driven gear side.
3) Pull out the pinion shaft, and remove the differ-
ential bevel pinion, differential bevel gear and
washer.
4) Using the ST, remove the roller bearing.
ST 899524100 PULLER SET
(A)
MT-00275
MT-00276
ST
(A) Pinion shaft
(B) Differential bevel pinion
(C) Differential bevel gear
(D) Washer
MT-00277
(A)
(D)
(D)
(C)
(C)
(B)
(B)
MT-00278
ST
5MT-70
2. SIDE RETAINER
NOTE:
Remove using the flat tip screwdriver.
Do not reuse the oil seal. Replace the oil seal
with a new part.
D: ASSEMBLY
1) Install the differential bevel gear and differential
bevel pinion together with washers, and insert the
pinion shaft.
NOTE:
Face the chamfered side of washer toward gear.
2) Measure the backlash between differential bevel
gear and differential pinion. If backlash is not within
specified value, install a suitable washer to adjust.
<Ref. to 5MT-72, BEVEL PINION GEAR BACK-
LASH, INSPECTION, Front Differential Assembly.>
NOTE:
Be sure the pinion gear teeth contacts adjacent
gear teeth during measurement.
Standard backlash
0.13 0.18 mm (0.0051 0.0071 in)
MT-00279
MT-01003
(A) Differential bevel pinion
(B) Differential bevel gear
(C) Pinion shaft
MT-00284
(A)
(B)
(C)
MT-00285
ST1
ST2
5MT-71
3) Align the pinion shaft and differential case with
each hole, and drive the straight pin into the holes
from the hypoid driven gear using the ST.
NOTE:
Lock the straight pin after installing.
4) Install the roller bearing to differential case.
CAUTION:
NOTE:
Be careful because the roller bearing outer races
are used as a set.
ST1 499277100 BUSHING 1-2 INSTALLER
5) Install the hypoid driven gear to the differential
case using twelve bolts.
Tightening torque:
T: 62 Nm (6.3 kgf-m, 45.6 ft-lb)
2. SIDE RETAINER
1) Install a new oil seal.
SEAL INSTALLER
CAUTION:
When press-fitting the oil seal to the side re-
tainer, tap with a plastic hammer etc. to press in.
Never use a press.
2) Install a new O-ring.
NOTE:
Do not stretch or damage the O-ring.
(A) Pinion shaft
(B) Differential case
(C) Straight pin
MT-00286
(A)
(C)
(B)
MT-00287
ST1
ST2
(B) Differential case
MT-00993
(B)
(A)
T
MT-00289
ST
MT-00279
5MT-72
E: INSPECTION
Repair or replace the differential gear in the follow-
ing cases:
When the hypoid drive gear and drive pinion
shaft tooth surfaces are damaged, excessively
worn, or seized.
When the roller bearing on the drive pinion shaft
has a worn or damaged roller path.
When there is damage, wear or seizure of the dif-
ferential bevel pinion, differential bevel gear, wash-
er, pinion shaft or straight pin.
When the differential case has worn or damaged
sliding surfaces.
1. BEVEL PINION GEAR BACKLASH
Measure the backlash between differential bevel
gear and differential bevel pinion. If backlash is not
within specified value, install a suitable washer to
adjust. <Ref. to 5MT-73, ADJUSTMENT, Front Dif-
ferential Assembly.>
Standard backlash
0.13 0.18 mm (0.0051 0.0071 in)
2. HYPOID GEAR BACKLASH
1) Set the ST1, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface on
the right corner, and check the backlash.
ST3 498255400 PLATE
2) Install SUBARU genuine axle shafts to both
sides, rotate in the inversion direction so that the
gauge contacts the tooth surface, and read the dial
gauge
Backlash
0.13 0.18 mm (0.0051 0.0071 in)
NOTE:
If the backlash is outside the specified range, ad-
just it by turning the side retainer in the right side
case.
(B) Hypoid driven gear
(C) Pinion shaft
(D) Straight pin
(E) Washer
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Roller bearing
(I) Differential case
MT-00291
(A)
(B)
(C)
(E)
(E)
(F)
(F)
(G)
(G)
(D)
(H)
(I)
(H)
MT-00285
ST1
ST2
MT-00293
ST1
ST2
ST3
5MT-73
3. TOOTH CONTACT OF HYPOID GEAR
Check tooth contact of hypoid gear as follows: Ap-
ply a thin uniform coat of lead-free red dye on both
teeth surfaces on 3 or 4 teeth of the hypoid gear.
Move the hypoid gear back and forth by turning the
transmission main shaft until a definite contact pat-
tern is developed on the hypoid gear, and judge
whether face contact is correct. If it is improper,
make adjustment. <Ref. to 5MT-73, ADJUST-
MENT, Front Differential Assembly.>
Tooth contact is correct.
F: ADJUSTMENT
1) Disassemble the front differential assembly.
<Ref. to 5MT-69, DISASSEMBLY, Front Differen-
tial Assembly.>
2) Select a different washer from the table and in-
stall.
3) Adjust until the standard value is obtained.
Backlash:
Standard
0.13 0.18 mm (0.0051 0.0071 in)
Adjust the backlash by turning the holder in the RH
side case.
NOTE:
Each time side retainer rotates one tooth, backlash
changes by 0.05 mm (0.020 in).
1) Adjust until correct teeth contact is obtained.
2) Check tooth contact, and perform the adjust-
ment as follows.
Tooth contact
side.)
(A) Toe
(B) Coast side
(C) Heel
(D) Drive side
Washer
803038021
0.925 0.950
(0.0364 0.0374)
803038022
0.975 1.000
(0.0384 0.0394)
803038023
1.025 1.050
(0.0404 0.0413)
MT-01402
(B) (D)
(C)
(A)
(A) Toe side
(B) Heel side
MT-00176
ST
MT-00296
0.05mm(0.0020 in)
(A)
(B)
MT-01401
5MT-74
Face contact
Contact pattern
Corrective action: Reduce thickness of pinion
height adjusting washer in order to bring the drive
pinion closer to driven gear side.
Flank contact
Contact pattern
Corrective action: Increase the thickness of the pin-
ion height adjusting washer in order to place the
drive pinion away from the driven gear.
Contact pattern
height adjusting washer according to the procedures
for moving the drive pinion closer to the driven gear.
Contact pattern
driven gear.
AT-00208
AT-00212
AT-00209
AT-00213
AT-00210
AT-00213
AT-00211
AT-00212
5MT-75
Reverse Idler Gear
18.Reverse Idler Gear
A: REMOVAL
2) Remove the back-up light switch and the neutral
position switch. <Ref. to 5MT-35, REMOVAL, Switch-
es and Harness.>
bly.>
5MT-68, REMOVAL, Front Differential Assembly.>
8) Remove the shifter forks and rods. <Ref. to 5MT-
77, REMOVAL, Shifter Fork and Rod.>
9) Pull out the straight pin, and remove the reverse
idler gear shaft, washer, reverse idler gear and
washer.
10) Remove the reverse shifter lever.
B: INSTALLATION
1) Install the reverse shifter lever, washer, reverse
idler gear, washer and reverse idler gear shaft, and
secure them with the straight pin.
NOTE:
Be sure to install the reverse idler gear shaft from
rear side.
2) Check and adjust clearance between the re-
verse idler gear and the timing case wall surface.
<Ref. to 5MT-75, INSTALLATION, Reverse Idler
Gear.> <Ref. to 5MT-76, ADJUSTMENT, Reverse
Idler Gear.>
3) Install the shifter forks and rods. <Ref. to 5MT-
78, INSTALLATION, Shifter Fork and Rod.>
sembly.>
sembly for Single-range.>
sembly.>
9) Install the back-up light switch & neutral position
switch. <Ref. to 5MT-36, INSTALLATION, Switch-
es and Harness.>
(A) Straight pin
(B) Reverse idler gear shaft
(C) Reverse idler gear
(D) Washer
(E) Washer
(F) Reverse shifter lever
MT-01565
(A)
(B)
(C)
(D)
(F)
(E)
(A) Straight pin
(B) Reverse idler gear shaft
(C) Reverse idler gear
(D) Washer
(E) Washer
(F) Reverse shifter lever
MT-01565
(A)
(B)
(C)
(D)
(F)
(E)
5MT-76
Reverse Idler Gear
C: INSPECTION
1) Move the reverse shifter rod toward the reverse
side. Check the clearance between the reverse
idler gear and the timing case wall surface.
If out of specification, select an appropriate reverse
shifter lever and adjust.
Clearance A:
6.0 7.5 mm (0.236 0.295 in)
2) After installing a suitable reverse shifter lever,
shift into neutral. Check the 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)
3) Check the reverse idler gear and shaft for dam-
age. Replace if it is damaged.
D: ADJUSTMENT
1) Select the appropriate reverse shifter lever from
the table below, and adjust until the clearance be-
tween the reverse idler gear and transmission case
wall is within specification.
Clearance A:
6.0 7.5 mm (0.236 0.295 in)
2) Select the appropriate washer from the table be-
low, and adjust until the clearance between the re-
verse idler gear and transmission case wall is
Clearance:
0 0.5 mm (0 0.020 in)
MT-00305
A
MT-00306
Reverse shifter lever
32820AA070 7 Far from case wall
32820AA080 8 Standard
32820AA090 9 Closer to case wall
Washer
803020151 0.4 (0.016)
803020152 1.1 (0.043)
803020153 1.5 (0.059)
803020154 1.9 (0.075)
803020155 2.3 (0.091)
MT-00305
A
MT-00306
5MT-77
Shifter Fork and Rod
19.Shifter Fork and Rod
A: REMOVAL
2) Remove the back-up light switch and the neutral
position switch. <Ref. to 5MT-35, REMOVAL, Switch-
es and Harness.>
bly.>
5MT-68, 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
9) Remove the plugs, springs and check balls.
10) Drive out the straight pin by tapping with the
ST, and pull out the 3rd 4th fork rod and shifter
fork.
NOTE:
When removing the rod, keep other rods in neutral.
Also, when pulling out the straight pin, remove it to-
ward the inside of case so that it does not hit
against the case.
11) Drive out the straight pin by tapping with the
ST, and pull out the 1st 2nd fork rod and shifter
fork.
12) Remove the snap ring (outer), and pull out the
reverse fork rod from reverse fork rod arm. Then
take out the ball, spring and interlock plunger from
the rod.
And then remove the rod.
NOTE:
When pulling out the reverse fork rod arm, be care-
ful not to let the ball pop out of arm.
13) Remove the reverse shifter lever.
(A) Straight pin
(B) 5th shifter fork
MT-00309
( A)
( B)
(A) Straight pin
(B) 3rd-4th fork rod
(C) Shifter fork
MT-00994
(A) (B)
(C)
5MT-78
B: INSTALLATION
1) Install the reverse arm fork spring, ball and inter-
lock 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.
NOTE:
Apply grease to plunger to prevent it from falling.
ST 399411700 ACCENT BALL INSTALLER
2) Position the ball, spring and new gasket in the
reverse fork rod hole on the left side of transmis-
sion case, and tighten the checking ball plug.
3) Install the 1st-2nd fork rod into 1st-2nd shifter
fork through the hole on the rear of transmission
case.
4) 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.
5) Attach the interlock plunger on 3rd-4th fork rod.
NOTE:
Apply grease to plunger to prevent it from falling.
6) Attach the 3rd-4th fork rod into 3rd-4th shifter
fork through the hole on the rear of transmission
case.
7) 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 installa-
tion) is on the reverse fork rod side.
8) 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.
9) Position the balls, check ball springs and new
gaskets into holes of the 3rd-4th fork rods and 1st-
2nd fork rods, and install the plugs.
Tightening torque:
20 Nm (2.0 kgf-m, 14.8 ft-lb)
sembly.>
11) Install the main shaft assembly for single-
range. <Ref. to 5MT-54, INSTALLATION, Main
Shaft Assembly for Single-range.>
sembly.>
15) Install the back-up light switch & neutral posi-
tion switch. <Ref. to 5MT-36, INSTALLATION,
(A) 5th shifter fork
(B) Reverse fork rod
(C) Straight pin
MT-00311
( C)
( A)
( B)
MT-00366
5MT-79
C: INSPECTION
1) Check the fork and rod for damage. Replace if it
is damaged.
2) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
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)
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) and (b):
7.3 mm (0.287 in)
(A) 1st driven gear
(B) Reverse driven gear
(C) 2nd driven gear
1st-2nd shifter fork
32804AA060 1
Approaches 1st gear
by 0.2 mm (0.008 in).
32804AA070 Standard
32804AA080 3
Approaches 2nd gear
by 0.2 mm (0.008 in).
MT-01635
(A)
(B)
(a) (b)
(C)
(A) 3rd drive gear
(B) Coupling sleeve
(C) 4th drive gear
3rd-4th shifter fork
32810AA061 1
Approaches 4th gear
by 0.2 mm (0.008 in).
32810AA071 Standard
32810AA101 3
Approaches 3rd gear
by 0.2 mm (0.008 in).
MT-00940
(A)
(B)
(C)
(a) (b)
5MT-80
5) Inspect the clearance between 5th drive gear
and coupling sleeve. If any clearance is not within
specifications, replace the shifter fork as required.
Clearance (a):
9.3 mm (0.366 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 (A):
3rd-4th 5th
0.5 1.3 mm (0.020 0.051 in)
Clearance (B):
1st-2nd 3rd-4th
0.4 1.4 mm (0.016 0.055 in)
(A) 5th drive gear
(B) Coupling sleeve
5th shifter fork (Non-turbo model), Identification paint (pink)
32812AA201 7
Approaches 5th gear by
0.2 mm (0.008 in).
32812AA221 9
Moves away from 5th gear
by 0.2 mm (0.008 in).
5th shifter fork (Turbo model), Identification paint (blue)
32812AA231 7
Approaches 5th gear by
0.2 mm (0.008 in).
32812AA251 9
Moves away from 5th gear
by 0.2 mm (0.008 in).
MT-01512
(A) (B) (a)
MT-00316
(B
)
(A
)
5MT-81
A: INSPECTION
1. Gears are difficult to intermesh.
NOTE:
The cause for difficulty in shifting gears
can be classified into two kinds: One is a
defective gear shift system and the other
is defective transmission. However, if the
operation is heavy and engagement of the
gears is difficult, a defective clutch disen-
gagement may also be responsible.
Check whether the clutch is correctly
functioning, before checking the gear shift
system and transmission.
(a) Worn, damaged or burred chamfer at
internal spline of the sleeve and reverse
driven gear
Replace.
(b) Worn, damaged or burred chamfer of
gear spline
Replace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact or wear between
synchronizer ring and gear cone
Correct or replace.
2. Gear slip-out
Gear slips out when coasting on rough
road.
Gear slips out during acceleration.
(a) Defective pitching stopper adjustment Adjust.
(b) Loose engine mounting bolts Tighten or replace.
(c) Worn fork shifter, broken shifter fork
rail spring
Replace.
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines
of synchronizer hub and synchronizer
sleeve
Replace.
(f) Worn tooth step of synchronizer hub
(caused by slip-out of 3rd gear)
Replace.
(g) Worn 1st driven gear and driven shaft Replace.
(h) Worn 2nd driven gear and bushing Replace.
(i) Worn 3rd drive gear and needle bear-
ing
Replace.
(j) Worn 4th drive gear and needle bear-
ing
Replace.
(k) Worn reverse idler gear and bushing Replace.
3. Noise emitted 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 com-
ing from the transmission.
(a) Insufficient or improper lubrication Lubricate with specified oil or replace.
(b) Worn or damaged gears and bearings
NOTE:
If the trouble is only wear of the tooth sur-
faces, merely a high roaring noise will oc-
cur at high speeds, but if any part is
broken, rhythmical knocking sound will be
heard even at low speeds.
Replace.
5MT-82
2. DIFFERENTIAL
1. Broken differential
(case, gear, bearing, etc.)
NOTE:
Noise will occur, and eventually the differ-
ential will not be able to operate due to
broken pieces obstructing the gear revo-
lution.
(a) Insufficient or improper oil Disassemble the differential and replace
broken components. At the same time
check other components for any trouble,
and replace if necessary.
(b) Use of vehicle under severe condi-
tions such as excessive load and
improper use of the clutch
Readjust the preload and backlash of the
bearing, and the contact surface of gear.
(c) Improper adjustment of taper roller
bearing
Adjust.
(d) Improper adjustment of the drive pin-
ion and the hypoid driven gear
Adjust.
(e) Excessive backlash of a vehicle under
severe operating conditions due to worn
differential side gear, washer or differen-
tial pinion.
Add recommended oil to the specified
level. Do not use vehicle under severe
operating conditions.
(f) Loose hypoid driven gear tightening
bolts
Tighten.
2. Differential and hypoid gear noises
Troubles of the differential and hypoid
gear always appear as noise problems.
Therefore noise is the first indication of
trouble. 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 fol-
lowing 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 bear-
ings and incorrect shim adjustment.
Bearing noise when driving or coasting:
Cracked, broken or damaged bearings
Noise mainly when turning:
Noise from differential side gear, differen-
tial pinion or differential pinion shaft, etc.
(a) Insufficient oil Lubricate.
(b) Improper adjustment of hypoid driven
gear and drive pinion
Check the tooth contact.
(c) Worn teeth of hypoid driven gear and
drive pinion
Replace as a set.
Readjust the bearing preload.
(d) Loose roller bearing Readjust the backlash of the hypoid
driven gear to drive pinion, and check the
tooth contact.
(e) Distorted hypoid driven gear or differ-
ential case
Replace.
(f) Worn washer and differential pinion
shaft
Replace.
6MT-2
General Description
A: SPECIFICATION
1. MANUAL TRANSMISSION AND FRONT DIFFERENTIAL
2. TRANSMISSION GEAR OIL
Recommended oil:
Type 6-forward speeds and 1-reverse
Transmission gear ratio
1st 3.636
2nd 2.235
3rd 1.521
4th 1.137
5th 0.891
6th 0.707
Rev. 3.545
Front reduction
gear
Final
Type of gear Hypoid
Gear ratio 3.900
Rear reduction
gear
Transfer
Type of gear Helical
Gear ratio 1.100
Final
Type of gear Hypoid
Gear ratio 3.545
Front differential Type and number of gear
Straight bevel gear
(Bevel pinion: 4, Bevel gear: 2)
Center differential Type and number of gear
Straight bevel gear
(Bevel pinion: 2, bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Transmission gear oil capacity 4.1 2 (4.3 US qt, 3.6 Imp qt)
6MT-3
General Description
B: COMPONENT
1. CLUTCH HOUSING
(1) Oil level gauge (6) Gasket Tightening torque: Nm (kgf-m, ft-lb)
(2) Plug (7) Oil seal T1: 6.4 (0.65, 4.7)
(3) Pitching stopper bracket (8) Clutch release bearing guide T2: 41 (4.2, 30.2)
(4) Clip (9) Return spring bracket T3: 50 (5.1, 36.9)
(5) Clutch housing (10) O-ring T4: 70 (7.1, 51.6)
MT-01476
(1)
(5)
(6)
(7)
(8)
T3
T4
T1
(4)
(3)
(2)
(9)
T2
(10)
6MT-4
General Description
2. ADAPTER PLATE
(1) Breather hose (7) Check plug (13) Adapter plate
(2) Transmission harness stay (8) O-ring
(3) Check plug (9) Check spring Tightening torque:Nm (kgf-m, ft-lb)
(4) O-ring (10) Check ball T1: 18 (1.8, 13.3)
(5) Check spring (11) Oil guide A T2: 37 (3.8, 27.3)
(6) Plunger (12) Oil guide B T3: 50 (5.1, 36.9)
MT-01609
(2)
(3)
(4)
(1)
(5)
(7)
(6)
(8)
(9)
(10)
(13)
T2
T1
T3
T2
T1
T3
(12)
T1
(11)
6MT-5
General Description
3. TRANSMISSION CASE
(1) Pilot bolt (6) Harness bracket Tightening torque: Nm (kgf-m, ft-lb)
(2) Neutral switch (7) Plunger T1: 13 (1.3, 9.6)
(3) Back-up light switch (8) Spring T2: 16 (1.6, 11.8)
(4) Adapter plate (9) Plug T3: 32 (3.3, 23.6)
(5) Transmission case (10) Gasket T4: 34 (3.5, 25.1)
T5: 41 (4.2, 30.2)
MT-01610
(2)
(3)
(1)
(10)
(10)
(10)
(4)
(5)
T1
T3
T4
T3
T1
T2
(6)
T2
(9)
(10)
(8)
(7)
T5
6MT-6
General Description
4. OIL PAN & OIL GUIDE
(1) Transmission case (6) Gasket Tightening torque: Nm (kgf-m, ft-lb)
(2) Transfer bearing holder (7) Oil guide F T1: 6.4 (0.65, 4.7)
(3) Oil guide G (8) Oil guide D T2: 18 (1.8, 13.3)
(4) Oil guide H (9) Oil guide E T3: 25 (2.5, 18.1)
(5) Oil pan (10) Oil guide C T4: 44 (4.5, 32.5)
MT-01611
(2)
(3)
(4)
T3
T3
(5)
(6)
T1
T4
(1)
T2
(10)
(7)
(8)
(9)
6MT-7
General Description
5. EXTENSION CASE AND CENTER DIFFERENTIAL
(1) Taper roller bearing (14) Snap ring (27) Reverse check lever COMPL
(2) Transfer driven gear (15) Oil guide (28) Straight pin
(3) Taper roller bearing (16) Extension case (29) Reverse check plug
(4) Shim (17) Oil seal (30) Spring
(5) Oil plate (18) Oil seal (31) Gasket
(6) Snap ring (19) Dust cover (32) Plug
(7) Collar (20) Snap ring (33) Plunger
(8) Center differential (21) Washer
(9) Shim (22) Bushing Tightening torque: Nm (kgf-m, ft-lb)
(10) Needle bearing (23) Spring T1: 25 (2.5, 18.4)
(11) Needle bearing (24) Reverse check shaft T2: 41 (4.2, 30.2)
(12) Transfer drive gear (25) Ball bearing T3: 48 (4.9, 35.4)
(13) Ball bearing (with flange) (26) Oil seal
MT-01088
(32)
(31)
(30)
(29)
(33)
(26)
(25)
(24)
(22)
(21)
(23)
(20)
(19)
(18)
(17)
(16)
(15)
(14)
(13)
(12)
(11)
(10)
(9)
(5)
(4)
(3)
(2)
(8)
(6)
(7)
(1)
(27)
(28)
T3
T1
T2
6MT-8
General Description
6. SHIFTER FORK AND FORK ROD
(1) Spring pin (9) Washer (17) 5th-6th shifter arm
(2) Interlock arm (10) Snap ring (18) 5th-6th fork COMPL
(3) Interlock block (11) Reverse fork COMPL (19) 3rd-4th fork rod
(4) Reverse interlock block (12) Reverse shifter arm (20) 3rd-4th shifter arm
(5) Interlock arm (13) Reverse fork rod (21) 1st-2nd shifter arm
(6) Striking rod (14) Selector arm (22) 3rd-4th fork COMPL
(7) Selector arm No. 2 (15) Shifter arm shaft (23) 1st-2nd fork rod
(8) Neutral set spring (16) 5th-6th fork rod (24) 1st-2nd fork COMPL
(7)
(8)
(9)
(10)
(15)
(14)
(18)
(17)
(22)
(1)
(1)
(20)
(1)
(1)
(1)
(1)
(1)
(21)
(24)
(1)
(19)
(16)
(13)
(12)
(11)
(23)
(1)
(1)
(1)
(1)
(5)
(6)
(4)
(3)
(2)
MT-01262
6MT-9
General Description
7. MAIN SHAFT ASSEMBLY
(1) Main shaft (12) 4th bushing (23) Needle bearing
(2) Needle bearing (13) Needle bearing (24) 6th bushing
(3) 3rd drive gear (14) 5th bushing (25) Taper roller bearing
(4) Inner baulk ring (15) Needle bearing (26) Snap ring
(5) Synchro cone (16) 5th drive gear (27) Washer
(6) Outer baulk ring (17) 5th baulk ring (28) Washer
(7) 3rd-4th sleeve (18) 5th-6th sleeve (29) Lock nut
(8) 3rd-4th hub (19) 5th-6th hub
(9) Shifting insert (20) Shifting insert Tightening torque:Nm (kgf-m, ft-lb)
(10) 4th baulk ring (21) 6th baulk ring T: 392 (40.0, 289)
(11) 4th gear (22) 6th drive gear
MT-01499
(2)
(16)
(17)
(18)
(19)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(14)
(15)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(1)
(10)
(11)
(12)
(13)
(20)
6MT-10
General Description
8. DRIVE PINION AND DRIVE SHAFT ASSEMBLY
(1) Drive pinion shaft (13) 1st-2nd sleeve (25) Lock nut
(2) Taper roller bearing (14) Shifting insert (26) Shim
(3) Shim (15) 1st-2nd hub (27) Collar
(4) Washer (16) Outer baulk ring
(5) Lock nut (17) Synchro cone Tightening torque:Nm (kgf-m, ft-lb)
(6) Thrust bearing (18) Inner baulk ring T1: 285 (29.1, 210)
(7) Needle bearing (19) 2nd driven gear * 265 (27.0, 195)
(8) Driven shaft (20) Needle bearing T2: 570 (58.1, 420)
(9) Key (21) 2nd bushing * 530 (54.0, 391)
(10) Needle bearing (22) 3rd-4th driven gear T3: 54 (5.5, 40)
(11) 1st driven gear (23) 5th-6th driven gear * Tightening torque when using the ST
(12) 1st synchro ring ASSY (24) Ball bearing
MT-01498
(26)
(25)
(27)
(16)
(17)
(18)
(19)
(20)
(8)
(1)
(2)
(10)
(9)
(11)
(12)
(13)
(14)
(15)
(22)
(23)
(24)
(3)
(5)
(6)
(7)
T1
T2
(4)
(21)
T3
6MT-11
General Description
9. REVERSE IDLER GEAR ASSEMBLY
(1) Base COMPL (9) Reverse coupling sleeve (17) Reverse idler holder
(2) Counter high and low washer (10) Reverse idler gear (18) Spring pin
(3) Reverse idler gear No. 2 (11) Spring (19) Knock pin
(4) Needle bearing (12) Sub gear (20) Washer
(5) Reverse idler synchro set (13) Friction plate (21) Gasket
(6) Reverse idler gear bushing (14) Snap ring
(7) Needle bearing (15) Counter high and low washer Tightening torque: Nm (kgf-m, ft-lb)
(8) Shifting insert (16) Snap ring T: 25 (2.5, 18.1)
MT-01500
(1)
(9)
(18)
(19)
(8)
(10)
(11)
(12)
(13)
(15)
(16)
(14)
(17)
(2)
(3)
(4)
(5)
(6)
(7)
T
T
(21)
(21)
(20)
6MT-12
General Description
10.FRONT DIFFERENTIAL
(1) Drive pinion shaft (8) Differential bevel gear (15) Retainer lock plate RH
(2) Hypoid driven gear (9) Differential bevel pinion (16) Retainer lock plate LH
(3) Pinion shaft (10) Pinion shaft joint (17) Differential side retainer LH
(4) Differential case RH (11) Roller bearing
(5) Straight pin (12) Oil seal Tightening torque: Nm (kgf-m, ft-lb)
(6) Differential case LH (13) Differential side retainer RH T1: 25 (2.5, 18.1)
(7) Washer (14) O-ring T2: 69 (7.0, 50.9)
MT-01529
(1)
(2)
T2
(3)
(11)
(3)
(3)
(6)
(8)
(9)
(9)
(9)
(11)
(14)
(14)
(12)
(12)
(17)
(15)
T1
T1
(16)
(13)
(7)
(7)
(9)
(10)
(5)
(8)
(4)
6MT-13
General Description
(1) Pitching stopper (7) Upper cushion rubber Tightening torque:Nm (kgf-m, ft-lb)
(2) Spacer (8) Center crossmember T1: 7.5 (0.8, 5.5)
(3) Lower cushion rubber (9) Rear plate T2: 35 (3.6, 25.8)
(4) Front plate (10) Front crossmember T3: 50 (5.1, 36.9)
(5) Transmission cushion rubber (11) Dynamic damper T4: 58 (5.9, 42.8)
(6) Rear crossmember (12) Upper cushion rubber T5: 70 (7.1, 51.6)
T6: 75 (7.5, 55.3)
T7: 140 (14.3, 103)
MT-01555
(1)
T4
T6
T5
T5
T2
T7
T2
T3
(2)
(4)
(5)
(12)
(8)
(7)
(3)
(2)
(9)
(6)
(3)
(10)
T1
(11)
6MT-14
General Description
C: CAUTION
forming any work.
loy parts, disassemble by using a plastic hammer.
Do not pry apart with screwdrivers or other tools.
Use SUBARU genuine transmission gear oil,
grease or the equivalent. Do not mix transmission
gear oil, grease etc. of different grades or manufac-
turers.
points.
Apply transmission gear oil onto sliding or revolv-
ing surfaces before installation.
new parts.
cient amount of transmission gear oil to avoid dam-
age and deformation.
O-rings, snap rings and other parts.
ing materials such as wood blocks, aluminum
plates, or waste cloth between the part and the
vise.
move the old liquid gasket.
6MT-15
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
398791700 REMOVER Used for removing and installing the spring pin
(6 mm).
399527700 PULLER SET Used for removing and installing the roller bear-
ing (Differential).
(1) BOLT (899521412)
(2) PULLER (399527702)
(3) HOLDER (399527703)
(4) ADAPTER (398497701)
(5) BOLT (899520107)
(6) NUT (021008000)
498515700 REMOVER Used for removing the roller bearing of the drive
pinion shaft.
498247001 MAGNET BASE Used for measuring backlash between the
side gear, pinion, and hypoid gear.
(498247100).
ST-398791700
ST-399527700
(1) (2) (3)
(4) (5) (6)
ST-498515700
ST-498247001
6MT-16
General Description
498247100 DIAL GAUGE Used for measuring backlash between the
side gear, pinion, and hypoid gear.
(498247001).
bearing.
899858600 REMOVER Used for removing the roller bearing.
499757002 INSTALLER Used for installing the bearing cone of the trans-
fer driven gear (extension core side).
RETAINER
tial side retainer RH.
be used.
ST-498247100
ST-498077000
ST-899858600
ST-499757002
ST18630AA010
6MT-17
General Description
499877000 RACE 4-5
INSTALLER
Used for disassembling the driven shaft and
transfer driven gear.
899864100 REMOVER Used for removing the transmission main shaft
and drive pinion parts.
498255400 PLATE Used for measuring backlash.
41099AA010 ENGINE SUPPORT
BRACKET
Used for supporting engine.
ST-499877000
ST-899864100
ST-498057300
ST-498255400
ST41099AA010
6MT-18
General Description
41099AA020 ENGINE SUPPORT Used for supporting engine.
398527700 PULLER ASSY Used for removing the extension case oil seal
and the front side retainer bearing outer race.
398177700 INSTALLER Used for assembling the main shaft.
399893600 PLIER Used for removing and installing the neutral
set spring.
Used together with the CLAW (18756AA000).
ST41099AA020
ST-398527700
ST-398643600
ST-398177700
ST-399893600
6MT-19
General Description
18756AA000 CLAW Used for removing and installing the neutral
set spring.
Used together with the PLIER (399893600).
499247400 INSTALLER Used for installing the ball bearing of the transfer
drive gear.
398497701 SEATS Used for installing the ball bearing of the transfer
drive gear.
398437700 INSTALLER Used for installing the front differential side bear-
ing.
18632AA000 STAND ASSY Used for disassembling and assembling the
transmission.
ST18756AA000
ST-499247400
ST-398497701
ST-398437700
ST18632AA000
6MT-20
General Description
18671AA000 OIL SEAL GUIDE Used for installing the oil seal to the reverse
check.
(18657AA010).
18657AA010 INSTALLER Used for installing the oil seal to the reverse
check.
Used together with the OIL SEAL GUIDE
(18671AA000).
18657AA000 INSTALLER Used for installing the oil seal to the shift rod.
18758AA000 PULLER Used for removing the extension taper roller
bearing outer race.
18831AA000 GAUGE Used for measuring the extension taper roller
bearing.
ST18671AA000
ST18657AA010
ST18657AA000
ST18758AA000
ST18831AA000
6MT-21
General Description
18631AA000 HANDLE Used for measuring the front differential back-
lash.
18754AA000 REMOVER Used to remove parts of the driven gear.
18757AA000 STRAIGHT PIN
REMOVER
Used for installing the reverse idler gear.
18665AA000 HOLDER Used for removing and installing the main
shaft lock nut.
Used together with the BASE (18664AA000).
18666AA000 HOLDER Used for removing and installing the driven
shaft lock nut.
ST18631AA000
ST18754AA000
ST18757AA000
ST18665AA000
ST18666AA000
6MT-22
General Description
18667AA000 HOLDER Used for removing and installing the drive pin-
ion shaft lock nut.
18664AA000 BASE Used for removing and installing the main
shaft lock nut.
Used for removing and installing the drive pin-
ion shaft lock nut.
Used for removing and installing the driven
shaft lock nut.
18722AA010 REMOVER Used for disassembling the main shaft.
18651AA000 INSTALLER Used for assembling the main shaft.
18852AA000 TORQUE WRENCH Used to tighten the main shaft lock nut.
Used to tighten the drive pinion shaft lock nut.
Used to tighten the driven shaft lock nut.
ST18667AA000
ST18664AA000
ST18722AA010
ST18651AA000
ST18852AA000
6MT-23
General Description
18668AA000 PUNCH Used to crimp the main shaft lock nut.
18669AA000 PUNCH Used to crimp the driven shaft lock nut.
18670AA000 PUNCH Used to crimp the drive pinion shaft lock nut.
18620AA000 ADAPTER
WRENCH
Used for removing and installing the driven gear
shaft lock nut.
18621AA000 ADAPTER
WRENCH
Used for removing and installing the drive pinion
shaft lock nut.
ST18668AA000
ST18669AA000
ST18670AA000
ST18620AA000
ST18621AA000
6MT-24
General Description
18723AA000 REMOVER Used for disassembling the driven shaft.
18630AA000 WRENCH ASSY Used for removing and installing the differential
side retainer LH.
18672AA000 GUIDE CLIP Used for installing the reverse idler snap ring.
18720AA000 REMOVER Used for disassembling the main shaft.
18654AA000 INSTALLER Used for assembling the driven shaft.
ST18723AA000
ST18630AA000
ST18672AA000
ST18720AA000
ST18654AA000
6MT-25
General Description
18663AA000 SOCKET Used for removing and installing the transfer
bearing holder.
18853AA000 HEIGHT GAUGE Used for selecting the shift rod.
18760AA000 CLAW Used for removing the front side retainer bear-
ing outer race.
Used together with PULLER ASSY
(398527700).
SIDE OIL SEAL
INSTALLER
seal.
28399SA010 OIL SEAL
PROTECTOR
Used for protecting oil seal when installing front
drive shaft.
ST18663AA000
ST18853AA000
ST18760AA000
ST18675AA000
ST28399SA010
6MT-26
General Description
2. GENERAL TOOL
18657AA020 OIL SEAL
INSTALLER
Used for installing the oil seal.
18270KA020 SOCKET (E20) Used for removing and installing the hypoid
driven gear.
TOOL NAME REMARKS
TORX
bit T70 Used for removing and installing transmission gear oil drain
plug.
ST18657AA020
ST18270KA020
6MT-27
2. Transmission Gear Oil
A: INSPECTION
2) Turn the ignition switch to OFF, and wait until the
engine cools.
4) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted in the proper
direction.
5) Pull out the oil level gauge again, and check the
oil level. If it is at the lower level or less, add oil
through the oil level gauge hole to bring the level up
to the upper level.
B: REPLACEMENT
1) Pull out the oil level gauge.
3) Drain transmission gear oil completely.
CAUTION:
Immediately after the engine has been running,
the transmission gear oil is hot. Be careful not
to burn yourself.
NOTE:
Tighten the drain plug of the transmission gear
oil after draining the transmission gear oil.
Be sure to use a new gasket.
Use TORX
bit T70 to remove and install the

drain plug on clutch housing side.
Tightening torque:
Oil pan side
44 Nm (4.5 kgf-m, 32.5 ft-lb)
Clutch housing side
70 Nm (7.1 kgf-m, 51.6 ft-lb)
5) Pour transmission gear oil through the gauge
hole.
Recommended gear oil
Transmission gear oil capacity
4.1 2 (4.3 US qt, 3.6 Imp qt)
6) Check the level of the transmission gear oil.
NOTE:
When inserting the level gauge into the transmis-
sion gear, align the protrusion on the top of the level
gauge with the notch in the gauge hole.
Keep the transmission gear oil level to be be-
tween the range marked on the level gauge.
(A) Oil level gauge
(B) Upper level
(C) Lower level
MT-00449
(A)
(A)
(B)
(C)
MT-01549
(A)
(B)
6MT-28
Oil Seal
3. Oil Seal
A: INSPECTION
Inspect for oil leakage from the oil seal. If there is
any deformation, hardening, wear or other malfunc-
tions of the oil seal, perform the following:
Replace the oil seal.
Inspect the propeller shaft.
B: REPLACEMENT
2) Drain transmission gear oil completely.
NOTE:
Tighten the drain plug after draining the trans-
mission gear oil.
Be sure to use a new gasket.
Use TORX
bit T70 to remove and install the

drain plug on clutch housing side.
Tightening torque:
Oil pan side
44 Nm (4.5 kgf-m, 32.5 ft-lb)
Clutch housing side
70 Nm (7.1 kgf-m, 51.6 ft-lb)
11) Pour in transmission gear oil and check the oil
level. <Ref. to 6MT-27, REPLACEMENT, Trans-
mission Gear Oil.>
MT-01549
(A)
(B)
(A) Oil seal
MT-00451
(A)
ST
MT-00099
6MT-29
4. Differential Side Retainer Oil
Seal
A: INSPECTION
Check that there is no oil leaking from the differen-
tial side retainer oil seal. If there is oil leakage, per-
form the following procedures.
Replace the oil seal.
Check the front drive shaft.
B: REPLACEMENT
2) Remove the front exhaust pipe and center ex-
haust pipe. <Ref. to EX(H4DOTC)-6, REMOVAL,
3) Remove the drain plug and completely drain the
transmission gear oil.
CAUTION:
ning or after idling for a long time, the transmis-
sion gear oil will be hot. Be careful not to burn
yourself.
Be careful not to spill the transmission gear
oil on exhaust pipe to prevent it from emitting
smoke or causing fires. If transmission gear oil
is spilled on the exhaust pipe, wipe it off com-
pletely.
NOTE:
Use TORX
bit T70 to remove the drain plug on

clutch housing side.
4) Tighten the drain plug.
NOTE:
Use a new gasket.
Use TORX
bit T70 to install the drain plug on

clutch housing side.
Tightening torque:
Oil pan side
44 Nm (4.5 kgf-m, 32.5 ft-lb)
Clutch housing side
70 Nm (7.1 kgf-m, 51.6 ft-lb)
Shaft.>
6) Remove the differential side retainer oil seal by
using a flat tip screwdriver or similar tools.
SEAL INSTALLER
8) Apply transmission gear oil to the oil seal lips.
9) Set the ST to the side retainer.
sion.
NOTE:
haust pipe. <Ref. to EX(H4DOTC)-7, INSTALLA-
TION, Front Exhaust Pipe.>
14) Fill with transmission gear oil through the oil
level gauge hole.
Transmission gear oil capacity:
4.1 2 (4.3 US qt, 3.6 Imp qt)
15) Check the level of the transmission gear oil.
<Ref. to 6MT-27, INSPECTION, Transmission
Gear Oil.>
MT-01549
(A)
(B)
6MT-30
5. Transmission Mounting
System
A: REMOVAL
1. PITCHING STOPPER
6) Set the transmission jack under the transmission
body.
CAUTION:
transmission jack.
7) Remove the front and rear crossmembers.
8) Remove the transmission 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, 42.8 ft-lb)
2) Install the intercooler.
cooler.>
1) Install the transmission cushion rubber.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
member.
Tightening torque:
T1: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
T2: 140 Nm (14.3 kgf-m, 103 ft-lb)
haust Pipe.>
MT-01559
MT-01264
MT-01560
T1
T2
MT-01265
T1
T2 T2
T1
6MT-31
C: INSPECTION
Perform the following inspection procedures and
repair or replace faulty parts.
1. PITCHING STOPPER
Check the pitching stopper for bends or damage.
Check that the rubber is not stiff, cracked or other-
wise damaged.
that the cushion rubber is not stiff, cracked, or oth-
erwise damaged.
6MT-32
6. Manual Transmission
Assembly
A: REMOVAL
1) Set the vehicle on a lift. Open the front hood, and
support it with the stay.
NOTE:
Set the hood stay into the specified hole.
6) Disconnect the following harness connectors,
and then remove the engine hanger rear.
7) Disconnect the ground cable on the upper side
of the transmission case and body.
8) Remove the starter assembly. <Ref. to SC(H4SO)-
6, REMOVAL, Starter.>
mission.
NOTE:
Hang the removed operating cylinder with a piece
of wire.
10) Remove the pitching stopper and pitching stop-
per bracket.
11) Set the ST.
ST1 41099AA010 ENGINE SUPPORT BRACKET
ST2 41099AA020 ENGINE SUPPORT
12) Remove the clutch release shaft.
(1) Remove the plug using a hexagon wrench.
(2) Attach a 6 mm (0.24 in) bolt to the release
shaft, and pull out the release shaft.
(3) Lift the release fork, and remove from the
claw of the release bearing. Pull the release
fork to the engine side, and make it so that it
moves freely.
(A) Neutral position switch backup light switch con-
nector
(C) Pitching stopper
MT-01540
(A)
(B)
(C)
MT-01266
MT-01267
CL-00445
MT-01526
ST2
ST1
MT-01524
6MT-33
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
19) Remove the front stabilizer link.
20) Remove the ball joint of front arm from the
housing.
21) Remove the front drive shaft. <Ref. to DS-23,
REMOVAL, Front Drive Shaft.>
22) Set the transmission jack under the transmis-
sion, and remove the front crossmember and rear
crossmember.
23) Move the transmission to the right side of the
vehicle, and remove the joint COMPL, stay bolts
and reverse check cable.
NOTE:
If the transmission is not moved aside, the joint
COMPL and stay bolts may contact the body and
cause damage.
24) Tighten the turnbuckle of the ST to tilt the en-
gine assembly towards the back.
25) Remove the bolts holding the bottom of trans-
mission to the engine, and remove the transmis-
sion from the vehicle.
NOTE:
During removal, be careful not to hit the trans-
mission against the body when pulling towards the
rear.
The clutch pipe and breather pipe may interfere
with each other. Remove carefully.
FS-00117
FS-00106
MT-01264
(A) Joint COMPL bolt
(B) Stay bolt
MT-00886
(C)
(A)
(B)
MT-00463
MT-01090
6MT-34
B: INSTALLATION
1) Set the release fork, release bearing and release
shaft to the transmission. <Ref. to CL-18, INSTAL-
LATION, Release Bearing and Lever.>
2) Replace the front differential side retainer oil
seal.
(1) Remove the oil seal by using flat tip screw-
driver etc.
(2) Apply gear oil to the lip of new oil seals.
(3) Install a new oil seal using ST.
SEAL INSTALLER
NOTE:
Be sure to replace the differential side oil seal after
the procedure of removing front drive shaft from
transmission.
3) Loosen the turnbuckle of ST to return the engine
to its original position.
4) Install the transmission.
NOTE:
Make sure that the main shaft spline is complete-
ly inserted.
Make sure that the rear end of the engine is set
low.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
6) Move the transmission to the right side of the ve-
hicle, and attach the joint COMPL, stay bolts and
reverse check cable.
Tightening torque:
T1: 11.8 Nm (1.2 kgf-m, 8.7 ft-lb)
T2: 32 Nm (3.3 kgf-m, 23.6 ft-lb)
member.
Tightening torque:
T1: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
T2: 140 Nm (14.3 kgf-m, 103 ft-lb)
8) Tighten the bolts which hold the upper side of
the transmission to the engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
MT-01527
MT-00464
MT-00465
(A)
T2
T1
MT-01265
T1
T2 T2
T1
MT-01524
6MT-35
9) Make sure that the release bearing is completely
inserted.
NOTE:
Push the release fork towards the operating cyl-
inder side until a clicking sound is heard. Pull the
release fork towards the engine side. If the release
fork is not in contact with the case, the setting is
complete.
Confirm that the boot cover is set securely.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
12) Install the clutch operating cylinder.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
NOTE:
Check that the clutch hose is routed properly.
13) Install the starter assembly. <Ref. to SC(H4SO)-
6, INSTALLATION, Starter.>
14) Attach the ground cable to the transmission
and body.
15) Connect the following harness connectors,
then attach the engine hanger rear.
16) Set the ST to side retainer.
sion.
NOTE:
MT-00467
MT-01560
T1
T2
CL-00445
(A) Neutral position switch backup light switch
connector
(C) Pitching stopper
MT-01266
MT-01267
MT-01540
(A)
(B)
(C)
6MT-36
19) Install the ball joint of the front arm.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
20) Install the front stabilizer link.
Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
NOTE:
Use a new self-locking nut.
haust Pipe.>
25) Fill the transmission gear oil.
<Ref. to 6MT-27, REPLACEMENT, Transmission
Gear Oil.>
tery.
FS-00106
FS-00117
6MT-37
7. Preparation for Overhaul
A: PROCEDURE
1) Clean oil, grease, dirt and dust from the trans-
mission.
2) Attach the transmission to the ST.
ST 18632AA000 STAND ASSY
3) Apply oil to rotating parts before assembly.
4) When reusing disassembled parts, reinstall in
the original positions and directions.
5) Gaskets, lock washers and lock nuts must be re-
placed with new parts.
6) Apply liquid gasket to the specified areas to pre-
vent leakage.
MT-00468
ST
ST
ST
6MT-38
Air Breather Hose
8. Air Breather Hose
A: REMOVAL
Disconnect the air breather hose.
B: INSTALLATION
Connect the air breather hose.
C: INSPECTION
MT-01091
MT-01091
6MT-39
Back-up Light Switch
9. Back-up Light Switch
A: REMOVAL
2) Disconnect the back-up light switch connector.
3) Disconnect the back-up light switch.
B: INSTALLATION
1) Install the back-up light switch.
NOTE:
Use a new gasket.
Tightening torque:
32 Nm (3.3 kgf-m, 23.6 ft-lb)
2) Connect the back-up light switch connector.
(A) Back-up light switch connector (White)
(B) Neutral position switch connector (Black)
(C) Clip
(A) Back-up light switch
(B) Neutral position switch
MT-00471
(A)
(B)
(C)
(C)
MT-00472
(A)
(B)
(C) Clip
MT-00472
(A)
(B)
MT-00471
(A)
(B)
(C)
(C)
6MT-40
Back-up Light Switch
C: INSPECTION
3) Disconnect the transmission harness and chas-
sis harness.
4) Measure the resistance between the back-up
light switch terminals. If it is not within the specifica-
tion, replace the back-up light switch.
(A) Transmission connector
Gear shift position Terminal No. Standard
Back position
2 and 4
Less than 1
MT-00473
(A)
MT-00474
1 2
3 4
6MT-41
Neutral Position Switch
10.Neutral Position Switch
A: REMOVAL
2) Disconnect the connector and clip of the neutral
position switch.
3) Remove the neutral position switch.
B: INSTALLATION
1) Install the neutral position switch.
NOTE:
Use a new gasket.
Tightening torque:
32 Nm (3.3 kgf-m, 23.6 ft-lb)
2) Connect the connector and clip of the neutral po-
sition switch.
(C) Clip
MT-00471
(A)
(B)
(C)
(C)
MT-00472
(A)
(B)
(C) Clip
MT-00472
(A)
(B)
MT-00471
(A)
(B)
(C)
(C)
6MT-42
Neutral Position Switch
C: INSPECTION
3) Disconnect the transmission harness and chas-
sis harness.
4) Measure the resistance between neutral posi-
tion switch terminals. If not within the standard val-
ues, replace the neutral position switch.
(A) Transmission connector
Gear shift position Terminal No. Standard
Neutral position
1 and 3
1 M or more
Other positions Less than 1
MT-00473
(A)
MT-01089
1 2
3 4
6MT-43
Extension Case
11.Extension Case
A: REMOVAL
2) Prepare the transmission for overhaul. <Ref. to
6MT-37, Preparation for Overhaul.>
4) Remove any remaining liquid gasket from the
extension case and transmission case.
B: INSTALLATION
1) Select the thrust washer of the transfer driven
gear, and attach to the extension case. <Ref. to
6MT-45, ADJUSTMENT, Extension Case.>
2) Apply a thin coat of oil to the outer surface of the
bearing cone, and attach to the extension case.
3) Select the thrust washer of the transfer drive
gear, and attach to the center differential.
4) Apply liquid gasket to the transmission case.
Liquid gasket:
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
C: DISASSEMBLY
1) Remove the transfer drive gear. <Ref. to 6MT-
53, REMOVAL, Transfer Drive Gear.>
2) Remove the oil guide.
3) Remove the shift bracket.
MT-00475
MT-00476
MT-00475
MT-00477
MT-00478
6MT-44
Extension Case
4) Remove the bearing cone using the ST.
ST 18758AA000 PULLER
5) Remove the thrust washer and oil plate.
6) Remove the shifter arm oil seal.
7) Remove the reverse check system. <Ref. to 6MT-
50, REMOVAL, Reverse Check System.>
8) Remove the extension oil seal. <Ref. to 6MT-28,
REPLACEMENT, Oil Seal.>
D: ASSEMBLY
1) Install the reverse check system. <Ref. to 6MT-
51, INSTALLATION, Reverse Check System.>
2) Install the extension case oil seal. <Ref. to 6MT-
28, REPLACEMENT, Oil Seal.>
3) Install a shifter arm oil seal using the ST.
ST1 18657AA000 INSTALLER
ST2 18671AA000 OIL SEAL GUIDE
4) Install the oil plate.
5) Select the thrust washer of the bearing, and at-
tach to the extension case. <Ref. to 6MT-45, AD-
JUSTMENT, Extension Case.>
6) Apply a thin coat of oil to the outer surface of the
bearing cone, and attach to the extension case.
7) Install the shift bracket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
8) Attach the oil guide and the transfer driven gear.
<Ref. to 6MT-53, INSTALLATION, Transfer Drive
Gear.>
(A) Bearing cone
(A) Thrust washer
(B) Oil plate
(A) Oil seal
MT-00479
(A)
ST
MT-00480
(A)
(B)
MT-00481
(A)
(A) Oil seal
MT-00482
(A)
ST1
ST2
MT-00483
MT-00478
6MT-45
Extension Case
E: INSPECTION
1) Check to make sure there is no damage or
cracks on the extension case. If damage or crack-
ing is found, replace the extension case.
2) Inspect for oil leaks at the extension case and
transmission case oil seals and mating surfaces. If
there are oil leaks, replace the oil seal and liquid
gasket.
F: ADJUSTMENT
1. TRANSFER DRIVEN GEAR BEARING
THRUST WASHER ADJUSTMENT
1) Remove the bearing cone from the extension
case using the ST.
2) Remove the thrust washer.
3) Measure depth Z between the extension case
end area and bearing cone contact area.
ST 398643600 GAUGE
NOTE:
When measuring depth Z, subtract the thickness of
the ST [15 mm (0.59 in)] from the measured value.
5) Remove the center differential. <Ref. to 6MT-57,
REMOVAL, Center Differential.>
6) Remove the oil guides G and H.
(A) Bearing cone
MT-00479
(A)
ST
(A) 15 mm (0.59 in)
MT-00484
(A)
Z
ST
ST
MT-01617
6MT-46
Extension Case
7) Remove the snap ring and flat washer from the
selector arm area.
8) Using an ST, remove the neutral set spring and
support.
ST1 18756AA000 CLAW
ST2 399893600 PLIER
9) Lift the striking rod, and remove the spring pin.
10) Remove the selector arm No. 2 and the shifter arm.
11) Attach the bearing cone to the transfer driven
gear.
12) Set the ST.
ST 18831AA000 GAUGE
13) Turn the transfer driven gear 10 or more times
to seat the bearing properly.
(A) Snap ring
(B) Flat washer
(A) Striking rod
(B) Spring pin
MT-01616
(B)
(A)
MT-01092
ST2
ST1
MT-01307
(A)
(B)
(A) Selector arm No. 2
(B) Shifter arm
(B)
(A)
MT-01618
MT-00489
ST
6MT-47
Extension Case
14) Measure depth Y between the end of the ST
and the bearing cone.
ST 18831AA000 GAUGE
15) Using the following calculation, calculate the
transfer driven gear bearing thrust washer value t.
t = Z (100 Y) {0.04 0.11 mm (0.0016
0.0043 in)}
16) Refer to the calculated value t to select the
closest thrust washer from the following table.
Standard clearance between the thrust washer
and taper roller bearing
0.04 0.11 mm (0.0016 0.0043 in)
17) Install the selector arm No. 2 and the shifter
arm.
18) Install a new spring pin.
t
mm (in)
Transfer driven gear bearing thrust
washer thickness
Y
mm (in)
Depth between the end of the ST
and the bearing cone.
Z
mm (in)
Depth between the end of the
extension case and the bearing
cone contact area.
0.04 0.11 mm
(0.0016 0.0043 in)
Standard clearance between the
thrust washer and taper roller bear-
ing
100 mm
(3.94 in)
Height of ST
MT-00490
Y
ST
Part No. Thickness t mm (in)
803050060 0.50 (0.0197)
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256)
803050064 0.70 (0.0276)
803050065 0.75 (0.0295)
803050066 0.80 (0.0315)
803050067 0.85 (0.0335)
803050068 0.90 (0.0354)
803050069 0.95 (0.0374)
803050070 1.00 (0.0394)
803050071 1.05 (0.0413)
803050072 1.10 (0.0433)
803050073 1.15 (0.0453)
803050074 1.20 (0.0472)
803050075 1.25 (0.0492)
803050076 1.30 (0.0512)
803050077 1.35 (0.0531)
803050078 1.40 (0.0551)
803050079 1.45 (0.0570)
(B) Shifter arm
(B)
(A)
MT-01618
6MT-48
Extension Case
19) Using the ST, install the neutral set spring and
support.
ST1 18756AA000 CLAW
ST2 399893600 PLIER
20) Install the flat washer and snap ring to the se-
lector arm area.
21) Install the center differential. <Ref. to 6MT-57,
INSTALLATION, Center Differential.>
2. TRANSFER DRIVE GEAR THRUST
WASHER SELECTION
1) Measure height Z between the transmission
case end area and ST.
ST 398643600 GAUGE
2) Measure depth Y between the end of the ST
and the transfer drive gear.
ST 398643600 GAUGE
(A) Snap ring
(B) Flat washer
MT-01092
ST2
ST1
MT-01616
(B)
(A)
MT-00492
Z
ST
MT-00493
Y
ST
ST
6MT-49
Extension Case
transfer drive gear thrust washer value t.
t = {Y 15 mm (0.59 in)} {Z 15 mm (0.59 in)}
0.45 0.65 mm (0.018 0.026 in)
4) Refer to the calculated value t to select the
closest thrust washer from the following table.
Standard clearance between the thrust washer
and transfer drive gear
0.45 0.65 mm (0.018 0.026 in)
5) Install the selected thrust washer.
t
mm (in)
Transfer drive gear thrust washer
thickness
Y
mm (in)
Depth between the end of the ST
and the transfer drive gear
Z
mm (in)
Height from the end of the transmis-
sion case to the end of the ST.
0.45 0.65 mm
(0.018 0.026 in)
Standard clearance between the
thrust washer and transfer drive
gear
15 mm (0.591 in) Thickness of ST
Thrust washer (36.3 52 t)
803036070 0.80 (0.0315)
803036071 0.95 (0.0374)
803036072 1.10 (0.0433)
803036073 1.25 (0.0492)
803036074 1.40 (0.0551)
803036075 0.65 (0.0256)
6MT-50
Reverse Check System
12.Reverse Check System
A: REMOVAL
3) Remove the extension case. <Ref. to 6MT-43,
4) Remove the snap ring and washer from the re-
verse check shaft.
5) Remove the reverse check shaft and spring from
the extension case.
6) Remove the spring pin, and remove the reverse
check lever and oil seal from the reverse check
shaft.
NOTE:
Do not reuse the oil seal.
7) Remove the plug from the extension case, and
remove the gasket, spring and plunger.
NOTE:
Do not reuse the gasket.
8) Remove the reverse lock plunger.
(A) Snap ring
(B) Washer
MT-00494
(A)
(B)
MT-00495
(A) Spring pin
(B) Reverse check lever
(C) Oil seal
(A) Plug
(B) Gasket
(C) Spring
(D) Plunger
(A) Reverse lock plunger
MT-00496
(A)
(C)
(B)
MT-00497
(A)
(B)
(C)
(D)
MT-00498
(A)
6MT-51
B: INSTALLATION
1) Insert the reverse lock plunger.
2) Install the reverse check plug, spring, gasket,
and plug in order.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
3) Install the spring and reverse check shaft to the
extension case.
NOTE:
Confirm that the end of the spring matches the hole
of the reverse check shaft and the cut out of the ex-
tension case.
5) Attach ST1 to the reverse check shaft. Install the
new oil seal, and push it in using ST2.
ST1 18671AA000 OIL SEAL GUIDE
6) Insert the reverse check lever, and turn the re-
verse check shaft until the plunger is pushed in
first.
(A) Plug
(B) Gasket
(C) Spring
(D) Reverse check plug
(A) Reverse check shaft
(B) Spring
(C) Hole
(D) Cut out
MT-00497
(A)
(B)
(C)
(D)
(A)
(A)
(C)
(D)
(B)
(B)
MT-00499
(A) Snap ring
(B) Washer
(A) Oil seal
(A) Plunger
(B) Reverse check shaft
MT-00494
(A)
(B)
MT-00500
(A)
ST2
ST1
MT-00501
(A)
(B)
6MT-52
7) Match the hole of the reverse check lever and
the reverse check shaft, and attach the spring pin.
8) Check that the reverse check is operating cor-
rectly. <Ref. to 6MT-52, INSPECTION, Reverse
Check System.>
9) Install the extension case. <Ref. to 6MT-43, IN-
C: INSPECTION
1) Check that there is no damage on any parts.
2) Check that the reverse check lever is operating
smoothly.
3) Inspect that there is no oil leak at the oil seal sec-
tion of the reverse check shaft. If there is oil leak-
age, replace the oil seal.
4) Check the operation of the reverse check.
(1) When the reverse check lever is in the fol-
lowing position, the plunger is pressed, or the
gear can shift into reverse.
(2) When the reverse check lever is in the fol-
lowing position, the plunger is not pressed, or
the gear cannot shift into reverse.
5) If it is not as specified, reassemble the reverse
check system.
(A) Reverse check shaft
(B) Reverse check lever
(C) Hole
MT-00502
(A) (B)
(C)
MT-00503
MT-00504
6MT-53
Transfer Drive Gear
13.Transfer Drive Gear
A: REMOVAL
4) Remove the transfer drive gear.
B: INSTALLATION
1) Install the transfer drive gear.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
2) When the ball bearing, transfer drive gear or
snap ring are replaced, select an appropriate thrust
washer for the transfer drive gear. <Ref. to 6MT-44,
ASSEMBLY, Extension Case.>
C: DISASSEMBLY
2) Remove the bearing using the ST.
ST 499877000 RACE 4-5 INSTALLER
NOTE:
Do not reuse the ball bearing.
MT-00505
MT-00505
MT-00506
MT-00507
ST
6MT-54
Transfer Drive Gear
D: ASSEMBLY
1) Using the ST, install the ball bearing.
ST2 398497701 SEATS
3) Inspect the clearance between the snap ring and
the ball bearing. <Ref. to 6MT-54, INSPECTION,
Transfer Drive Gear.>
E: INSPECTION
1) Bearing
Breakage or rusting of the bearing
Wear and damage
The bearing does not rotate smoothly or an ab-
normal noise is emitted.
2) Drive gear
Replace the drive gear in the following cases.
The drive gear tooth surface and shaft are ex-
cessively broken or damaged.
3) Measure the clearance between the snap ring
and ball bearing inner race with a thickness gauge.
Standard clearance between the snap ring
and inner race:
0 0.15 mm (0 0.0059 in)
4) If the measurement is not within specification,
select a suitable snap ring.
After replacing the snap ring, reinspect the clear-
ance.
MT-00508
ST2
ST1
MT-00506
Thrust washer
805045050 1.76 (0.069)
805045060 1.88 (0.074)
805045070 2.00 (0.079)
MT-00509
6MT-55
14.Transfer Driven Gear
A: REMOVAL
B: INSTALLATION
2) When the bearing or the transfer driven gear is
replaced, select an appropriate thrust washer for
the transfer driven gear. <Ref. to 6MT-45, AD-
JUSTMENT, Extension Case.>
C: DISASSEMBLY
(transmission case side).
MT-00510
MT-00510
MT-00511
ST
MT-00512
ST2
ST1
6MT-56
D: ASSEMBLY
CAUTION:
Do not apply pressure in excess of 10 kN
(transmission case side).
CAUTION:
E: INSPECTION
1) Bearing
Breakage or rusting of the bearing
Wear and damage
After applying transmission gear oil, bearing
does not rotate smoothly or an abnormal noise is
emitted.
2) Driven gear
Replace the driven gear in the following cases.
The driven gear tooth surface and shaft are ex-
cessively broken or damaged.
(A) Roller bearing
(A) Roller bearing
MT-00513
(A)
ST1
ST2
MT-00514
(A)
ST
6MT-57
Center Differential
A: REMOVAL
1) Remove the manual transmission case from the
vehicle. <Ref. to 6MT-32, REMOVAL, Manual
4) Remove the thrust washer and center differen-
tial.
6) Remove the needle bearing.
B: INSTALLATION
1) Install the needle bearing.
3) Install the thrust washer and center differential.
4) When replacing the center differential, select
and install the appropriate transfer drive gear and
thrust washer. <Ref. to 6MT-45, ADJUSTMENT,
Extension Case.>
6) Install the manual transmission case assembly
to the vehicle. <Ref. to 6MT-34, INSTALLATION,
C: INSPECTION
Check that there is no damage on the center differ-
ential. Replace if damaged.
(A) Thrust washer
(B) Center differential
MT-00515
(A)
(B)
MT-00516
(A) Thrust washer
(B) Center differential
MT-00516
MT-00515
(A)
(B)
6MT-58
Transmission Case
16.Transmission Case
A: REMOVAL
3) Remove the neutral position switch, back-up
light switch and harness. <Ref. to 6MT-41, RE-
MOVAL, Neutral Position Switch.> <Ref. to 6MT-
39, REMOVAL, Back-up Light Switch.>
7) Remove the oil guides G and H.
8) Remove the snap ring and flat washer from the
selector arm area.
9) Using an ST, remove the neutral set spring and
support.
ST1 18756AA000 CLAW
ST2 399893600 PLIER
10) Lift the striking rod, and remove the spring pin.
11) Remove the selector arm No. 2 and the shifter
arm.
(A) Snap ring
(B) Flat washer
MT-01617
MT-01616
(B)
(A)
(A) Striking rod
(B) Spring pin
(B) Shifter arm
MT-01092
ST2
ST1
MT-01307
(A)
(B)
(B)
(A)
MT-01618
6MT-59
Transmission Case
12) Remove the transfer bearing holder.
NOTE:
Using a general tool may cause damage. Remove
the bolt using the ST.
ST 18663AA000 SOCKET
13) Remove the thrust washer on the main shaft
section.
14) Remove the driven gear assembly shim and
spacer.
16) Remove the pilot bolt.
17) Remove the holder reverse bolt.
18) Remove the transmission case.
NOTE:
If the oil guide is caught between the shift fork, it
may be difficult to remove the transmission case.
Move the oil guide, then remove. Do not pull on the
transmission case with excessive force.
transmission case and adapter plate.
(A) Driven gear ASSY
MT-01619
(A)
MT-00526
MT-00527
MT-00528
MT-00529
MT-00530
6MT-60
Transmission Case
B: INSTALLATION
1) Check that the shifter fork and the interlock block
are both shifted into the neutral position. If they are
not, shift into the neutral position.
2) Apply liquid gasket to the adapter plate.
Liquid gasket:
3) Install the transmission case.
4) By inspecting from the pilot bolt attachment hole,
check that the interlock block and the reverse inter-
lock block are aligned to the neutral position. If not
aligned, remove the transmission case, and shift
the shifter fork and interlock block to the neutral po-
sition.
5) Use a new gasket to temporarily attach the pilot
bolt.
6) Affix the transmission case with the bolts and
nuts.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
7) Tighten the pilot bolt.
Tightening torque:
34 Nm (3.5 kgf-m, 25.1 ft-lb)
8) Tighten the holder reverse bolt.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
(A) Striking rod
(B) Reverse interlock block
(C) Interlock block
(A)
(C)
MT-01620
(B)
MT-00532
(A) Interlock block
(B) Reverse interlock block
MT-00533
(A)
(B)
6MT-61
Transmission Case
9) Install the snap ring, washer and collar of the
driven gear assembly.
10) Attach the thrust washer to the main shaft.
11) Install the transfer bearing holder.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
ST 18663AA000 SOCKET
12) When replacing the transfer bearing holder, se-
lect the appropriate transfer driven gear and thrust
washer, and install to the extension case. <Ref. to
6MT-45, ADJUSTMENT, Extension Case.>
13) Install the selector arm No. 2 and the shifter arm.
15) Using the ST, install the neutral set spring.
ST1 18756AA000 CLAW
ST2 399893600 PLIER
(A) Washer
(B) Snap ring
(C) Collar
(D) Washer
(C)
(B)
(A)
(C)
(B)
(D)
(A)
MT-01621
MT-01619
(B) Shifter arm
(B)
(A)
MT-01618
MT-01092
ST2
ST1
6MT-62
Transmission Case
16) Install the snap ring and flat washer to the se-
lector arm area.
17) Install the oil guides G and H.
19) Install the transfer driven gear. <Ref. to 6MT-
55, INSTALLATION, Transfer Driven Gear.>
21) Install the neutral position switch, back-up light
switch and harness. <Ref. to 6MT-41, INSTALLA-
TION, Neutral Position Switch.> <Ref. to 6MT-39,
INSTALLATION, Back-up Light Switch.>
C: DISASSEMBLY
1) Remove the oil guides C, D, E and F.
2) Remove the harness bracket.
transmission case and oil pan.
(A) Snap ring
(B) Flat washer
MT-01616
(B)
(A)
MT-01617
(A) Oil guide C
(B) Oil guide D
(C) Oil guide E
(D) Oil guide F
(A)
(B)
(C)
(D)
T
MT-01622
MT-00538
MT-00539
6MT-63
Transmission Case
D: ASSEMBLY
1) Apply liquid gasket to the oil pan.
Liquid gasket:
2) Install the oil pan.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
3) Install the relief valve, relief valve spring and a
new O-ring.
4) Install the ball, valve spring and a new O-ring.
Tightening torque:
T1: 13 Nm (1.3 kgf-m, 9.6 ft-lb)
T2: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
5) Install the oil guides C, D, E and F.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
E: INSPECTION
1) If the sludge is accumulated in the oil pan, use a
waste cloth to wipe it off completely.
2) Check that there is no damage on any parts. Re-
place damaged parts with new parts.
(A) Harness bracket
MT-00541
MT-00539
MT-01629
(A)
T2
T1
T1
(A) Oil guide C
(B) Oil guide D
(C) Oil guide E
(D) Oil guide F
(A)
(B)
(C)
(D)
T
MT-01622
6MT-64
Main Shaft Assembly
17.Main Shaft Assembly
A: REMOVAL
MOVAL, Neutral Position Switch.>, <Ref. to 6MT-
8) Remove the striking rod.
9) Remove the oil guide B.
10) Use a screw driver to shift to the 4th gear posi-
tion.
11) Remove the reverse idler holder.
12) Remove the check plug, O-ring, check spring,
plunger and check ball from the adapter plate.
NOTE:
Do not reuse the O-ring.
(A) 3rd-4th shift rod
MT-01623
MT-00543
(A)
(A) Reverse idler holder
(A) Check plug
(B) O-ring
(C) Check spring
(D) Plunger
(E) Check ball
MT-00544
(A)
(D)
(E)
(A)
(A)
(B)
(B) (C)
(C)
MT-00545
6MT-65
Main Shaft Assembly
13) Remove the bolt and gasket holding the re-
verse idler shaft.
14) Push the main shaft assembly, driven gear as-
sembly, reverse idler gear and shifter forks to re-
move from the adapter plate all at once.
NOTE:
B: INSTALLATION
1) Adjust the 3rd-4th and 5th-6th shifter fork rods.
<Ref. to 6MT-112, ADJUSTMENT, Shifter Fork
and Rod.>
2) Turn the sub gear counterclockwise for approxi-
mately 3 teeth. Match the sub gear and reverse
idler gear holes, and insert the ST.
ST 18757AA000 STRAIGHT PIN
3) Attach the driven gear assembly to the 1st-2nd
shifter fork assembly.
4) Attach the main shaft assembly to the 3rd-4th
shifter fork, and assemble to the driven gear as-
sembly.
(A) Sub gear
(B) Reverse idler gear
MT-00546
MT-00547
(A)
(B)
ST
(A) 1st-2nd shifter fork
(B) Driven gear ASSY
(C) 1st-2nd sleeve
(A) 3rd-4th shifter fork
(B) 3rd-4th sleeve
(C) Driven gear ASSY
(D) Main shaft ASSY
MT-00548
(A)
(B)
(C)
MT-00549
(C)
(A)
(B)
(C)
(D)
(D)
(A)
(B)
6MT-66
Main Shaft Assembly
5) Attach the 5th-6th shifter fork assembly to the
main shaft assembly.
6) Attach the reverse shifter fork assembly to the
reverse idler gear assembly.
7) Install the reverse idler gear assembly.
8) Install the thrust bearing of the driven gear as-
sembly.
9) Push on the shifter forks, main shaft assembly,
driven gear assembly and reverse idler gear as-
semblies, to attach to the adapter plate all at once.
NOTE:
10) Install the plunger, check spring, new O-ring
and check plug.
Tightening torque:
37 Nm (3.8 kgf-m, 27.3 ft-lb)
(A) 5th-6th shifter fork
(B) 5th-6th sleeve
(C) Main shaft ASSY
(A) Reverse idler gear ASSY
(B) Reverse shifter fork
(C) Reverse sleeve
(A) Reverse idler gear ASSY
(B) 1st drive gear
(C) Reverse gear
MT-00550
(B)
(A)
(C)
MT-00551
(A)
(B)
(C)
MT-00552
(B)
(A)
(C)
(A) Check plug
(B) O-ring
(C) Check spring
(D) Plunger
MT-00553
(D)
(A)
(B)
(C)
6MT-67
Main Shaft Assembly
11) Install the check ball, check spring, new O-ring
and check plug.
Tightening torque:
37 Nm (3.8 kgf-m, 27.3 ft-lb)
12) Install a bolt and a new gasket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
13) Use a screw driver to shift to the 4th gear posi-
tion.
14) Install the reverse idler holder.
15) Install the oil guide B.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
16) Install the striking rod.
18) Install the selected main shaft snap ring and
washers.
TION, Neutral Position Switch.>, <Ref. to 6MT-39,
(A) Check plug
(B) O-ring
(C) Check spring
(D) Check ball
MT-00554
(D)
(A)
(B)
(C)
MT-00546
(A) Reverse idler holder
MT-00544
(A)
MT-01623
6MT-68
Main Shaft Assembly
C: DISASSEMBLY
NOTE:
Individual sleeves and hubs meet at a specified po-
sition. Before disassembly, mark the meeting posi-
tion of the sleeve and hub.
1) Affix the ST to the work table.
ST 18664AA000 BASE
2) Flatten the tab of the axle nut.
3) Set the main shaft assembly to the ST, and re-
move the lock nut and washer.
ST2 18664AA000 BASE
NOTE:
Use a 38 mm socket wrench.
4) Remove the main shaft assembly from the ST.
5) Set the ST1 to the 6th drive gear, and use a press
to remove the taper roller bearing, bushing and 6th
drive gear.
ST1 18722AA010 REMOVER
6) Remove the 5th-6th sleeve, 6th needle bearing
and 6th baulk ring.
MT-00556
ST2
ST1
(A) Taper roller bearing
(B) Bushing
(C) 6th drive gear
(A) Needle bearing
(B) 6th baulk ring
(C) 5th-6th sleeve
MT-00557
(A)
(B) (C)
ST1
ST2
ST1
(A)
(B)
(C)
MT-00558
6MT-69
Main Shaft Assembly
7) Set the ST to the 3rd drive gear, and use a press
to remove individual parts.
D: ASSEMBLY
NOTE:
When replacing the following parts, replace as a
set.
Sleeve and hub
Outer baulk ring, 3rd synchro cone and inner
baulk ring
Taper roller bearing
1) Apply adequate transmission gear oil to the main
shaft, 3rd needle bearing and 3rd drive gear inner
surface.
2) Install the 3rd needle bearing and 3rd drive gear
to the main shaft.
3) Install the inner baulk ring, 3rd synchro cone and
outer baulk ring.
NOTE:
Install the 3rd synchro cone by aligning the protru-
sion of the 3rd synchro cone with the hole on the
3rd drive gear.
(A) 3rd drive gear
(B) 3rd-4th sleeve
(A) 3rd needle bearing
(B) 3rd drive gear
(A)
ST
(B)
(B)
ST
MT-01406
MT-00560
(A)
(B)
(A) Inner baulk ring
(B) Outer baulk ring
(A)
(B)
MT-00561
MT-01501
6MT-70
Main Shaft Assembly
4) Install the 3rd-4th hub and 4th bushing.
(1) Being careful of the install direction of the
3rd-4th hub, set to the main shaft.
(2) Being careful not to cover the oil holes of the
main shaft and 4th bushing, attach to the main
shaft.
(3) Using the ST, push in to the 3rd-4th hub and
4th bushing all at once.
CAUTION:
(4.0 ton, 4.4 US ton, 3.9 Imp ton).
NOTE:
When pushing into the 3rd-4th hub and 4th bush-
ing, move the outer baulk ring to match the protru-
sion of the outer baulk ring and the cut out on the
3rd-4th bushing.
5) Make sure that the 3rd drive gear can be turned
smoothly by hand. If it does not turn smoothly, re-
assemble.
(A) Main shaft
(B) 3rd-4th hub
(C) 3rd drive gear
(A) 4th bushing
(B) 3rd-4th hub
(C) 4th bushing oil hole
(D) Main shaft oil hole
MT-00884
(A)
(B)
(C)
MT-00885
(A)
(B)
A
(D)
(C)
A
(C)
(C)
(D)
A - A
(A)
(A) 3rd-4th hub
(C) Cut out on the 3rd-4th hub
(D) Protrusion of the outer baulk ring
(E) 4th bushing
MT-00555
(D)
(C)
(A)
(E)
(E)
(A)
(B)
ST1
ST2
6MT-71
Main Shaft Assembly
6) Attach the 3rd-4th shifting insert key at the ap-
propriate position of the 3rd-4th sleeve.
NOTE:
The angle of each shifting insert key is 120.
Refer to the following figure to install the shifting
insert key.
7) Attach the 3rd-4th sleeve to the 3rd-4th hub.
NOTE:
There is an identification groove on the 3rd-4th
sleeve.
Place the groove towards the 3rd drive gear, and
attach the 3rd-4th sleeve.
8) Install the 4th baulk ring.
shaft, 4th needle bearing and 4th drive gear inner
surface.
10) Install the 4th needle bearing and 4th drive
gear.
(A) Attach the straight part of the shifting insert key
to the sleeve convex portion.
(B) Shifting insert key
(C) 3rd-4th sleeve
(D) 3rd-4th shifting insert key
(A) 3rd drive gear
(B) 3rd-4th sleeve identification groove (1)
(D)
(C)
MT-01641
(A)
(B)
( A )
MT-00563
(A)
(B)
(A) 4th needle bearing
(B) 4th drive gear
MT-00564
MT-00565
(A)
(B)
6MT-72
Main Shaft Assembly
11) Install the 5th bushing.
(1) Being careful not to cover the oil holes of the
main shaft and 5th bushing, attach to the main
shaft.
(2) Using the ST, push into the 5th bushing.
CAUTION:
12) Make sure that the 4th drive gear can be turned
assemble.
13) Apply adequate transmission gear oil to the
main shaft, 5th needle bearing and 5th drive gear
inner surface.
14) Install the 5th needle bearing and 5th drive
gear.
(A) 5th bushing
(B) Main shaft oil hole
(C) Main shaft
(D) 5th bushing oil hole
(E) 4th drive gear
MT-00566
(C)
(A)
A - A
(C)
(B)
(A)
A
(D)
(C)
(E)
(B)
A
MT-00567
ST1
ST2
(A) 5th needle bearing
(B) 5th drive gear
MT-00568
(A)
(B)
MT-00569
6MT-73
Main Shaft Assembly
16) Install the 5th-6th hub.
(1) Being careful of the install direction of the
5th-6th hub, set to the main shaft.
(2) Using the ST, push into the 5th-6th hub.
CAUTION:
NOTE:
When pushing into the 5th-6th hub, move the outer
baulk ring to match the protrusion of the outer baulk
ring and the cut out on the 5th-6th bushing.
assemble.
18) Attach the 5th-6th shifting insert key at the ap-
propriate position of the 5th-6th sleeve.
NOTE:
insert key.
(A) Main shaft
(B) 5th-6th hub
(C) 5th drive gear
(A) 5th-6th hub
(C) Cut out on the 5th-6th hub
MT-00570
(A)
(B)
(C)
MT-00571
(D)
(C)
(B)
(A)
(A)
ST1
ST2
(C) 5th-6th sleeve
(D) Shifting insert key
(D)
(C)
MT-01641
(A)
(B)
( A )
6MT-74
Main Shaft Assembly
19) Attach the 5th-6th sleeve to the 5th-6th hub.
NOTE:
There are 2 identification grooves on the 5th-6th
sleeve.
Place the grooves towards the 5th drive gear,
and attach the 5th-6th sleeve.
main shaft, 6th needle bearing and 6th drive gear
inner surface.
22) Install the 6th drive gear.
23) Install the 6th needle bearing.
24) Being careful not to cover the oil holes of the
6th bushing and the main shaft, set the 6th bushing
to the main shaft.
25) Using the ST, install the 6th bushing.
CAUTION:
assemble.
(A) 5th drive gear
(B) 5th-6th sleeve identification groove (2)
MT-00572
(A)
(B)
MT-00573
MT-00574
(A) 6th bushing oil hole
(B) Main shaft oil hole
MT-00575
MT-00576
(A)
(A)
(B)
MT-00577
ST1
ST2
6MT-75
Main Shaft Assembly
27) Using the ST, install the inner bearing of the
taper roller bearing.
CAUTION:
28) Using the ST, install the outer race and the out-
er bearing of the taper roller bearing.
CAUTION:
NOTE:
Confirm that the outer race is installed in the
proper direction.
Push in until there is no backlash on the outer
race and the bearing turns smoothly by hand.
29) Make sure that the taper roller bearing turns
smoothly by hand. If it does not rotate smoothly, re-
place the taper roller bearing as a set, and reas-
semble.
30) Attach the lock washer and a new lock nut.
31) Set the main shaft assembly to the ST, and
tighten the lock nut.
ST2 18664AA000 BASE
Tightening torque:
392 Nm (40.0 kgf-m, 289 ft-lb)
32) Using the ST, crimp the lock nut in 4 locations,
with dimensions within A 270.3 mm (1.060.01 in).
ST 18668AA000 PUNCH
NOTE:
Do not damage the crimp area of the lock nut.
(A) Outer race
(B) Outer bearing of the taper roller bearing
MT-00578
ST1
ST2
MT-00579
(B)
(A)
(A)
ST2
ST1
MT-00556
ST2
ST1
MT-00580
A
A
ST
6MT-76
Main Shaft Assembly
E: INSPECTION
1) Bearing
Wear, rusting or damage of the bearings
normal noise is emitted when turning.
The bearing has other defects.
The sliding surface is damaged or abnormally
worn.
3) Gear
The gear teeth surface is damaged or excessive-
ly worn.
The contact area of the baulk ring is damaged.
The inner face of the gear is worn.
4) Baulk ring, synchro cone
Replace the baulk ring and synchro cone in the fol-
lowing cases.
Wear, rusting or damage of the baulk ring
Replace the shifting insert key if deformed, exces-
sively worn or defective in any way.
F: ADJUSTMENT
1. MAIN SHAFT SNAP RING
& WASHER SELECTION
NOTE:
In the following conditions, perform the procedures
below.
Replacing driven gears 1st through 6th
Replacing the 1st and 2nd synchro ring assem-
bly
Replacing the ball bearing
Replacing the adapter plate
Replacing the driven shaft
1) Insert the drive pinion assembly into the adapter
plate.
NOTE:
Confirm that the thrust bearing outer race has not
been removed and the drive pinion is not lifted.
2) Set the height gauge to the adapter plate. Lower
the height gauge indicator to the mating surface of
the adapter plate and case, and set to 0 points.
ST 18853AA000 HEIGHT GAUGE
NOTE:
The adapter plate will be the base point for the
measurement. Use a scraper to remove any gasket
material remaining on the end face.
During measurement, do not place the height
gauge in the shaded area shown in the figure.
MT-00581
MT-00582
ST
MT-00583
6MT-77
Main Shaft Assembly
3) Measure the height to the ball bearing end face
(height H).
NOTE:
Set the height gauge indicator near the measure-
ment target, and lock dial (1) as shown in the figure.
Turn dial (2), and set the indicator to the end face of
the bearing.
Turn approximately 120 at a time, and measure
the ball bearing in 5 locations. Round off the 2 high-
est and 2 lowest measurement values. The remain-
ing center value is used as the measurement value.
4) According to the measurement value, select the
snap ring and washer from the following table.
Snap ring
Washer
(A) Ball bearing
(A)
MT-00955
H
MT-00585
(2)
(1)
H: mm (in) Part No. Thickness: mm (in)
270.83 271.40
(10.66 10.69)
805072010
1.65
(0.065)
271.41 271.98
(10.69 10.71)
805072011
1.95
(0.077)
271.99 272.56
(10.71 10.73)
805072012
2.25
(0.089)
H: mm (in) Part No. Thickness: mm (in)
270.83 271.40
(10.66 10.69)
803067012
1.6
(0.063)
271.41 271.98
(10.69 10.71)
803067011
1.3
(0.051)
271.99 272.56
(10.71 10.73)
803067010
1.0
(0.039)
6MT-78
Driven Gear Assembly
18.Driven Gear Assembly
A: REMOVAL
8) Remove the driven gear assembly. <Ref. to
6MT-64, REMOVAL, Main Shaft Assembly.>
9) Remove the 1st needle bearing.
10) Remove the thrust needle bearing.
B: INSTALLATION
1) Adjust the main shaft snap ring. <Ref. to 6MT-
76, ADJUSTMENT, Main Shaft Assembly.>
2) Adjust the 1st-2nd shifter rod. <Ref. to 6MT-112,
ADJUSTMENT, Shifter Fork and Rod.>
3) Install the thrust needle bearing.
NOTE:
Confirm that the thrust needle bearing is installed in
the proper direction.
4) Install the 1st needle bearing.
5) Install the driven gear assembly. <Ref. to 6MT-
65, INSTALLATION, Main Shaft Assembly.>
7) Adjust the backlash of the driven gear assembly
in the axial direction. <Ref. to 6MT-86, ADJUST-
MENT, Driven Gear Assembly.>
MT-00586
MT-00587
6MT-79
C: DISASSEMBLY
NOTE:
Individual sleeves and hubs meet at a specified po-
ST 18664AA000 BASE
3) Attach ST3 to the lock nut, set the driven gear
assembly to the ST, and remove the lock nut and
washer.
ST2 18664AA000 BASE
ST3 18620AA000 ADAPTER WRENCH
4) Attach ST1 to the 6th gear, then remove the ball
bearing and 5th-6th driven gear.
5) Attach ST1 to the 4th gear, then remove the 3rd-
4th driven gear.
6) Remove the driven gear key.
7) Remove the 2nd gear.
8) Remove the needle bearing and 1st-2nd sleeve. (A) Ball bearing
(B) 5th-6th driven gear
MT-00588
ST3 ST2
ST1
MT-01480
(A)
(B)
ST2
ST1
(A) 3rd-4th driven gear
(A) Needle bearing
(B) 1st-2nd sleeve
MT-01481
(A)
ST2
ST1
MT-00590
MT-00591
MT-00592
(A)
(B)
6MT-80
9) Remove the outer baulk ring, 2nd synchro cone
and inner baulk ring.
10) Using the ST, remove individual parts.
D: ASSEMBLY
NOTE:
When replacing the following parts, replace as a
set.
Sleeve and hub
Outer baulk ring, 1st synchro cone and inner
baulk ring
Outer baulk ring, 2nd synchro cone and inner
baulk ring
shaft, 1st needle bearing and 1st drive gear inner
surface.
2) Install the 1st needle bearing.
3) Attach the 1st driven gear to the driven shaft.
4) Install the inner baulk ring.
(A) Outer baulk ring
(B) 2nd synchro cone
(A) 2nd bushing
(B) 1st-2nd hub
(C) Outer baulk ring
(D) 1st synchro cone
(E) Inner baulk ring
(F) 1st driven gear
(G) 1st needle bearing
MT-01502
(B)
(A)
(C)
(A)
(E)
(B)
(C)
(D)
(F)
(G)
MT-00594
ST
ST
MT-00595
MT-01503
MT-01504
6MT-81
5) Match the protrusion of the 1st synchro cone to
the hole of the 1st drive gear, then install.
6) Install the outer baulk ring.
7) Install the 1st-2nd hub.
NOTE:
Match the cut out of the 1st-2nd hub with the pro-
trusion on the outer baulk ring, then install.
Make sure that the 1st-2nd hub is installed in the
correct direction.
8) Using the ST, install the 2nd hub.
CAUTION:
MT-01505
MT-00599
(A) 1st-2nd hub
(C) 1st-2nd hub cut out section
(E) 1st driven gear
(A) 2nd bushing
(B) 1st-2nd hub
MT-00600
(E)
(D)
(C)
(A)
(B)
(E)
(A)
MT-00601
(B)
(A)
ST
6MT-82
9) Make sure that the 1st drive gear can be turned
assemble.
10) Attach the shifting insert key to the appropriate
position of the 1st-2nd sleeve.
NOTE:
insert key.
11) Attach the 1st-2nd sleeve to the 1st-2nd hub.
NOTE:
Make sure that the 1st-2nd sleeve is installed in the
correct direction.
12) Install the outer baulk ring.
13) Install the 2nd synchro cone.
(C) 1st-2nd sleeve
(D) Shifting insert key
(D)
(C)
MT-01642
(A)
(B)
( A )
(A) 1st driven gear
(B) 1st-2nd sleeve
(C) 1st driven gear side
MT-00603
(B)
(A)
(C)
(B)
MT-00604
MT-01506
6MT-83
14) Install the inner baulk ring.
bushing, 2nd needle bearing and 2nd drive gear in-
ner surface.
16) Install the 2nd needle bearing and 2nd driven
gear.
NOTE:
Match the protrusion of the 2nd synchro cone to the
hole of the 2nd driven gear, then install.
17) Attach the key.
18) Using the ST, install the 3rd-4th driven gear.
CAUTION:
NOTE:
Make sure that the 3rd-4th driven gear is in-
stalled in the correct direction.
Match the groove on the 3rd-4th driven gear to
the key.
19) Make sure that the 2nd driven gear can be
turned smoothly by hand. If it does not turn smooth-
ly, reassemble.
20) Attach the key.
(A) 2nd needle bearing
(B) 2nd driven gear
(C) Protrusion of the 2nd synchro cone
MT-00606
MT-00607
(A)
(C)
(B)
MT-00608
(A) 4th gear
(B) 3rd gear
(C) 2nd gear
MT-00609
(A)
(C)
(B)
ST
MT-00610
6MT-84
21) Using the ST, install the 5th-6th driven gear.
CAUTION:
NOTE:
Make sure that the 5th-6th driven gear is in-
stalled in the correct direction.
Match the groove on the 5th-6th driven gear to
the key.
22) Using the ST, install the ball bearing.
CAUTION:
NOTE:
Confirm that the ball bearing is installed in the prop-
er direction.
23) Make sure that the ball bearing turns smoothly
by hand. If it does not turn smoothly, reassemble.
24) Install a new lock nut.
25) Attach ST3 to the lock nut, attach ST to the driv-
en gear assembly, and tighten the lock nut.
ST2 18664AA000 BASE
ST4 18852AA000 TORQUE WRENCH
Tightening torque:
530 Nm (54.0 kgf-m, 391 ft-lb)
NOTE:
When using a torque wrench other than ST4, use
the calculation below to calculate and tighten the
lock nut.
T = L1 / (0.1 + L1) 570
(A) 6th gear
(B) 5th gear
(C) 4th gear
MT-00611
(B)
ST
(A)
(C)
MT-00612
ST
T Nm (kgf-m, ft-lb) Torque wrench setting
L1 m (in) Torque wrench length
0.1 m (3.94 in) Length of ST
570 Nm (58.1 kgf-m, 420 ft-lb)
Tightening torque
(lock nut):
(A) 0.1 m (3.94 in)
MT-00613
ST1
ST2
ST4
ST3
MT-00614
(A)
L1
6MT-85
ST 18669AA000 PUNCH DRIVEN SHAFT
NOTE:
E: INSPECTION
1) Bearing
worn.
3) Gear
ly worn.
lowing cases.
MT-00615
A
A
ST
MT-00581
6MT-86
F: ADJUSTMENT
1) Measure the length H from the transmission
case and transfer bearing holder mating surface, to
the end face of the ball bearing.
thickness of the driven gear assembly washer.
T = H {5.80.05 mm (0.230.002 in)} {0.1 0.3 mm
(0.0039 0.0118 in)}
3) Select 0 to 3 washers from the following table,
and adjust the backlash that is closest to the stan-
dard value.
Driven gear assembly axial direction backlash
standard:
0.1 0.3 mm (0.0039 0.0118 in)
(A) Transmission case
(B) Ball bearing
(C) Driven gear ASSY
t Washer thickness
H
Length from the transmission case
and transfer bearing holder mating
surface to the end face of the ball
bearing
5.80.05 mm
(0.230.002 in)
Collar thickness
0.1 0.3 mm
(0.0039 0.0118 in)
Driven gear assembly axial direction
backlash standard
Washer
Part No. Thickness t mm (in)
803072030 0.15 (0.0059)
803072031 0.30 (0.0118)
803072032 0.45 (0.0177)
803072033 0.60 (0.0236)
MT-00616
(A)
H
(C)
(B)
6MT-87
Reverse Idler Gear Assembly
19.Reverse Idler Gear Assembly
A: REMOVAL
8) Remove the reverse idler gear assembly. <Ref.
to 6MT-64, REMOVAL, Main Shaft Assembly.>
B: INSTALLATION
1) Select the reverse fork rod. <Ref. to 6MT-112,
ADJUSTMENT, Shifter Fork and Rod.>
2) Install the reverse idler gear assembly. <Ref. to
6MT-65, INSTALLATION, Main Shaft Assembly.>
C: DISASSEMBLY
NOTE:
Sleeves and reverse gears meet at a specified po-
1) Remove the spring pin.
2) Remove the snap ring and washer.
3) Remove the counter high & low washer and re-
verse idler gear.
(A) Counter high and low washer
(B) Reverse idler gear
MT-00617
MT-00618
MT-00619
(B)
(A)
6MT-88
4) Remove the knock pin and reverse idler gear
needle bearing.
5) Remove the collar.
6) Remove the reverse sleeve.
7) Remove the outer baulk ring, reverse synchro
cone and inner baulk ring from the reverse sleeve.
8) Remove reverse idler gear No. 2.
9) Remove the counter high & low washer and nee-
dle bearing.
10) Remove the knock pin.
11) Remove the snap ring and friction plate from
reverse gear.
(A) Knock pin
(B) Reverse idler gear needle bearing
(A) Reverse sleeve
(C) Reverse synchro cone
(D) Inner baulk ring
MT-00620
(A)
(B)
MT-00622
MT-01507
(A)
(B)
(C)
(D)
(A) Needle bearing
(B) Counter high and low washer
(A) Snap ring
(B) Friction plate
MT-00624
MT-00625
(A)
(B)
MT-00626
MT-00627
(B)
(A)
6MT-89
12) Remove the sub gear and spring.
D: ASSEMBLY
1) Attach the sub gear and spring.
NOTE:
Turn the white marking on the hook section to-
wards the sub gear side, and attach the spring.
Point the stamp (marking A) towards the outside,
and install the sub gear.
While paying attention to the direction of the sub
gear attachment hole, attach the spring and sub
gear.
2) Install the friction plate and snap ring.
NOTE:
Confirm that the friction plate is installed in the
proper direction.
3) Apply adequate transmission gear oil to the shaft,
needle bearing and reverse drive gear inner surface.
4) Install the knock pin.
5) Install the counter high & low washer and needle
bearing.
NOTE:
Point the groove towards the reverse idler gear,
and attach the washer.
(A) Sub gear
(B) Spring
(C) Stamp (Marking A)
(A) Sub gear
(B) Spring
(C) Stamp (Marking A)
(A) Attachment hole
MT-00628
(B)
(A)
(C)
A
MT-00628
(B)
(A)
(C)
A
MT-00629
(A)
A
(A) Friction plate
(B) Snap ring
(C) Snap ring side
(D) Sub gear side
(A) Groove
(B) Counter high and low washer
(C) Needle bearing
MT-00630
(C)
(D)
(A)
(B)
MT-00626
MT-00631
(C)
(B)
(A)
6MT-90
6) Install the reverse idler gear No. 2.
7) Attach the shifting insert key to the appropriate
location of the reverse sleeve.
NOTE:
8) Attach the reverse sleeve to the reverse idler
gear No. 2.
NOTE:
Confirm that the reverse sleeve is installed in the
proper direction.
9) Apply adequate transmission gear oil to the col-
lar, needle bearing and reverse drive gear inner
surface.
10) Install the outer baulk ring, reverse synchro
cone and inner baulk ring.
11) Install the collar and needle bearing, then the
knock pin.
(A) Reverse sleeve
MT-00632
(B)
(A)
(B)
(A)
MT-00633
(A) Outer baulk ring
(B) Reverse synchro cone
(A) Collar
(B) Needle bearing
(C) Knock pin
MT-00634
MT-00635
(A)
(B)
(C)
MT-00636
(C)
(B)
(A)
6MT-91
12) Match the protrusion of the reverse synchro
cone to the hole on the reverse idler gear, and in-
stall the reverse idler gear.
13) Point the groove towards the reverse idler gear,
and attach the counter high & low washer and the
washer.
14) Using the ST, install the snap ring.
ST 18672AA000 GUIDE CLIP
15) Inspect and adjust the clearance between the
snap ring and the washer. <Ref. to 6MT-91, IN-
SPECTION, Reverse Idler Gear Assembly.>
E: INSPECTION
1) Bearing
worn.
3) Gear
ly worn.
lowing cases.
washer.
Clearance specification:
0.1 0.3 mm (0.0039 0.0118 in)
If the clearance is out of the specification, select a
snap ring from the following table and replace it.
After replacing the snap ring, inspect the clearance.
(A) Protrusion on the reverse synchro cone
(B) Hole of the reverse idler gear
MT-01508
(A)
(B)
MT-00638
ST
Snap ring
031319000 1.50 (0.059)
805019030 1.60 (0.062)
805019010 1.72 (0.068)
MT-00581
MT-00639
6MT-92
A: REMOVAL
8) Remove the individual gear assemblies. <Ref. to
9) Remove the drive pinion shaft assembly.
B: INSTALLATION
1) Remove any remaining gasket material from the
drive plate and clutch housing.
2) Apply liquid gasket to the clutch housing.
Liquid gasket:
3) Install the individual gear assemblies. <Ref. to
6MT-65, INSTALLATION, Main Shaft Assembly.>
C: DISASSEMBLY
NOTE:
Replace the drive pinion shaft and hypoid driven
gear as a set.
1) Remove the oil guide A.
2) Remove the drive pinion shaft and shim from the
adapter plate.
ST 18664AA000 BASE
MT-00640
MT-00532
(A) Oil guide A
MT-01624
(A)
MT-00642
6MT-93
5) Attach ST3 to the lock nut, and set the drive pin-
ion shaft to ST. Remove the lock nut and washer.
ST2 18664AA000 BASE
6) Using the ST, remove the taper roller bearing as-
sembly.
D: ASSEMBLY
1) Using the ST, measure drive pinion measure-
ment A.
NOTE:
When selecting the drive pinion shim, refer to mea-
surement A.
ST 398643600 GAUGE
2) Using the ST and a press, attach the inner bear-
ing of the taper roller bearing to the drive pinion
shaft.
CAUTION:
3) Using the ST and a press, attach the outer race
and the taper roller bearing to the drive pinion shaft.
NOTE:
Push in to a position where the bearing rotates
smoothly.
MT-00643
ST2
ST3
ST1
MT-00644
ST
(A) Outer race
MT-00645 A
ST
MT-00646
ST
MT-00647
(A)
ST
6MT-94
4) Attach the washer and a new lock nut.
5) Set the ST to the drive pinion, and tighten the
lock nut.
ST2 18664AA000 BASE
ST4 18852AA000 TORQUE WRENCH
NOTE:
Tighten using the ST and the straight line torque
wrench.
Tightening torque:
265 Nm (27.0 kgf-m, 195 ft-lb)
NOTE:
When using a torque wrench other than ST4, use
the calculation below to calculate and tighten the
lock nut.
Tighten using the ST and the straight line torque
wrench.
T = L1 / (0.1 + L1) 285
6) Measure the starting torque. <Ref. to 6MT-95,
INSPECTION, Drive Pinion Shaft Assembly.>
ST 18670AA000 PUNCH
NOTE:
8) Using the ST, measure drive pinion measure-
ment B.
ST 398643600 GAUGE
T Nm (kgf-m, ft-lb) Torque wrench setting
L1 m (in) Torque wrench length
0.1 m (3.94 in) Length of ST
285 Nm (29.0 kgf-m, 210 ft-lb)
Tightening torque
(lock nut)
(A) 0.1 m (3.94 in)
MT-00648
ST2
ST4
ST3
ST1
MT-00614
(A)
L1
MT-00649
A
ST
MT-00650
B
ST
6MT-95
9) Calculate from the calculation below to select
1 or 2 drive pinion shims from the following table.
6.50.0625 mm (B A) [0.260.0025 in (B A)]
NOTE:
A: Measurement value in step 1)
B: Measurement value in step 8)
10) Apply transmission gear oil to the side face of
the taper roller bearing, and attach the drive pinion
shaft and the selected shims to the adapter plate.
Tightening torque:
54 Nm (5.5 kgf-m, 40 ft-lb)
11) Install the oil guide A.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
E: INSPECTION
1) Using a spring scale, measure the starting
torque. If the starting torque is outside the specifi-
cation range, replace the taper roller bearing.
Starting torque:
0 0.95 N (0 0.097 kgf, 0 0.21 lb)
2) Gear
ly worn.
3) Bearing
4) Adapter plate
Replace the adapter plate in the following cases:
Damage of the adapter plate
5) Check that the pipes and pipe chambers are not
damaged or clogged. Repair or replace if damaged
or clogged.
Drive pinion shim
32295AA270 0.15 (0.0059)
32295AA280 0.175 (0.0069)
32295AA290 0.20 (0.0079)
32295AA300 0.225 (0.0089)
32295AA310 0.25 (0.0098)
32295AA320 0.275 (0.0108)
(A) Oil guide A
MT-00642
MT-01624
(A)
MT-00651
6MT-96
F: ADJUSTMENT
1) Inspect and adjust the hypoid driven gear-to-
drive pinion backlash. <Ref. to 6MT-105, HYPOID
GEAR BACKLASH, ADJUSTMENT, Front Differ-
ential Assembly.>
2) Apply a thin uniform coat of lead-free red dye on
the surfaces of 3 or 4 hypoid driven gear teeth.
3) Install the drive pinion shaft assembly to the
clutch housing, and tighten at least 4 bolts.
NOTE:
Install with the remaining liquid gasket, so that the
clutch housing and the adapter plate will not be
damaged.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
4) Turn a few times using the ST.
ST 18631AA000 HANDLE
5) Remove the drive pinion shaft assembly, and in-
spect the mating condition of the teeth. If the mat-
ing is not correct, change shim thickness to adjust
backlash.
Check item: Tooth contact surface is slightly shift-
ed toward the toe side under a no-load condition.
(When driving, it moves towards the heel side.)
Face contact
Contact pattern
Adjustment: Reconfirm and adjust backlash.
MT-00652
MT-00653
ST
(A) Toe side
(B) Heel side
(A)
(B)
MT-01401
AT-00208
AT-01253
6MT-97
Flank contact
Contact pattern
Adjustment: Reconfirm and adjust backlash.
Contact pattern
Adjustment: Reduce the thickness of the drive pin-
ion shim according to the procedure for moving the
drive pinion away from the driven gear.
Contact pattern
Adjustment: Increase thickness of the drive pinion
shim according to the procedures for moving the
drive pinion closer to the driven gear.
AT-00209
AT-01254
AT-00210
AT-00213
AT-00211
AT-00212
6MT-98
A: REMOVAL
1) Remove the manual transmission assembly.
<Ref. to 6MT-32, REMOVAL, Manual Transmis-
sion Assembly.>
bly.>
10) Remove the lock plates on both sides.
11) Remove the differential side retainers on both
sides using the ST.
ST1 18630AA010 WRENCH COMPL RETAINER
(RH side)
ST2 18630AA000 WRENCH ASSEMBLY
(LH side)
NOTE:
Be careful not to damage the section where the
clutch case retainer will be attached.
12) Remove the front differential.
(A) Lock plate
MT-01022
(A)
(A) LH side
(B) RH side
(A)
(B)
MT-00657
ST1
ST2
6MT-99
B: INSTALLATION
1) Install the differential assembly to the clutch
housing.
2) Apply oil to the screw threads of the side retainer.
3) Remove the O-rings on both sides of the side re-
tainer.
4) Install the differential side retainers to both
sides, using the ST.
(RH side)
ST2 18630AA000 WRENCH ASSY
(LH side)
NOTE:
Be careful not to damage the oil seal.
5) Inspect and adjust the hypoid gear backlash.
<Ref. to 6MT-104, HYPOID GEAR BACKLASH,
INSPECTION, Front Differential Assembly.>
6) Inspect and adjust the tooth contact. <Ref. to
6MT-96, ADJUSTMENT, Drive Pinion Shaft As-
sembly.>
7) Mark the mating positions of the left and right
side retainers and the clutch housing.
8) Remove the differential side retainers from both
sides.
NOTE:
When removing the side retainer, record how many
times it was turned to remove.
9) Install new O-rings to the side retainers on both
sides.
10) Attach the differential side retainers to both
sides.
NOTE:
When attaching, turn the side retainer the same
number of turns it took to remove, and align the
marks.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
NOTE:
Be careful not to confuse the left and right side lock
plates.
(A) LH side
(B) RH side
(A)
(B)
MT-00657
ST1
ST2
(A) LH
(B) RH
MT-00658
MT-00659
(A) (B)
6MT-100
clutch housing and adapter plate.
13) Apply liquid gasket to the clutch housing.
Liquid gasket:
sembly.>
15) Install the individual gear assemblies all at
once. <Ref. to 6MT-65, INSTALLATION, Main
Shaft Assembly.>
C: DISASSEMBLY
1. DIFFERENTIAL CASE
1) Fix the differential assembly on a vice, and re-
move the hypoid driven gear.
ST 18270KA020 SOCKET (E20)
ST 399527700 PULLER SET
4) Remove the differential case LH.
MT-00532
MT-00660
MT-00663
ST
MT-00665
ST
MT-01532
6MT-101
5) Remove the differential bevel gear and washer.
6) Using a manet tool, etc., remove 3 straight pins.
7) Remove 3 pinion shafts.
8) Remove differential bevel pinion and pinion shaft
joint.
9) Remove the differential bevel gear and washer.
2. SIDE RETAINER
3) Remove the claw of ST1, and attach the claw of
ST2.
ST1 398527700 PULLER ASSY
ST2 18760AA000 CLAW
(A) Differential bevel gear
(B) Washer
(A) Straight pin
(B) Pinion shaft joint
MT-01533
(B)
(A)
MT-01534
(A)
(A)
(A)
MT-01535
MT-01536
(A)
(B)
(A) CLAW
MT-00666
AT-00220
MT-00668
(A)
ST2
ST1
6MT-102
4) Remove the bearing outer race from the side re-
tainer, using the ST.
ST2 18760AA000 CLAW
D: ASSEMBLY
1. DIFFERENTIAL CASE
1) Install differential bevel gear and washer to the
differential case RH.
NOTE:
2) Install differential bevel pinion and pinion shaft
joint.
3) Install 3 pinion shafts.
4) Install 3 straight pins.
NOTE:
Make sure the straight pins are inserted completely.
5) Attach the differential bevel gear and washer.
NOTE:
(A) Side retainer
(B) Pinion shaft joint
MT-00669
(A)
ST2
ST1
MT-01537
MT-01536
(A)
(B)
(A) Straight pin
(A) Differential bevel gear
(B) Washer
MT-01535
MT-01534
(A)
(A)
(A)
MT-01533
(B)
(A)
6MT-103
6) Install the differential case LH.
7) Use the ST to attach bearings of differential cas-
es RH and LH.
ST2 398497701 SEATS
CAUTION:
NOTE:
Always replace bearings and outer races as a set.
8) Attach the hypoid driven gear to the differential
case.
ST 18270KA020 SOCKET (E20)
Tightening torque:
69 Nm (7.0 kgf-m, 50.9 ft-lb)
9) Inspect the backlash of the bevel pinion gear.
LASH, INSPECTION, Front Differential Assem-
bly.>
2. SIDE RETAINER
NOTE:
Install the oil seal and O-ring of side retainer after
the adjustment of backlash and tooth contact.
1) Install the bearing outer race to side retainer.
ST 18675AA000 DIFFERENTIAL SIDE
OIL SEAL INSTALLER
NOTE:
Use a new oil seal.
3) Install the O-ring.
NOTE:
Use new O-rings.
MT-01532
MT-01538
ST1
ST2
MT-00660
AT-00226
ST
AT-00219
6MT-104
E: INSPECTION
Repair or replace the differential in the following
cases:
If gears are damaged, seized, or are excessively
worn.
If differential case sliding surfaces are damaged,
seized, or are excessively worn.
If there is damage, rust or wear in the bearings or
bearing locations.
If the bearing does not rotate smoothly or an ab-
Measure the backlash of the differential bevel pin-
ion. If backlash is not within standard value, install
a suitable washer to adjust. <Ref. to 6MT-105, AD-
JUSTMENT, Front Differential Assembly.>
CAUTION:
When measuring the backlash, hold the differ-
ential assembly in upright position.
NOTE:
It is recommended that backlash be measured
by 2 people. One person should push the differen-
tial bevel gear upward (differential case LH side),
and the other person measure the backlash.
Before measuring backlash, turn so that the
gears will settle in their individual locations.
Standard backlash
0.13 0.18 mm (0.0051 0.0071 in)
Inspect the hypoid gear backlash. Adjust if out of
standard. <Ref. to 6MT-105, HYPOID GEAR
BACKLASH, ADJUSTMENT, Front Differential As-
sembly.>
1) Check that the hypoid gear backlash is within the
standard value. Adjust if out of standard. <Ref. to
6MT-105, HYPOID GEAR BACKLASH, ADJUST-
MENT, Front Differential Assembly.>
2) Apply a thin uniform coat of lead-free red dye on
the surfaces of 3 or 4 hypoid driven gear teeth.
3) Attach the drive pinion shaft assembly, and affix
with 4 bolts.
NOTE:
Use old gaskets and washers to prevent the mating
surfaces of the housing from becoming damaged.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
4) Turn the drive pinion shaft to the left and right for
several turns.
MT-01542
MT-01543
ST1
ST2
MT-00652
6MT-105
5) Remove the drive pinion shaft assembly, and in-
spect the mating condition of the teeth. If tooth con-
tact is not correct, perform adjustment. <Ref. to
6MT-96, ADJUSTMENT, Drive Pinion Shaft As-
sembly.>
NOTE:
In a no load condition, the tooth contact from the
center to the toe side is 50 60% (While driving,
the tooth contact will shift towards the heel side.).
F: ADJUSTMENT
1) Measure the backlash of the bevel pinion gear.
LASH, INSPECTION, Front Differential Assem-
bly.>
2) Disassemble the differential case. <Ref. to 6MT-
100, DIFFERENTIAL CASE, DISASSEMBLY,
3) Select a washer from the following table, and as-
semble the differential case. <Ref. to 6MT-102,
DIFFERENTIAL CASE, ASSEMBLY, Front Differ-
ential Assembly.>
NOTE:
If the backlash is excessive, select a thicker wash-
er. If the backlash is too small, select a thinner
washer.
1) Attach the RH and LH side retainers.
(RH side)
(LH side)
NOTE:
Twist in the RH side side retainer a little further
than the LH side.
WRENCH ASSEMBLY (499787000) can also be
used.
2) Attach the drive pinion shaft assembly, and affix
with 4 bolts.
NOTE:
Use old gaskets and washers to prevent the mating
surfaces of the housing from becoming damaged.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
3) Using the ST, twist in the side retainer LH until it
just contacts the drive pinion and hypoid driven
gear. Loosen side retainer RH.
(RH side)
(LH side)
NOTE:
WRENCH ASSEMBLY (499787000) can also be
used.
4) Use the ST to turn the drive pinion shaft a few
times.
ST 18631AA000 HANDLE
5) Repeat steps 3) and 4) until side retainer LH
does not turn anymore. For side retainer RH, twist
in until the inner race and outer race just comes into
contact. This is the zero backlash state.
(A) Toe side
(B) Heel side
Washer
803038021
0.950
(0.0374)
803038022
1.000
(0.0394)
803038023
1.050
(0.0413)
803038024
0.900
(0.0354)
803038025
1.100
(0.0433)
(A)
(B)
MT-01401
MT-00653
ST
6MT-106
6) Mark the mating positions of the left and right
side retainers and the clutch housing.
7) Turn the back side retainer LH by 3 notches, and
screw in the side retainer RH by 3 notches.
8) Use the ST to fix the drive pinion shaft in place.
ST 18621AA000 ADAPTER WRENCH
9) Install the SUBARU genuine axle shaft to the
front differential left and right sides.
Part No. 38415AA000AXLE SHAFT
10) After turning the drive pinion shaft several
turns, use the ST to measure the hypoid gear back-
lash.
ST1 498255400 PLATE
Hypoid gear backlash:
0.13 0.18 mm (0.0051 0.0071 in)
11) If the backlash is out of specified range, turn
the right and left side retainers to adjust.
12) Turn the RH side retainer by 1.75 notches or
more.
Regarding teeth contact conditions, refer to the
drive pinion section. <Ref. to 6MT-104, TOOTH
CONTACT OF HYPOID GEAR, INSPECTION,
MT-00658
ST
MT-00674
MT-00675
ST2 ST1
ST3
6MT-107
22.Shifter Fork and Rod
A: REMOVAL
B: INSTALLATION
1) Install the individual gear assemblies all at once.
sembly.>
C: DISASSEMBLY
NOTE:
Discard the removed spring pin, and replace with a
new part.
1. REVERSE SHIFTER FORK
1) Remove the reverse fork using the ST.
2) Remove the reverse shifter arm using the ST.
MT-00680
ST
MT-00681
ST
6MT-108
2. 1ST-2ND, 3RD-4TH SHIFTER FORK
1) Using the ST, remove the 3rd-4th shifter fork.
2) Using the ST, remove the 3rd-4th shifter arm.
3) Using the ST, remove the 1st-2nd shifter arm
and 1st-2nd shifter fork.
3. 5TH-6TH SHIFTER FORK
1) Using the ST, remove the 5th-6th shifter fork.
2) Using the ST, remove the 5th-6th shifter arm.
4. SHIFTER ARM SHAFT
Remove the selector arm using the ST.
(A) 1st-2nd shifter arm
(B) 1st-2nd shifter fork
MT-00682
ST
MT-00683
ST
MT-00684
(A)
(B)
MT-00685
ST
MT-00686
ST
MT-01095
ST
6MT-109
5. STRIKING ROD
1) Remove the reverse interlock block and the in-
terlock block from the striking rod.
2) Remove the reverse interlock arm using the ST.
3) Remove the interlock arm using the ST.
D: ASSEMBLY
1. REVERSE SHIFTER FORK
1) Using the ST, install the reverse fork.
NOTE:
Confirm that the reverse fork and rod are installed
in the proper direction.
2) Using the ST, install the reverse arm.
NOTE:
Confirm that the reverse arm and rod are installed
(A) Reverse interlock block
(B) Interlock block
(A) Reverse interlock arm
(B) Interlock arm
(A) Interlock arm
MT-00688
(A) (B)
MT-00689
(A)
(B)
ST
MT-00690
(A)
ST
(A) Reverse fork
(B) Reverse rod
(C) Spring pin
(A) Reverse arm
(B) Reverse rod
(C) Spring pin
MT-00691
(C)
(B)
(A)
MT-00692
(C)
(B)
(A)
6MT-110
2. 1ST-2ND, 3RD-4TH SHIFTER FORK
1) Using the ST, install the 1st-2nd shifter fork.
NOTE:
Make sure that the 1st-2nd shifter fork and rod are
installed in the correct direction.
2) Using the ST, install the 1st-2nd shifter arm.
NOTE:
Make sure that the 1st-2nd shifter arm and fork are
3) Using the ST, install the 3rd-4th shifter arm.
NOTE:
Make sure that the 3rd-4th shifter arm and rod are
4) Attach the 3rd-4th fork rod to the 1st-2nd shifter
arm.
5) Using the ST, install the 3rd-4th shifter fork.
NOTE:
Make sure that the 3rd-4th shifter fork is installed in
the correct direction.
(B) 1st-2nd shifter rod
(C) Spring pin
(B) 1st-2nd shifter arm
(C) Spring pin
MT-00693
(C)
(B)
(A)
MT-00694
(C)
(B)
(A)
(A) 3rd-4th shifter rod
(B) 3rd-4th shifter arm
(C) Spring pin
(A) 3rd-4th shifter fork
(B) Spring pin
MT-00695
(C)
(B)
(A)
MT-00696
MT-00697
(B)
(A)
6MT-111
3. 5TH-6TH SHIFTER FORK
1) Using the ST, install the 5th-6th shifter arm.
NOTE:
Make sure that the 5th-6th shifter arm and rod are
2) Using the ST, install the 5th-6th shifter fork.
NOTE:
Check that the 5th-6th shifter fork and arm are in-
stalled.
4. SHIFTER ARM SHAFT
Using the ST, install the selector arm.
NOTE:
Confirm that the selector arm and rod are installed
5. STRIKING ROD
1) Using the ST, install the reverse interlock arm
and interlock arm.
NOTE:
Confirm that the reverse interlock arm and rod
are installed in the proper direction.
Confirm that the interlock arm and rod are in-
stalled in the proper direction.
(A) 5th-6th shifter arm
(B) 5th-6th shifter rod
(C) Spring pin
(A) 5th-6th shifter fork
(B) 5th-6th shifter arm
(C) Spring pin
MT-00698
(C)
(B)
(A)
MT-00699
(C)
(B)
(A)
(A) Selector rod
(B) Selector arm
(C) Spring pin
(A) Reverse interlock arm
(B) Interlock arm
(C) Spring pin
MT-01096
(B)
(A)
(C)
MT-00701
(C) (C)
(B)
(A)
6MT-112
2) Attach the reverse interlock block and interlock
block to the striking rod.
NOTE:
Confirm that the reverse interlock block and inter-
lock block are installed in the proper direction.
E: INSPECTION
1) Check the shift shaft and shift rod for damage.
Replace if damaged.
2) Repair or replace the gearshift mechanism if ex-
F: ADJUSTMENT
1. 1ST-2ND FORK ROD SELECTION
NOTE:
below.
Replacing the 1st and 2nd driven gear
Replacing the 1st and 2nd synchro ring assem-
bly
Replacing the driven shaft
Replacing the 1st-2nd hub and sleeve assem-
blies
1) Insert the drive pinion assembly into the adapter
plate.
NOTE:
Confirm that the thrust bearing outer race has not
been removed and the drive pinion is not lifted.
NOTE:
3) Select the main shaft snap ring. <Ref. to 6MT-
76, ADJUSTMENT, Main Shaft Assembly.>
4) Measure B1 and B2 as shown in the figure.
(A) Reverse interlock block
(B) Interlock block
MT-00688
(A) (B)
MT-00582
ST
MT-00583
MT-00979
B1
B2
6MT-113
5) Shift the 1st-2nd sleeve to the 1st driven gear
side, push down to the stopper, and measure B1.
NOTE:
Turn dial (2), and set the indicator to the 1st side
end surface of the sleeve.
the sleeve in 5 locations. Round off the 2 highest
and 2 lowest measurement values. The remaining
center value is used as the measurement value.
6) Set the height gauge indicator upside down.
7) Shift the 1st-2nd sleeve to the 2nd driven gear
side, push up on the stopper, and measure B2.
NOTE:
Turn dial (2), and set the indicator to the 2nd side
The measurement is to be performed with 2 per-
sons, while holding the sleeve straight.
(A) 1st driven gear
(B) 1st-2nd sleeve
(A) Indicator
MT-00702
(A)
(B)
MT-00585
(2)
(1)
MT-00703
(A)
(A) 2nd driven gear
(B) 1st-2nd sleeve
MT-00704
(A)
(B)
MT-00585
(2)
(1)
6MT-114
8) According to both of the measurements, calcu-
late the neutral position of the 1st-2nd sleeve. From
the following calculation, select a fork rod which
matches the calculated value.
Calculation: T = (B1 + B2) / 2
T: 1st-2nd sleeve center position
B1: Height from the adapter plate end to the sleeve
end, when shifted to 1st gear
B2: Measured height from the adapter plate end to
the sleeve end, when shifted to 2nd gear: +55 mm
(2.17 in)
NOTE:
Attach the indicator upside down in comparison to
the setting procedures for the 0 point. Add d1 [Nu-
merical value: 55 mm (2.17 in)] from the figure be-
low to B2, and measure B2.
2. 3RD-4TH FORK ROD SELECTION
NOTE:
below.
Replacing the main shaft
Replacing the 3rd, and 3rd to 6th drive gear and
bushing
Replacing the 3rd, and 3rd to 6th synchro as-
semblies
Replacing the 3rd-4th hub and sleeve assem-
blies
1) Insert the main shaft assembly into the adapter
plate.
the height gauge indicator to the top surface of the
snap ring groove, and set to the 0 point on the up-
per side of the main rear bearing.
NOTE:
The height gauge will be set on the adapter plate
during the measurement. Use a scraper to remove
any gasket material remaining on the end face.
T mm (in) Lot No. (marking)
62.93 63.23
(2.4776 2.4894)
32801AA111 (1)
63.23 63.53
(2.4894 2.5012)
32801AA131 (none)
63.53 63.83
(2.5012 2.5130)
32801AA141 (2)
MT-00705
d1
(A) Ball bearing
MT-00706
(A)
MT-00583
6MT-115
3) Use a height gauge to measure C1 and C2 as
(1) Shift the 3rd-4th sleeve to the 4th gear side,
push up on the stopper, and measure C2.
NOTE:
Turn dial (2), and set the indicator to the 4th side
(2) Set the height gauge indicator upside down.
(A) 3rd drive gear
(B) 4th drive gear
(A) 4th drive gear
MT-00707
C1
C2
(A)
(B)
MT-00708
(A)
(A) Indicator
MT-00585
(2)
(1)
MT-00710
(A)
6MT-116
(3) Shift the 3rd-4th sleeve to the 3rd drive gear
side, push down to the stopper, and measure
C1.
NOTE:
Turn dial (2), and set the indicator to the 3rd side
late the neutral position of the 3rd-4th sleeve. From
Calculation: T = (C1 + C2) / 2
T: 3rd-4th sleeve center position
C1: Measured depth from the main shaft rear bear-
ing snap ring groove to the sleeve end, when shift-
ed to 3rd gear: +55 mm (2.17 in)
C2: Measured depth from the main shaft rear bear-
ing snap ring groove to the sleeve end, when shift-
ed to 4th gear
NOTE:
merical value: 55 mm (2.17 in)] from the figure be-
low to C1, and measure C1.
(A) 3rd drive gear
MT-00711
(A)
MT-00585
(2)
(1)
T mm (in)
Lot No. (marking)
M.SFT
Snap ring
805072010
[t = 1.65 mm
(0.065 in)]
M.SFT
Snap ring
805072011
[t = 1.95 mm
(0.077 in)]
M.SFT
Snap ring
805072012
[t = 2.25 mm
(0.089 in)]
137.22
137.52
(5.4024
5.4142)
32809AA17
1 (none)
32809AA18
1 (2)
32809AA19
1 (4)
137.52
137.82
(5.4142
5.4260)
32809AA16
1 (1)
32809AA17
1 (none)
32809AA18
1 (2)
137.82
138.12
(5.4260
5.4379)
32809AA14
1 (3)
32809AA16
1 (1)
32809AA17
1 (none)
T = Thickness
MT-00705
d1
6MT-117
3. 5TH-6TH FORK ROD SELECTION
NOTE:
below.
Replacing the main shaft
Replacing the 3rd to 6th drive gear and bushing
Replacing the 3rd to 6th synchro ring assemblies
Replacing the 3rd-4th hub and sleeve assem-
blies
Replacing the 5th-6th hub and sleeve assem-
blies
1) Insert the main shaft assembly into the adapter
plate.
the height gauge indicator to the upper face of the
snap ring groove or the upper side of the main rear
bearing. Set to 0 point.
NOTE:
The height gauge will be set on the adapter plate
during the measurement. Use a scraper to remove
any gasket material remaining on the end face.
3) Use a height gauge to measure D1 and D2 as
(A) Ball bearing
MT-00706
(A)
MT-00583
(A) 5th main gear
(B) 6th main gear
MT-00712
D1
D2
(A)
(B)
6MT-118
(1) Shift the 5th-6th sleeve to the 6th main gear
side, push up on the stopper, and measure
D2.
NOTE:
(2) Set the height gauge indicator upside down.
(3) Shift the 5th-6th sleeve to the 5th main gear
side, push down to the stopper, and measure
D1.
NOTE:
(A) 6th main gear
(A) Indicator
MT-00713
(A)
MT-00585
(2)
(1)
MT-00710
(A)
(A) 5th main gear
MT-00714
(A)
MT-00585
(2)
(1)
6MT-119
late the neutral position of the 5th-6th sleeve. From
Calculation: T = (D1 + D2) / 2
T: 5th-6th sleeve center position
D1: Measured length from the shaft rear bearing snap
ring groove to the sleeve groove end, when shifted to
5th gear [Measured value +55 mm (2.17 in)]
D2: Measured length from the main shaft rear bear-
ing snap ring groove to the sleeve groove end,
when shifted to 6th gear
NOTE:
merical value: 55 mm (2.17 in) from the figure be-
low to D1, and measure D1.
4. REVERSE FORK ROD SELECTION
NOTE:
below.
Replacing the reverse idler gear
Replacing the reverse idler gear No. 2
Replacing the base
1) Insert the reverse idler gear assembly into the
adapter plate.
2) Tighten the base COMPL attachment bolts.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
NOTE:
T mm (in)
Lot No. (marking)
M.SFT
Snap ring
805072010
[t = 1.65 mm
(0.065 in)]
M.SFT
Snap ring
805072011
[t = 1.95 mm
(0.077 in)]
M.SFT
Snap ring
805072012
[t = 2.25 mm
(0.089 in)]
64.12 64.42
(2.5244
2.5362)
32945AA02
1 (none)
32945AA03
1 (2)
32945AA04
1 (4)
64.42 64.72
(2.5362
2.5480)
32945AA01
1 (1)
32945AA02
1 (none)
32945AA03
1 (2)
64.72 65.02
(2.5480
2.5598)
32945AA00
1 (3)
32945AA01
1 (1)
32945AA02
1 (none)
T = Thickness
MT-00705
d1
MT-00546
MT-00582
ST
MT-00583
6MT-120
4) Press fit the reverse sleeve to the reverse idler
gear No. 2, and measure T.
NOTE:
Turn dial (2), and set the indicator to the end face of
the reverse sleeve side.
5) Calculate the neutral position of the reverse
sleeve according to the measurement. From the
following calculation, select a fork rod which match-
es the calculated value.
Calculation: T + 4.8 mm (0.189 in)
(A) Reverse idler gear No. 2
(A) Reverse idler gear No. 2
MT-00715
(A)
T
MT-00716
(A)
MT-00585
(2)
(1)
T + 4.8 mm (0.189 in) mm (in) Lot No. (marking)
33.50 33.80
(1.3189 1.3307)
32816AA110 (1)
33.80 34.10
(1.3307 1.3425)
32816AA130 (none)
34.10 34.40
(1.3425 1.3543)
32816AA140 (2)
T = Thickness
6MT-121
Clutch Housing
23.Clutch Housing
A: REMOVAL
bly.>
10) Remove the front differential assembly. <Ref.
to 6MT-98, REMOVAL, Front Differential Assem-
bly.>
B: INSTALLATION
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
sembly.>
sembly.>
4) Install the individual gear assemblies all at once.
sembly.>
6MT-122
Clutch Housing
C: DISASSEMBLY
1) Remove the clutch release bearing guide.
D: ASSEMBLY
1) Attach the oil seal to the clutch housing, being
careful not to damage the seal.
NOTE:
Use a new oil seal.
ST 18657AA020 OIL SEAL INSTALLER
2) Install the clutch release bearing guide.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
E: INSPECTION
1) Check to make sure there is no damage or
cracks on the clutch housing. If there is excessive
damage, replace the clutch housing.
2) Inspect the clutch housing for transmission gear
oil leakage. If any oil leaks are found, repair or re-
place the applicable part.
MT-01383
MT-01381
MT-01382
ST
MT-01383
6MT-123
A: INSPECTION
1. Gears are difficult to engage
NOTE:
The cause for difficulty in shifting gears
can be classified into two types: One is a
defective gear shift system and the other
is defective transmission. However, if the
operation is heavy and engagement of the
gears is difficult, a defective clutch func-
tion may also be responsible. Check
whether the clutch is correctly functioning,
before checking the gear shift system and
transmission.
(a) Worn, damaged or burred chamfer at
internal spline of the sleeve
Replace.
(b) Gear spline wear, damage, dents Replace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact or wear between
synchronizer ring and gear cone
Correct or replace.
2. Gear slip-out
Gear slips out when coasting on rough
road.
Gear slips out during acceleration.
(a) Defective pitching stopper Adjust.
(b) Loose engine mounting bolts Tighten or replace.
(c) Worn fork shifter, broken shifter fork
rail spring
Replace.
(d) Worn or damaged ball bearing Replace.
(e) Large clearance between splines of
synchronizer hub and synchronizer
sleeve
Replace.
(f) Worn in the synchronizer hub chamfer
angle
Replace.
(g) Worn 1st driven gear, needle bearing
and race
Replace.
(h) Worn 2nd driven gear, needle bearing
and race
Replace.
(i) Worn 3rd drive gear and bushing Replace.
(j) Worn 4th drive gear and bushing Replace.
(k) Worn 5th drive gear and bushing Replace.
(l) Worn 6th drive gear and bushing Replace.
(m) Worn reverse idler gear and bushing Replace.
3. Noise emitted from transmission
NOTE:
If a noise is heard when the vehicle is
parked with its engine idling and ceases
when the clutch is disengaged, it may be
considered that the noise is coming from
the transmission.
(a) Insufficient or improper lubrication Replenish or replace with the specified
amount of recommended oil.
(b) Worn or damaged gears and bearings
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 bro-
ken, rhythmical clicking sounds will be
heard even at low speeds.
Replace.
6MT-124
2. DIFFERENTIAL
1. Broken differential (case, gear, bear-
ing, etc.)
NOTE:
Noise will occur, and eventually the differ-
ential will not be able to operate due to
broken pieces obstructing the gear revo-
lution.
(a) Insufficient or improper oil Disassemble the differential and replace
broken components. At the same time
check other components for any trouble,
and replace if necessary.
(b) Use of vehicle under severe condi-
tions such as excessive load and
improper use of the clutch
Readjust the preload and backlash of the
bearing, and the contact surface of gear.
(c) Improper adjustment of taper roller
bearing
Adjust.
(d) Improper adjustment of the drive pin-
ion and the hypoid driven gear
Adjust.
(e) Loose hypoid driven gear clump bolts Tighten.
2. Differential and hypoid gear noises
Troubles of the differential and hypoid
gear always appear as noise problems.
Therefore noise is the first indication of
trouble. 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 fol-
lowing 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.
(a) Insufficient oil Replenish or replace with the specified
amount of recommended oil.
(b) Improper adjustment of hypoid driven
gear and drive pinion
Check the tooth contact.
(c) Worn teeth of hypoid driven gear and
drive pinion
Replace as a set.
Readjust the bearing preload.
(d) Loose roller bearing Readjust the backlash of the hypoid
driven gear to drive pinion, and check the
tooth contact.
(e) Distorted hypoid driven gear or differ-
ential case
Replace.
CL-2
General Description
CLUTCH SYSTEM
A: SPECIFICATION
Model 2.5 L non-turbo 2.5 L turbo
Transmission type 5MT
Clutch cover Type Push type
Diaphragm set load N (kgf, lbf) 5,688 (580, 1,279) 7,850 (800, 1,764)
Clutch disc
Facing material Woven
O.D. I.D. thickness mm (in)
225 150 3.5
(8.86 5.91 0.138)
230 155 3.2
(9.06 6.10 0.126)
Spline outer diameter mm (in) 25.2 (0.992)
Depth of rivet head
mm (in)
Standard value 1.3 1.9 (0.051 0.075)
Limit of sinking 0.3 (0.012)
Deflection limit mm (in) 0.7 (0.027) at R = 110 (4.33) 1.0 (0.039) at R = 110 (4.33)
Clutch release lever ratio 1.6
Release bearing Grease-packed self-aligning
Clutch pedal
Full stroke mm (in) 130 135 (5.12 5.31) 135 140 (5.31 5.51)
Free play mm (in) 4 13 (0.16 0.51)
Flywheel Type Flexible
Model 2.5 L turbo
Transmission type 6MT
Clutch cover Type Pull type
Diaphragm set load N (kgf, lbf) 7,160 (730, 1,610)
Clutch disc
Facing material Woven
O.D. I.D. thickness
mm (in)
Flywheel side 240 160 3.2 (9.45 6.30 0.126)
Clutch cover side 240 160 3.5 (9.45 6.30 0.138)
Spline outer diameter mm (in) 25.2 (0.992)
Depth of rivet head
mm (in)
Flywheel side 1.35 1.95 (0.053 0.077)
Clutch cover side 1.65 2.25 (0.065 0.089)
Limit of sinking 0.3 (0.012)
Deflection limit mm (in) 1.0 (0.039) at R = 110 (4.33)
Clutch release lever ratio 1.7
Release bearing Grease-packed self-aligning
Clutch pedal
Full stroke mm (in) 130 135 (5.12 5.31)
Free play mm (in) 4 13 (0.16 0.51)
Flywheel Type Conventional
CL-3
General Description
CLUTCH SYSTEM
B: COMPONENT
1. CLUTCH ASSEMBLY
5MT non-turbo model
(1) Dust cover (6) Release bearing Tightening torque:Nm (kgf-m, ft-lb)
(2) Lever spring (7) Clutch cover T1: 16 (1.6, 11.8)
(3) Pivot (8) Clutch disc T2: 72 (7.3, 52.8)
(4) Release lever (9) Flexible flywheel
(5) Clip
CL-00496
(4)
(2)
(1)
(9)
(5)
(6)
(7)
(8)
(3)
(5)
T2
T1
T1
CL-4
General Description
CLUTCH SYSTEM
5MT turbo model
(2) Lever spring (6) Clutch cover T1: 16 (1.6, 11.8)
(3) Pivot (7) Clutch disc T2: 72 (7.3, 52.8)
(4) Release lever (8) Flexible flywheel
(1)
(2)
(4)
(3)
(5)
T1
(6)
(7)
T1
T2
(8)
CL-00508
CL-5
General Description
CLUTCH SYSTEM
6MT model
(2) Release lever (6) Clutch cover T1: 16 (1.6, 11.8)
(3) Release shaft (7) Clutch disc T2: 44 (4.5, 32.5)
(4) Plug (8) Conventional flywheel T3: 81 (8.2, 59.4)
(1)
(2)
(5)
(3)
(4)
(6)
(7)
(8)
T1
T2
T3
CL-00501
CL-6
General Description
CLUTCH SYSTEM
2. CLUTCH PIPE AND HOSE
(1) Master cylinder ASSY (8) Operating cylinder
(5MT turbo model)
(2) Clutch pipe T1: 8 (0.8, 5.8)
(3) Clamp (9) Operating cylinder
(6MT turbo model)
T2: 15 (1.5, 10.8)
(4) Bracket T3: 18 (1.8, 13.0)
(5) Clutch hose (10) Clip T4: 37 (3.8, 27.5)
(6) Washer T5: 25 (2.5, 18.4)
(7) Operating cylinder
(5MT non-turbo model)
(1)
(2)
(3)
(10)
(4)
(5)
(6)
T4
T4
T5
T2
T3
T1
T1
T3
(7)
(8)
T4
(9)
T3
(6)
CL-00502
(5)
(6)
T3
(5)
CL-7
General Description
CLUTCH SYSTEM
3. MASTER CYLINDER
(1) Reservoir cap (7) Gasket Tightening torque:Nm (kgf-m, ft-lb)
(2) Reservoir tank (8) Return spring T1: 10 (1.0, 7)
(3) Oil seal (9) Piston T2: 46.6 (4.75, 34.4)
(4) Straight pin (10) Push rod ASSY
(5) Master cylinder (11) Piston stop ring
(6) Clutch damper (12) Seat
CL-00511
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
T2
T1
(9)
(10)
(11)
(12)
CL-8
General Description
CLUTCH SYSTEM
4. OPERATING CYLINDER
5MT non-turbo model
(1) Push rod (4) Piston spring Tightening torque:Nm (kgf-m, ft-lb)
(2) Boot (5) Operating cylinder T: 8 (0.8, 5.8)
(3) Piston (6) Bleeder screw
CL-00503
T
(5)
(4)
(3)
(2)
(1)
(6)
CL-9
General Description
CLUTCH SYSTEM
5MT turbo model
(1) Push rod (4) Piston spring Tightening torque:Nm (kgf-m, ft-lb)
(2) Boot (5) Operating cylinder T: 8 (0.8, 5.8)
(3) Piston (6) Bleeder screw
CL-00504
T
(5)
(4)
(3)
(2)
(1)
(6)
CL-10
General Description
CLUTCH SYSTEM
5. CLUTCH PEDAL
(1) Stopper (10) Clutch pedal (19) Stop light switch
(2) Bushing (11) Bushing C (20) Pedal bracket
(3) Spring pin (12) Clutch clevis pin (21) Clutch master cylinder bracket
(4) Snap pin (13) Assist rod A (22) Lever
(5) Brake pedal pad (14) Clip (23) Clutch switch (Clutch start)
(6) Brake pedal (15) Assist spring
(7) Clevis pin (16) Assist bushing Tightening torque:Nm (kgf-m, ft-lb)
(8) Brake pedal spring (17) Assist rod B T1: 8 (0.8, 5.8)
(9) Clutch pedal pad (18) Clutch switch (Cruise control) T2: 18 (1.8, 13.0)
CL-00533
(7)
(7)
(7)
T1
T1
T1
T1
T2
T2
T2
(22)
(11)
(11)
(4)
(2)
(3)
(21)
(19)
(18)
(23)
(1)
(1)
(1)
(2)
(2)
(6)
(9)
(10)
(11)
(12)
(15)
(16)
(17)
(14)
(13)
(14)
(5)
(2)
(8)
(4)
(20)
CL-11
General Description
CLUTCH SYSTEM
C: CAUTION
forming any work.
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 installing O-rings or snap rings, apply suf-
ficient amount of fluid to avoid damage and defor-
mation.
Before securing a part in a vise, place cushioning
material such as wood blocks, aluminum plate or
cloth between the part and the vise.
Keep fluids away from the vehicle body. If any
fluid contacts the vehicle body, immediately flush
the area with water.
CL-12
General Description
CLUTCH SYSTEM
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
STOPPER
Used for stopping rotation of the flywheel.
499747100 CLUTCH DISC
GUIDE
Used when installing the clutch disc to the fly-
wheel.
499057000 TORX
PLUS Used for removing and installing the flywheel.

(5MT turbo model)
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and ampere.
Dial gauge Used for measuring clutch disc run-out.
Depth gauge Used for measuring clutch disc wear.
ST-498497100
ST-499747100
ST-499057000
CL-13
Clutch Disc and Cover
CLUTCH SYSTEM
2. Clutch Disc and Cover
A: REMOVAL
NOTE:
The illustration below is for a 5MT non-turbo model.
However, perform the same procedures for models
other than 5MT non-turbo model as well.
body. <Ref. to 5MT-26, REMOVAL, Manual Trans-
mission Assembly.> <Ref. to 6MT-32, REMOVAL,
2) Insert the ST on the flywheel.
ST 499747100 CLUTCH DISC GUIDE
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.
B: INSTALLATION
NOTE:
The illustration below is for a 5MT non-turbo model.
However, perform the same procedures for models
other than 5MT non-turbo model as well.
1) Insert the ST into the clutch disc and attach to
the flywheel by inserting the ST end into pilot bear-
ing.
NOTE:
When installing the clutch disc, be careful to attach
in the correct direction.
(A) Clutch cover
CL-00011
( A)
ST
(A) Flywheel side
(A)
ST
CL-00012
CL-14
CLUTCH SYSTEM
2) Install the clutch cover to the flywheel and tight-
en the bolts to the specified torque.
NOTE:
When installing the clutch cover to the flywheel,
position the clutch cover so that the distance be-
tween unbalance marks ( paint marks) is at least
120. (The unbalance marks indicate the direc-
tions of residual unbalance.)
Note the front and rear of the clutch disc when in-
stalling.
Tighten the clutch cover installing bolts gradual-
ly. Each bolt should be tightened to the specified
torque in a crisscross order.
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
3) Remove the ST.
4) Install the transmission assembly. <Ref. to 5MT-
28, INSTALLATION, Manual Transmission Assem-
bly.> <Ref. to 6MT-34, INSTALLATION, Manual
C: INSPECTION
NOTE:
The illustration below is for a Non-turbo model.
However, perform the same procedures for the
Turbo model.
1. CLUTCH DISC
1) Facing wear:
Measure the depth from the facing surface to the
rivet head. Replace if the face is worn locally or
worn down to less than the specified value.
Depth to rivet head:
Limit of sinking
0.3 mm (0.012 in)
NOTE:
Do not wash the clutch disc with any type of clean-
ing fluid.
2) Hardened facing
Replace the clutch disc.
3) Oil soakage on facing
Replace the clutch disc and inspect the transmis-
sion front oil seal, transmission case mating sur-
face, engine rear oil seal and other locations for oil
leakage.
(A) Unbalance mark (paint)
CL-00013
( A)
ST
( 2 )
( 5 )
( 3 ) ( 1 )
( 6 )
( 4 )
(A) Clutch facing
CL-00014
CL-00015
(A)
CL-15
CLUTCH SYSTEM
4) Deflection on facing:
If deflection exceeds the specified value at the out-
er circumference of the facing, replace the clutch
disc.
Limit for deflection:
Turbo model
1.0 mm (0.039 in) at R = 110 mm (4.33 in)
Non-turbo model
0.7 mm (0.027 in) at R = 110 mm (4.33 in)
5) If there is spline wear, loose rivets, failed damper
springs, etc., replace the clutch disc.
2. CLUTCH COVER
NOTE:
Visually check the following items without disas-
sembling, and replace or repair if defective.
1) Loose thrust rivet
2) Damaged or worn bearing contact area at the
center of diaphragm spring
3) Damaged or worn disc contact surface of the pres-
sure plate
4) Loose strap plate installation area
5) Worn diaphragm sliding area
(A) Spline
(B) Rivet
(C) Damper spring
CL-00016
ST
CL-00017
(A) Thrust rivet
(B) Diaphragm spring
(A) Pressure plate
(B) Strap plate
CL-00018
(A)
(B)
CL-00177
(A)
(B)
CL-16
Flywheel
CLUTCH SYSTEM
3. Flywheel
A: REMOVAL
1) Remove the transmission assembly. <Ref. to
5MT-26, REMOVAL, Manual Transmission Assem-
bly.> <Ref. to 6MT-32, REMOVAL, Manual Trans-
mission Assembly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-13, REMOVAL, Clutch Disc and Cover.>
3) Using the ST, remove the flywheel.
ST 499057000 TORX
PLUS
(Used for 5MT turbo model)
B: INSTALLATION
1) Install the flywheel and ST.
2) Tighten the flywheel mounting bolts to the spec-
ified torque.
ST 499057000 TORX
PLUS
(Used for 5MT turbo model)
CAUTION:
The bolts without identification groove as
shown in the figure must be used as flywheel
attaching bolts for 5MT turbo model.
NOTE:
Tighten the flywheel attachment bolts gradually.
Each bolt should be tightened to the specified torque
in crisscross order.
Tightening torque:
5MT model
72 Nm (7.3 kgf-m, 52.8 ft-lb)
6MT model
81 Nm (8.2 kgf-m, 59.4 ft-lb)
3) Install the clutch disc and cover. <Ref. to CL-13,
INSTALLATION, Clutch Disc and Cover.>
bly.> <Ref. to 6MT-34, INSTALLATION, Manual
(A) Flywheel
CL-00019
ST
( A)
CL-00020
ST
(A) Bolt with identification groove
(B) Bolt without identification groove
CL-00505
(A) (B)
CL-00021
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
CL-17
Flywheel
CLUTCH SYSTEM
C: INSPECTION
NOTE:
The illustration below is for a Turbo model. Howev-
er, perform the same procedures for the Non-turbo
model.
CAUTION:
Since this bearing is grease-sealed and is a
non-lubrication type, do not wash with gasoline
or any solvents.
1) Damage on sliding surface of facing and the ring
gear
If defective, replace the flywheel.
2) Smoothness of rotation
Rotate the ball bearing while applying pressure in
the thrust direction.
3) If noise or excessive play is noted, replace the
flywheel.
(A) Flywheel
(B) Ring gear
CL-00366
(A)
(B)
CL-18
Release Bearing and Lever
CLUTCH SYSTEM
4. Release Bearing and Lever
A: REMOVAL
1. 5MT MODEL
body.
<Ref. to 5MT-26, REMOVAL, Manual Transmis-
sion Assembly.>
2) Remove the two clips from the release lever and
remove the release bearing. (Non-turbo model)
CAUTION:
Be careful not to deform the clips.
3) Remove the release bearing from the clutch re-
lease lever. (Turbo model)
4) Remove the dust cover.
5) Remove the lever spring from the pivot with a
screwdriver by accessing it through the clutch
housing release lever hole. Then remove the re-
lease lever.
2. 6MT MODEL
body. <Ref. to 6MT-32, REMOVAL, Manual Trans-
mission Assembly.>
2) Remove the release lever from the transmission.
3) Install the release bearing to the engine side.
4) Using a flat tip screwdriver, remove the release
bearing from the clutch cover.
B: INSTALLATION
1. 5MT MODEL
NOTE:
Apply the specified grease to lubricate the following
points before installation.
Contact surface of lever and pivot
Contact surface of lever and bearing
Transmission main shaft spline (Use grease con-
taining molybdenum disulphide.)
1) While pushing the release lever to the pivot and
twisting it to both sides, fit the lever spring onto the
raised portion of the pivot.
NOTE:
Apply grease (KOPR-KOTE: Part No. 003603001)
to the contact point of the release lever and operating
cylinder.
Observing from the main case hole, check that
the lever spring is installed securely.
2) Install the release bearing and fasten it with two
clips. (Non-turbo model)
(A) Release lever
(B) Dust cover
(A) Release lever
(B) Screwdriver
CL-00023
( A)
( B)
CL-00024
( B)
( A)
(A) Release bearing
(A) Release lever
CL-00025
( A)
CL-00026
( A)
CL-19
CLUTCH SYSTEM
3) Install the release bearing. (Turbo model)
4) Install the dust cover.
5) Check the bearing for smooth movement by op-
erating the release lever.
<Ref. to 5MT-28, INSTALLATION, Manual Trans-
mission Assembly.>
2. 6MT MODEL
1) Attach the release bearing to the transmission.
2) Insert the release lever into the release bearing
tab.
3) Apply grease to splines.
Grease:
NICHIMOLY N-130
4) Insert the release shaft into the release lever.
NOTE:
Make sure the cut portion of the release shaft
comes into contact with the spring pin.
(A) Release lever
(B) Dust cover
(A) Release lever
(B) Release bearing
CL-00023
( A)
( B)
ME-00052
(A)
(B)
(A) Spline
(A) Release lever
(B) Release shaft
(C) Spring pin
CL-00341
(A)
CL-00030
( A) ( B)
( C)
CL-20
CLUTCH SYSTEM
5) Tighten the plugs.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
6) Check the release bearing and release lever for
smooth movement by operating the release lever.
bly.>
C: INSPECTION
1. RELEASE BEARING
NOTE:
Since this bearing is grease-sealed and is a non-lu-
brication type, do not wash with gasoline or any
other solvent when servicing the clutch.
1) Check the bearing for smooth movement by ap-
plying force to the bearing in the radial direction.
Radial direction stroke:
1.6 mm (0.063 in)
2) While applying force to the bearing in the rota-
tional direction, check the bearing for smooth rota-
tion.
3) Check for wear and damage at the bearing case
surface in contact with the lever.
2. RELEASE LEVER
Check the pivot portion of the lever and the contact
area with the release bearing case for wear.
(A) Bearing case
CL-00031
CL-00032
(A)
(A) Bearing case
(A) Clutch release lever
(B) Pivot
(C) Clutch release bearing
CL-00160
(A)
CL-00034
(A)
(B)
(C)
CL-21
Operating Cylinder
CLUTCH SYSTEM
5. Operating Cylinder
A: REMOVAL
Chamber.>
3) Disconnect the clutch hose from the operating
cylinder.
CAUTION:
Cover the hose joint to prevent the clutch flu-
id from flowing out.
Do not loosen or remove the cap bolts. (5MT
turbo model)
5MT model
NOTE:
Turbo model.
6MT model
mission.
5MT model
NOTE:
Turbo model.
6MT model
(A) Clutch hose
(B) Operating cylinder
(A) Clutch hose
(B) Operating cylinder
(C) Cap bolt
CL-00367
(A)
(B)
CL-00420
(B)
(A)
(C)
(A) Operating cylinder
MT-01220
CL-00441
(A)
CL-22
Operating Cylinder
CLUTCH SYSTEM
B: INSTALLATION
1. 5MT MODEL
NOTE:
Before installing the operating cylinder, apply
grease (KOPR-KOTE: Part No. 003603001) to the
contact point of the release lever and operating cyl-
inder.
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:
Turbo model.
2) After bleeding air from the operating cylinder,
ensure that the clutch operates properly.
<Ref. to CL-29, Clutch Fluid Air Bleeding.>
2. 6MT MODEL
NOTE:
Before installing the operating cylinder, apply
grease (KOPR-KOTE: Part No. 003603001) to the
contact point of the release lever and operating cyl-
inder.
Tightening torque:
T1: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
T2: 41 Nm (4.2 kgf-m, 30.2 ft-lb)
NOTE:
Be sure to install the clutch hose with the mark
side facing upward.
Be careful not to twist the clutch hose during in-
stallation.
2) After bleeding air from the operating cylinder,
ensure that the clutch operates properly.
CL-00368
T1
T2
T2
(A) Mark
(B) Clutch hose
CL-00442
T2
T1
CL-00443
(A) (B)
(C)
CL-23
Operating Cylinder
CLUTCH SYSTEM
C: DISASSEMBLY
1) Remove the boots and push rod assembly.
NOTE:
Only 5MT model can be disassembled.
2) Apply compressed air through clutch hose at-
taching port.
NOTE:
Face the piston port down and place a piece of
wood underneath to prevent the piston from pop-
ping out.
3) Separate the piston and piston spring.
NOTE:
D: ASSEMBLY
NOTE:
During assembly, apply hydraulic oil to all parts.
Recommended brake fluid
FMVSS No. 116, fresh DOT3 or 4 brake fluid
1) Install the piston spring to the piston.
NOTE:
Only 5MT model can be assembled.
2) Insert piston to the operating cylinder.
3) Install push rod to the boot.
4) Install boot and push rod to the operating cylin-
der.
NOTE:
E: INSPECTION
1) Check the operating cylinder for damage. If op-
erating 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-00457
CL-00458
CL-00459
CL-00459
CL-00457
CL-24
Master Cylinder
CLUTCH SYSTEM
6. Master Cylinder
A: REMOVAL
1) Thoroughly drain the brake fluid from the reser-
voir tank.
2) Remove the snap pin and clevis pin, and then
separate the push rod of the master cylinder from
clutch pedal.
Chamber.>
5) Remove the clutch pipe from the master cylin-
der.
6) Remove the master cylinder and reservoir tank
as a unit.
CAUTION:
Be careful not to spill the brake fluid. Brake flu-
id spilled on the vehicle body will harm the
paint surface; wipe off quickly if spilled.
B: INSTALLATION
1) Install the master cylinder to the vehicle body,
and connect the clutch pipe to the master cylinder.
NOTE:
Check that the pipe is routed properly.
Tightening torque:
T1: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
T2: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
2) Connect the push rod of the master cylinder to
the clutch pedal, and install the clevis pin and snap
pin.
NOTE:
Apply grease to the clevis pin.
3) After bleeding air from the clutch system, ensure
that the clutch operates properly.
Chamber.>
(A) Clevis pin
(B) Snap pin
(C) Push rod
(D) Lock nut
(A) Master cylinder ASSY
(B) Clutch pipe
CL-00042
(A)
(B)
(C)
(D)
CL-00152
(A)
(B)
(A) Clevis pin
(B) Snap pin
(C) Push rod
CL-00153
T1
T2
CL-00045
(A)
(B)
(C)
CL-25
Master Cylinder
CLUTCH SYSTEM
C: DISASSEMBLY
1) Remove the straight pin and reservoir tank.
3) Move the seat towards the rear.
CAUTION:
Be careful when removing the snap ring, to pre-
vent the rod, washer, piston and return spring
from flying out.
5) Remove the clutch damper.
D: ASSEMBLY
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.
Grease:
SILICONE GREASE G40M (Part No. 004404003)
3) Assemble in the reverse order of disassembly.
Tightening torque:
10 Nm (1.0 kgf-m, 7 ft-lb)
E: INSPECTION
If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
rod, fluid reservoir, return spring, gasket, clutch
damper, seat or hose, replace the faulty part.
(A) Reservoir tank
(B) Straight pin
(A) Oil seal
(B) Master cylinder
(A) Seat
(B) Master cylinder
CL-00046
(A)
(B)
CL-00047
(A)
(B)
CL-00513
(A)
(B)
(A) Master cylinder body
(B) Return spring
(C) Piston
(D) Stop ring
(E) Push rod ASSY
(F) Clutch damper
(G) Seat
CL-00515
CL-00517
(B)
(C)
(D)
(E)
(A)
(F)
(G)
CL-26
Clutch Pipe and Hose
CLUTCH SYSTEM
7. Clutch Pipe and Hose
A: REMOVAL
Chamber.>
3) Drain the clutch fluid. <Ref. to CL-28, Clutch Flu-
id.>
4) Disconnect the clutch pipe from the clutch hose
and master cylinder.
5) Pull out the clamp, then remove the clutch hose
from the bracket.
6) Disconnect the hose from the operating cylinder.
7) Remove the bracket.
B: INSTALLATION
NOTE:
Bleed air from the clutch fluid. <Ref. to CL-29,
Clutch Fluid Air Bleeding.>
5MT model
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, 18.4 ft-lb)
(A) Clamp
(B) Clutch hose
CL-00057
(A)
(B)
(A) Clutch pipe
(B) Clip
(C) Clutch hose (Non-turbo model)
(D) Operating cylinder (Non-turbo model)
(E) Operating cylinder (Turbo model)
(F) Clutch hose (Turbo model)
T1
T2
(A)
(B)
(C)
(D)
(E)
(C)
T1
T3
T2
(F)
CL-00506
CL-27
Clutch Pipe and Hose
CLUTCH SYSTEM
6MT model
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, 18.4 ft-lb)
C: INSPECTION
Check pipes and hoses for cracks, breakage or
damage. Check joints for fluid leakage. If any
cracks, breakage, damage or leakage is found, re-
pair or replace the defective pipe or hose.
(A) Clutch pipe
(B) Clip
(C) Clutch hose
(D) Operating cylinder (6MT turbo model)
CL-00507
T1
(A)
(B)
(C)
T1
T3
(C)
T2
(D)
CL-28
Clutch Fluid
CLUTCH SYSTEM
8. Clutch Fluid
A: INSPECTION
2) Inspect the fluid level using the scale on the out-
side of the reservoir tank. If the level is below MIN,
add fluid to bring it up to MAX, and also inspect for
leakage.
B: REPLACEMENT
CAUTION:
Use new FMVSS No. 116, DOT3 or 4 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 enter the
reservoir tank.
NOTE:
During bleeding operation, keep the clutch reser-
voir tank filled with brake fluid to prevent entry of
air.
Clutch pedal must be operated very slowly.
For convenience and safety, it is advisable to
have two people working.
The amount of brake fluid required is approxi-
mately 70 m2 (2.4 US fl oz, 2.5 Imp fl oz) for total
clutch system.
Chamber.>
3) Drain the brake fluid from the reservoir tank.
4) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
5) If necessary, bleed air from the clutch fluid. <Ref.
to CL-29, Clutch Fluid Air Bleeding.>
(A) Reservoir tank
(B) MAX. level
(C) MIN. level
CL-00183
MI N
MAX
(A)
(B)
(C)
CL-29
Clutch Fluid Air Bleeding
CLUTCH SYSTEM
9. Clutch Fluid Air Bleeding
A: PROCEDURE
1. 5MT MODEL
NOTE:
Bleed air from the oil line with help of a co-worker.
Chamber.>
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.
NOTE:
Turbo model.
4) Slowly depress the clutch pedal and keep it de-
pressed. 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.
CAUTION:
NOTE:
Turbo model.
5) Repeat procedure 4), until there are no more air
bubbles in the vinyl tube.
6) Tighten the air bleeder.
Tightening torque:
T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
NOTE:
Turbo model.
7) After stepping on the clutch pedal, make sure
that there are no leaks evident in the entire clutch
system.
8) After bleeding the air from clutch system, ensure
that the clutch operates properly.
(A) Clutch hose
(B) Air bleeder
CL-00369
(A)
(B)
(B) Vinyl tube
CL-00370
(B)
(A)
CL-00372
T
CL-30
Clutch Fluid Air Bleeding
CLUTCH SYSTEM
2. 6MT MODEL
NOTE:
Bleed air from the oil line with help of a co-worker.
2) Fit one end of a vinyl tube to the air bleeder of
the master cylinder, and put the other end into a
3) Remove the operating cylinder.
NOTE:
Do not remove the clutch hose.
4) Hold the piston with a clamp to prevent piston
from popping out.
5) Fit one end of a vinyl tube into the air bleeder of
the operating cylinder, and put the other end into a
6) Slowly depress the clutch pedal and keep it de-
pressed. 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.
NOTE:
When performing this procedure, place the screw
portion of the air bleeder higher than the end of op-
erating cylinder.
7) Repeat these steps until there are no more air
bubbles in the vinyl tube.
CAUTION:
8) Tighten the air bleeder.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
9) Install the operating cylinder.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
10) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
11) After bleeding air from system, ensure that the
clutch operates properly.
CL-00445
CL-00446
(B) Vinyl tube
CL-00447
(B)
(A)
CL-00445
CL-31
Clutch Pedal
CLUTCH SYSTEM
10.Clutch Pedal
A: REMOVAL
2) Remove the steering column. <Ref. to PS-17,
REMOVAL, Tilt Steering Column.>
3) Disconnect the connectors of the stop light switch
and clutch switch.
4) Remove the snap pins from clevis pins which se-
cure the lever to the push rod and operating rod.
5) Pull out the clevis pins which secures the lever to
the push rod and operating rod.
6) Remove the nut which secures the clutch master
cylinder.
7) Remove the bolt which secures the brake pedal
and clutch pedal, and remove the pedal assembly.
B: INSTALLATION
Tightening torque:
T: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Always use a new clevis pin.
2) Adjust the clutch pedal after installation. <Ref. to
CL-32, ADJUSTMENT, Clutch Pedal.>
C: DISASSEMBLY
1) Remove the clutch switches.
2) Remove the clip, assist spring, rod and bushing.
3) Extract the spring pin and remove the lever.
4) Remove the clutch pedal and bushing.
(A) Operating rod
(B) Push rod
(C) Snap pin
(D) Clevis pin
(D)
(B)
(C)
(C)
(D)
(A)
CL-00292
CL-00093
(A) Clip
(B) Assist spring
(C) Assist rod
(D) Bushing
(E) Clevis pin
(A) Pin
(B) Lever
(A) Clutch pedal
(B) Bushing
CL-00094
(A)
(B)
(C)
(C)
(D)
(D)
(D)
(E)
(E)
CL-00095
(A)
(B)
(A)
(B)
(B)
CL-00534
CL-32
Clutch Pedal
CLUTCH SYSTEM
5) Remove the stopper.
6) Remove the stopper from the clutch pedal.
7) Remove the clutch pedal pad.
D: ASSEMBLY
1) Temporarily assemble the clutch switch, etc. to
pedal bracket.
2) Clean the clutch pedal and brake pedal bushing
holes, apply a thin coat of grease, and install the
bushings.
3) Align the holes of the pedal bracket, clutch pedal
and brake pedal, and install the brake pedal return
spring, assist rod, spring and bushing.
NOTE:
Clean the inside of bushings and apply a thin coat
of grease before installing the spacer.
E: INSPECTION
1. CLUTCH PEDAL
Move the clutch pedal pads in the lateral direction
with a force of approximately 10 N (1 kgf, 2 lbf) to
check that the clutch pedal deflection is within the
service limit.
If it exceeds the service limit, replace with new
bushings.
Deflection of the clutch pedal:
Service limit
5.0 mm (0.197 in) or less
F: ADJUSTMENT
1) Measure the full stroke of the clutch pedal.
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.
Specified clutch pedal full stroke A:
5MT non-turbo model and 6MT model:
130 135 mm (5.12 5.31 in)
5MT turbo model:
135 140 mm (5.31 5.51 in)
2) If the full stroke is not within the specified value,
loosen the clutch switch lock nut to adjust.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
3) Loosen the push rod lock nuts.
(A) Stopper
(A) Clutch pedal
(B) Brake pedal
(A)
CL-00535
CL-00098
(A)
(B)
(A) Clutch pedal (Full stroke condition)
(B) Scale
(C) Seats
(A) Clevis pin
(B) Snap pin
(C) Push rod
(D) Push rod lock nut
CL-00078
(A)
(B)
(C)
A
CL-00042
(A)
(B)
(C)
(D)
CL-33
Clutch Pedal
CLUTCH SYSTEM
4) Rotate the push rod to adjust.
(1) Make sure that the clutch pedal contacts the
clutch switch side when the pedal is released.
(2) Make sure that the clutch pedal contacts the
clutch pedal bracket stopper when the clutch
pedal is at the maximum stroke position.
5) Turn the push rod to shorten until a clearance is
gained on the clutch switch side.
6) Turn the push rod to lengthen until clutch pedal
contacts the clutch switch.
7) Turn further in the direction that will shorten the
push rod (arrow direction shown in figure) by 270.
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) Depress and release the clutch pedal two or
three times to ensure that the clutch pedal and re-
lease fork operate smoothly. If the clutch pedal and
release fork do not operate smoothly, bleed air
from the clutch hydraulic system. <Ref. to CL-29,
Clutch Fluid Air Bleeding.>
11) Measure the clutch pedal full stroke length
again to ensure that it is within specifications. If it is
not within specifications, repeat adjustment proce-
dures again from the beginning.
Specified clutch pedal full stroke:
5MT non-turbo model and 6MT model:
130 135 mm (5.12 5.31 in)
5MT turbo model:
135 140 mm (5.31 5.51 in)
12) Move the clevis pin to left, then to right. The cle-
vis pin should move without resistance even if it is
rattling. If resistance is felt, repeat adjustment pro-
cedures again from the beginning.
(A) Clevis hole
(B) Push rod lock nut
(C) In the shorter direction
(D) In the longer direction
(E) Push rod
(F) U shaped hardware
(A) Clutch switch
(B) Stopper
(C) Clearance
CL-00080
(B)
(A)
(C)
(D)
(E)
(F)
(A)
(B)
(C)
CL-00538
(A) Accelerator pedal
(B) Clevis
CL-00101
(B)
(A)
CL-34
Clutch Pedal
CLUTCH SYSTEM
13) Push the release lever until the operating cylin-
der push rod retracts. Make sure that the clutch flu-
id level in the reservoir tank increases. If the clutch
fluid level increases, the hydraulic clutch is properly
adjusted; if the fluid level does not increase or the
push rod does not retract, replace the master cylin-
der. <Ref. to CL-24, Master Cylinder.>
5MT model
NOTE:
Turbo model.
6MT model
side of the reservoir tank. If the level is below MIN,
fill fluid up to MAX level.
Recommended clutch fluid:
(1) Push rod
(2) Release lever
(1) Push rod
(2) Release lever
CL-00371
(1)
(3)
(2)
CL-00448
(1)
(2)
(3)
(A) Reservoir tank
(B) MIN. level
(C) MAX. level
CL-00159
MI N
MAX
( A )
( C )
( B )
CL-35
Clutch Switch
CLUTCH SYSTEM
11.Clutch Switch
A: REMOVAL
2) Remove the instrument panel lower cover.
3) Disconnect the connector from clutch switch.
4) Remove the clutch switches.
B: INSTALLATION
1. CLUTCH SWITCH
(WITH CRUISE CONTROL)
1) Install so that there is a gap of 0 mm (0 in) of the
clutch switch and clutch pedal stopper.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
2) Measure the stroke of the clutch pedal.
Clutch pedal standard full stroke: A
5MT non-turbo model and 6MT model
130 135 mm (5.12 5.31 in)
5MT turbo model
135 140 mm (5.31 5.51 in)
3) If the clutch pedal stroke is out of specification,
adjust the stroke. <Ref. to CL-32, ADJUSTMENT,
Clutch Pedal.>
4) Connect the clutch switch connector.
2. CLUTCH SWITCH (CLUTCH START)
1) Fully depress the clutch and hold it.
2) Install the clutch pedal plate and clutch pedal so that
the gap between them is 2 2.5 mm (0.08 0.10 in),
and then tighten the lock nut.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
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.
(A) Clutch switch
(B) Stopper
(C) 0 mm (0 in)
(A) Clutch pedal (Full stroke condition)
(B) Scale
(C) Seats
(A)
(B)
(C)
CL-00536
CL-00078
(A)
(B)
(C)
A
(A) Plate
(B) Clutch pedal
(C) 2 2.5 mm (0.08 0.10 in)
CL-00104
(A)
(B)
(C)
CL-36
Clutch Switch
CLUTCH SYSTEM
C: INSPECTION
1) Make sure that engine does not start with clutch
pedal not depressed. If the engine starts, adjust the
clutch switch and inspect the starter interlock cir-
cuit.
2) Make sure that engine starts with clutch pedal
fully depressed. If the engine does not start, adjust
the clutch switch and inspect the starter interlock
circuit.
3) Check the clutch switch for continuity. If the re-
sistance 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 (Clutch start)
Clutch switch (Cruise control)
D: ADJUSTMENT
1) Loosen the lock nut of 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 2 2.5 mm (0.08 0.10 in).
4) Tighten the lock nut.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
Condition Terminal No.
Specified
resistance
When clutch pedal is
depressed
1 and 2 Less than 1
When the clutch pedal
is depressed.
1 and 2 1 M or more
CL-00102
1
2
CL-00084
2 1
(A) Lock nut
(B) Clutch switch (Clutch start)
(A) Plate
(B) Clutch switch (Clutch start)
(C) 2 2.5 mm (0.08 0.10 in)
(A)
(B)
CL-00537
CL-00104
(A)
(B)
(C)
CL-37
CLUTCH SYSTEM
A: INSPECTION
1. CLUTCH
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 possi-
ble and vehicle speed does not increase
in proportion to the increase in engine
speed.
Power drops particularly when ascend-
ing 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.
(a) Oil on the clutch face Replace.
(b) Worn clutch face Replace.
(c) Deteriorated diaphragm spring Replace.
(d) Warped pressure plate or flywheel Correct or replace.
(e) Defective release bearing holder Correct or replace.
2. Clutch drags.
As a symptom of this trouble, 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-38, DIAG-
NOSTIC DIAGRAM OF CLUTCH DRAG,
INSPECTION, General Diagnostic
Table.>
The problem is caused by insufficient dis-
engagement of the clutch if an abnormal
noise occurs during this test.
(a) Worn or rusty clutch disc hub spline Replace the clutch disc.
(b) Excessive deflection of clutch disc
face
Correct or replace.
(c) Crankshaft pilot needle bearing stick-
ing
Replace.
(d) Cracked clutch disc face Replace.
(e) Stuck clutch disc (smeared by oil or
water)
Replace.
3. Clutch chatters.
Clutch chattering is an unpleasant vibra-
tion to the whole vehicle when the vehicle
is just started with clutch partially
engaged.
(a) Adhesion of oil on the clutch face Replace the clutch disc.
(b) Weak or broken damper spring Replace the clutch disc.
(c) Poor contact of the disc surface or
excessively worn disc
Replace the faulty clutch disc.
(d) Warped pressure plate or flywheel Correct or replace.
(e) Loose disc rivets Replace the clutch disc.
(f) Loose engine mounting Retighten or replace mounting.
(g) Improper adjustment of the pitching
stopper
Adjust.
CL-38
CLUTCH SYSTEM
2. CLUTCH PEDAL
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
4. Noisy clutch
Examine whether the noise is generated
when the clutch is disengaged, engaged,
or partially engaged.
(a) Broken, worn or insufficiently lubri-
cated release bearing
Replace the release bearing.
(b) Insufficient lubrication of the pilot
bearing
Replace the pilot bearing.
(c) Loose clutch disc hub Replace the clutch disc.
(d) Loose damper spring retainer Replace the clutch disc.
(e) Deteriorated or broken damper spring Replace the clutch disc.
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.
(a) Grease or oil on facing Replace the clutch disc.
(b) Deteriorated cushioning spring Replace the clutch disc.
(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 damper spring Replace the clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f) Deteriorated diaphragm spring Replace.
Symptom Corrective action
Insufficient pedal play Adjust the free play of the pedal.
Insufficient clutch pedal free play Adjust the free play of the pedal.
Excessively worn and damaged pedal shaft and/or bushing Replace the bushing or shaft with a new part.
Step Check Yes No
1 CHECK GEAR NOISE.
2) Disengage the clutch and shift quickly from
neutral to reverse in idling condition.
Is there any abnormal noise
from the transmission gear?
Go to step 2. Clutch is normal.
2 CHECK GEAR NOISE.
Disengage the clutch at idle and shift from neu-
tral to reverse within 0.5 1.0 seconds.
Go to step 3. Defective trans-
mission or exces-
sive clutch drag
torque. Inspect
Pilot bearing,
clutch disc, trans-
mission and clutch
disc hub spline.
3 CHECK GEAR NOISE.
1) Disengage the clutch at idle and shift from
neutral to reverse within 0.5 1.0 seconds.
2) With the clutch disengaged, shift from neu-
tral to reverse, reverse to neutral several times.
Inadequate clutch
disengage. Inspect
the clutch disc,
clutch cover, clutch
release, and clutch
pedal free play.
Clutch and fly-
wheel seizure.
Inspect the clutch
disc and the spline
of the clutch disc
hub.
FS-2
General Description
FRONT SUSPENSION
A: SPECIFICATION
*1
: OUTBACK model
3 0 mm (0.12 0 in) Toe angle (sum of both wheels): 015 0
*2
: Except for OUTBACK model
03 mm (00.12 in) Toe angle (sum of both wheels): 0015
Model
Sedan Wagon
2.5 i 2.5 GT
2.5 GT
spec.B, 3.0 R
2.5 i 2.5 GT OUTBACK
Front
Wheel arch height
(Tolerance:
+12 mm
24 mm
(
+0.47 in
0.94 in
))
mm (in) 381 (15.0) 381 (15.0) 439 (17.3)
Camber (Tolerance: 045 Differences
between RH and LH: 45 or less)
015 015 040
Caster (Referential Value) 555 540 455
Steering angle
(Tolerance: 1.5)
Inner
wheel
37.6 33.8 37.6
Outer
wheel
33.0 30.2 33.0
Toe-in mm (in) 03 (00.12) Toe angle (sum of both wheels): 0015
Kingpin angle (Referential Value) 1345 1345 1205
Rear
Wheel arch height
(Tolerance:
+12 mm
24 mm
(
+0.47 in

0.94 in
))
mm (in) 365 (14.4) 375 (14.8) 438 (17.2)
Camber (Tolerance: 045 Differences
between RH and LH: 45 or less)
040 030 010
Toe-in mm (in)
*2 *1
Thrust angle
(Tolerance: 030)
0
FS-3
General Description
FRONT SUSPENSION
NOTE:
Front and rear toe-in and front camber can be
adjusted. Adjust if the toe-in or camber tolerance
exceeds specifications.
Other items indicated in the specifications table
cannot be adjusted. If other items exceed specifica-
tions, check the suspension parts and connections
for deformation, and replace with new parts as re-
quired.
(1) Front
A B = Positive: Toe-in, Negative: Toe-out
= Individual toe angles
FS-00001
B
A
(1)
FS-4
General Description
FRONT SUSPENSION
B: COMPONENT
FS-00256
T1
T13
T7
T10
T10
T6
T11
T12
T9
T5
T2
T8
T5
(16)
(26)
(17)
(19)
(20)
(1)
(21)
(22)
(23)
(24)
(26)
(9)
(10)
(11)
(12)
(13)
(15)
(26) (26)
(26)
T2
T8
(26)
(14)
(26)
T8
T8
T8
(2)
(5)
(8)
(7)
T4
(3)
(4)
(25)
(27)
(6)
(18)
T3
(27)
(3)
(7)
(28)
(25)
(6)
FS-5
General Description
FRONT SUSPENSION
C: CAUTION
forming any work.
Use SUBARU genuine grease etc. or equivalent.
Do not mix grease etc. of different grades or man-
ufacturers.
points.
(1) Front crossmember (15) Jack-up plate Tightening torque:Nm (kgf-m, ft-lb)
(2) Housing (16) Dust seal T1: 20 (2.0, 14.5)
(3) Ball joint (17) Strut mount T2: 25 (2.5, 18.1)
(4) Front arm (steel type) (18) Spacer T3: 30 (3.1, 22)
(5) Support plate (19) Upper spring seat T4: 39 (4.0, 28.8)
(6) Rear bushing (20) Dust cover T5: 45 (4.6, 33.2)
(7) Front bushing (21) Helper T6: 50 (5.1, 36.9)
(8) Stud bolt (22) Coil spring T7: 55 (5.6, 41)
(9) Stabilizer link (23) Damper strut T8: 60 (6.1, 44.3)
(10) Bracket (24) Adjusting bolt T9: 88 (9.0, 64.9)
(11) Bushing (25) Castle nut T10: 95 (9.7, 70.1)
(12) Stabilizer (26) Self-locking nut T11: 110 (11.2, 81.1)
(13) Crossmember support plate
(Large type)
(27) Cotter pin T12: 150 (15.3, 110.6)
(28) Front arm (aluminium type) T13: 152 (15.5, 112.1)
(Small type)
FS-6
General Description
FRONT SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOL
927680000 INSTALLER &
REMOVER SET
Used for replacing front arm front bushing.
20299AG000 REMOVER Used for replacing front arm rear bushing.
Used together with BASE (20999AG010).
20299AG010 BASE Used for replacing front arm rear bushing.
Used together with REMOVER (20999AG000).
20299AG020 STUD BOLT
SOCKET
Used for removing and installing the stud bolt for
front arm installing portion.
ST-927680000
ST20299AG000
ST20299AG010
ST20299AG020
FS-7
General Description
FRONT SUSPENSION
2. GENERAL TOOL
20399AG000 STRUT MOUNT
SOCKET
Used for disassembling and assembling strut
mount.
TOOL NAME REMARKS
Alignment gauge Used for measuring wheel alignment.
Alignment gauge adapter Used for measuring wheel alignment.
Turning radius gauge Used for measuring wheel alignment.
Toe-in gauge Used for toe-in measurement.
Dial gauge Used for damper strut measurement.
Coil spring compressor Used for strut assembly/disassembly.
ST20399AG000
FS-8
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-9, WHEEL ARCH HEIGHT, INSPECTION, Wheel Alignment.>
Camber (front and rear wheels)

<Ref. to FS-10, CAMBER, INSPECTION, Wheel Alignment.>
Caster (front wheel)

<Ref. to FS-12, CASTER, INSPECTION, Wheel Alignment.>
Steering angle
<Ref. to FS-12, STEERING ANGLE, INSPECTION, Wheel Alignment.>
Front wheel toe-in

<Ref. to FS-13, FRONT WHEEL TOE-IN, INSPECTION, Wheel Alignment.>
Rear wheel toe-in

<Ref. to FS-13, REAR WHEEL TOE-IN, INSPECTION, Wheel Alignment.>
Thrust angle
<Ref. to FS-15, THRUST ANGLE, INSPECTION, Wheel Alignment.>
FS-9
Wheel Alignment
FRONT SUSPENSION
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 5 m (16 ft) or more.
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.
5) Measure the distance between the point A and the center of wheel.
(1) Wheel arch height (4) Front wheel arch height (7) Point of measurement
(2) Front fender (5) Rear wheel arch height (8) End of spindle
(3) Rear quarter (6) Flange bend line
Wheel arch height specification mm (in) (Tolerance:
+12 mm
24 mm
(
+0.47 in
0.94 in
))
Model
Sedan Wagon
All models Except for OUTBACK OUTBACK
Front 381 (15.0) 381 (15.0) 439 (17.3)
Rear 365 (14.4) 375 (14.8) 438 (17.2)
FS-00125
A
A
A
(4)
(1)
(2) (3)
(1)
(5)
(1)
(7)
(6)
(8)
FS-10
Wheel Alignment
FRONT SUSPENSION
2. CAMBER
INSPECTION
1) Place the front wheel on the turning radius
gauge. Make sure the ground contact 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.
3) Measure the camber angle in accordance with
the operation manual for wheel alignment gauge.
FRONT CAMBER ADJUSTMENT
1) When adjusting the camber, adjust it to the fol-
lowing value.
2) Loosen the two self-locking nuts located at the
front lower section 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 cam-
ber is set at specification.
NOTE:
Moving the adjusting bolt by one scale changes the
camber by approximately 015.
(1) Alignment gauge
(2) Turning radius gauge
(3) Adapter
Model
Camber (Difference between RH
and LH 45 or less)
Except for
OUTBACK
015045
OUTBACK 040045
FS-00213
(1)
(2)
(3)
Model
Camber (Difference between RH
and LH 45 or less)
Except for
OUTBACK
015030
OUTBACK 040030
(1) Strut
(2) Adjusting bolt
(3) Housing
(4) Outer
(5) Inner
(6) Camber is increased.
(7) Camber is decreased.
(1)
(4)
(6) (7)
(2)
(3)
FS-00008
(5)
FS-11
Wheel Alignment
FRONT SUSPENSION
4) Tighten two new self-locking nuts.
Tightening torque:
152 Nm (15.5 kgf-m, 112.1 ft-lb)
To increase camber:
Rotate the left side counterclockwise. Rotate the right side clockwise.
To decrease camber:
Rotate the left side clockwise. Rotate the right side counterclockwise.
FS-00009 FS-00010
FS-00010 FS-00009
FS-12
Wheel Alignment
FRONT SUSPENSION
3. CASTER
INSPECTION
1) Place the front wheel on the turning radius
gauge. Make sure the ground contact 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.
3) Measure the caster angle in accordance with the
operation manual for wheel alignment gauge.
4. STEERING ANGLE
INSPECTION
1) Place the vehicle on turning radius gauge.
2) While depressing the brake pedal, turn the steer-
ing 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.
ADJUSTMENT
1) Turn the tie-rod to adjust the steering angle of
both inner and outer wheels.
2) Check the toe-in.
NOTE:
Correct the boot if it is twisted. (1) Alignment gauge
(2) Turning radius gauge
(3) Adapter
Model Caster (Reference)
Sedan 555
Wagon 540
OUTBACK 455
FS-00213
(1)
(2)
(3)
Model Inner wheel Outer wheel
2.5 GT spec.B,
3.0 R
33.81.5 30.21.5
Other than above 37.61.5 33.01.5
(1) Lock nut
FS-00014
(1)
FS-13
Wheel Alignment
FRONT SUSPENSION
5. FRONT WHEEL TOE-IN
INSPECTION
Toe-in:
03 mm (00.12 in)
1) Set the toe-in gauge in the position at wheel axis
center height behind the right and left front tires.
2) Place a mark at the center of both left and right
tires, and measure 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 equa-
tion:
A B = Toe-in
ADJUSTMENT
When adjusting the toe-in, adjust it to the following
value.
Toe-in:
02 mm (00.08 in)
1) Check that the left and right wheel steering an-
gles 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 specification.
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).
4) Tighten the tie-rod lock nut.
Tightening torque:
85 Nm (8.7 kgf-m, 62.7 ft-lb)
NOTE:
Check and correct the tie rod boot if twisted.
6. REAR WHEEL TOE-IN
INSPECTION
Toe-in:
OUTBACK model
3 0 mm (0.12 0 in)
Except for OUTBACK model
03 mm (00.12 in)
Refer to FRONT WHEEL TOE-IN for rear toe-in in-
spection procedures.
<Ref. to FS-13, FRONT WHEEL TOE-IN, INSPEC-
TION, Wheel Alignment.>
ADJUSTMENT
When adjusting, adjust it to the following value.
Toe-in:
OUTBACK model
3 0 mm (0.12 0 in)
Except for OUTBACK model
02 mm (00.08 in)
1) Loosen the self-locking nut on the inner side of
rear link.
NOTE:
When loosening or tightening the adjusting bolt,
hold the bolt head and turn the self-locking nut.
(1) Lock nut
FS-00015
A
B
FS-00014
(1)
(1) Adjusting bolt
(2) Rear link
FS-00103
(1)
(2)
FS-14
Wheel Alignment
FRONT SUSPENSION
2) Turn the adjusting bolt until toe-in is within the
specification.
NOTE:
When the left and right wheels are adjusted for toe-in
at the same time, the movement of one scale gradu-
ation changes toe-in by approx. 0.6 mm (0.02 in).
3) Attach and tighten a new self-locking nut.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
To increase toe-in:
Rotate the left side clockwise. Rotate the right side counterclockwise.
To decrease toe-in:
Rotate the left side counterclockwise. Rotate the right side clockwise.
FS-00018 FS-00019
FS-00019 FS-00018
FS-15
Wheel Alignment
FRONT SUSPENSION
7. THRUST ANGLE
INSPECTION
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
030
Less than 30 when L is 23 mm (0.9 in) or
less.
ADJUSTMENT
When adjusting, adjust it to the following value.
Thrust angle
020
Less than 20 when L is 15 mm (0.6 in) or
less.
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 di-
rection, adjust the other rear wheel equally in toe-
out direction, in order to make the thrust angle ad-
justment.
3) When the left and right adjusting bolts are turned
by one graduation, the thrust angle will change ap-
prox. 17 (L is approx. 13 mm (0.51 in)).
NOTE:
Thrust angle is a mean value of left and right wheel
toe angles in relation to the vehicle body center
line. Vehicle is driven straight in the thrust angle di-
rection while slanting in the oblique direction de-
pending on the degree of the mean thrust angle.
Thrust angle: r = ( )/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) Center line of loci (front axle)
(2) Center line of loci (rear axle)
(1)
(2)
L
FS-00022
(1) Front
(2) Thrust angle
(3) Body center line
(1) Front
(2) Body center line
FS-00024
(2)
(3)
(1)
FS-00976
(1) (2)
FS-16
Front Crossmember Support Plate
FRONT SUSPENSION
3. Front Crossmember Support
Plate
A: REMOVAL
2) Remove the front under cover. <Ref. to EI-26,
REMOVAL, Front Under Cover.>
3) Remove the bolt and remove front crossmember
support plate.
Large type
Small type
B: INSTALLATION
NOTE:
Tighten the small type crossmember support plate
together with stabilizer bracket.
After installing the stabilizer bracket to the cross-
member, tighten the crossmember support plate to-
gether.
Tightening torque:
Crossmember support plate:
60 Nm (6.1 kgf-m, 44.3 ft-lb)
Crossmember support plate (Tightened to-
gether with the stabilizer bracket):
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Jack-up plate:
60 Nm (6.1 kgf-m, 44.3 ft-lb)
(2) Jack-up plate
FS-00104
FS-00105
(2)
(1)
(1)
FS-17
Front Stabilizer
FRONT SUSPENSION
4. Front Stabilizer
A: REMOVAL
1) Lift up the vehicle, and then remove the front
wheels.
2) Remove the front under cover. <Ref. to EI-26,
REMOVAL, Front Under Cover.>
Support Plate.>
4) Remove the stabilizer link.
5) Remove the stabilizer bracket.
B: INSTALLATION
NOTE:
Ensure the stabilizer bushing and stabilizer have
the same identification colors.
Install the stabilizer bushing (front crossmember
side) while aligning it with the paint mark on stabi-
lizer.
The stabilizer bracket has a set orientation. In-
stall it with the arrow mark facing the upper side of
the vehicle.
Tightening torque:
Stabilizer link:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
Stabilizer bracket:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
1) Check the bushing for abnormal fatigue or dam-
age.
2) Check the stabilizer link for damage.
FS-00117
FS-00228
(1) Front side of vehicle
(1)
FS-00229
FS-18
Front Ball Joint
FRONT SUSPENSION
5. Front Ball Joint
A: REMOVAL
1) Lift up the vehicle, and remove the front wheels.
2) Remove the both sides of stabilizer bracket.
3) Pull out the pin from ball stud, remove the castle
nut, and extract the ball stud from front arm.
4) Remove the bolt installing ball joint to housing.
5) Extract the ball joint from housing.
B: INSTALLATION
1) Insert the ball joint into housing.
Tightening torque (Bolt):
50 Nm (5.1 kgf-m, 36.9 ft-lb)
CAUTION:
Do not apply grease to the tapered portion of
ball stud.
2) Install the ball joint into front arm.
Tightening torque (castle nut):
Front arm (aluminium type):
30 Nm (3.1 kgf-m, 22 ft-lb)
Front arm (steel type):
39 Nm (4.0 kgf-m, 28.8 ft-lb)
3) Retighten the castle nut further up to 60 until the
hole in the ball stud is aligned with a slot in castle
nut. Then, insert a new cotter pin and bend it
around the castle nut.
4) Install the stabilizer bracket.
NOTE:
The stabilizer bracket has a set orientation. Install it
with the arrow mark facing the upper side of the ve-
hicle.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
FS-00228
FS-00115
(1) Front side of vehicle
(1)
FS-00229
FS-19
Front Ball Joint
FRONT SUSPENSION
C: INSPECTION
1) Measure the play of the ball joint using the fol-
lowing procedures. Replace with a new part if the
play exceeds specification.
(1) With 686 N (70 kgf, 154 lb) loaded in direc-
tion shown in the figure, measure the length 2
1
.
(2) With 686 N (70 kgf, 154 lb) loaded in direc-
tion shown in the figure, measure the length 2
2
.
(3) Determine free play using the following for-
mula.
S = 2
2
2
1
(4) Replace with a new part if the play exceeds
specification.
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-00035
FS-00036
FS-20
Front Arm
FRONT SUSPENSION
6. Front Arm
A: REMOVAL
wheels.
Support Plate.>
3) Remove the front stabilizer. <Ref. to FS-17, RE-
MOVAL, Front Stabilizer.>
4) Remove the ball joint of front arm.
5) Remove the nut securing the front arm to cross-
member. (Do not remove the bolt.)
6) Remove the front arm support plate.
7) Remove the bolt securing front arm to cross-
member and pull the front arm out of the cross-
member.
8) To remove the stud bolt, use the ST.
ST 20299AG020 STUD BOLT SOCKET
CAUTION:
Do not remove the stud bolt without necessity.
Always replace the parts with new parts when
removed.
B: INSTALLATION
1) Using the ST, install the stud bolt.
ST 20299AG020 STUD BOLT SOCKET
Tightening torque:
110 Nm (11.2 kgf-m, 81.1 ft-lb)
2) Using new bolts and self-locking nuts, temporari-
ly tighten the front arm to crossmember.
3) Secure the front arm to body, and then install the
support plate with new bolts and self-locking nuts.
Tightening torque:
Support plate to Front arm:
88 Nm (9.0 kgf-m, 64.9 ft-lb)
Support plate to Body:
150 Nm (15.3 kgf-m, 110.6 ft-lb)
4) Install the ball joint into housing.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
5) Install the stabilizer. <Ref. to FS-17, INSTALLA-
TION, Front Stabilizer.>
6) Lower the vehicle from lift, and tighten the bolt
which secures the front arm to crossmember with
wheels in full contact with the ground and the vehi-
cle at curb weight.
Tightening torque:
95 Nm (9.7 kgf-m, 70.1 ft-lb)
7) Inspect the wheel alignment and adjust if neces-
sary.
FS-00106
FS-00107
FS-00108
(1) Vehicle body
(2) Stud bolt
FS-00109
(2)
(1)
ST
FS-21
Front Arm
FRONT SUSPENSION
C: DISASSEMBLY
1. FRONT BUSHING
Using the ST and a press, remove the front bush-
ing.
ST 927680000 INSTALLER & REMOVER SET
2. REAR BUSHING
1) Put an alignment mark on the front arm based on
the center of rear bushing recess portion.
CAUTION:
Always put an alignment mark for aligning the
position on bushing installation.
2) Using the ST and a press, remove the rear bush-
ing.
ST1 20299AG000 REMOVER
ST2 20299AG010 BASE
D: ASSEMBLY
1. FRONT BUSHING
2. REAR BUSHING
1) Install the rear bushing with its longer inner cyl-
inder facing upward and the shorter facing down-
ward and protruding part rearward as shown in the
figure.
2) Align the center of rear bushing recess portion
with the aligning mark on the front arm.
(1) Put an alignment mark.
(2) Recess section
(1) Press
(2) Front arm
(3) Rear bushing
ST
FS-00110
FS-00136
(2)
(1)
(1)
(1)
(2)
(3)
ST2
ST1
FS-00126
(1) Front arm
(2) Bushing inner cylinder
(3) Longer
(4) Shorter
(5) Protrusion portion
(1) Alignment mark
(2) Recess section
FS-00113
(2)
(1)
(3)
(4)
(5)
FS-00136
(2)
(1)
(1)
FS-22
Front Arm
FRONT SUSPENSION
3) Using the ST and a press, install the rear bush-
ing.
ST1 20299AG000 REMOVER
ST2 20299AG010 BASE
E: INSPECTION
1) Check the front arm for damage or cracks, and
correct or replace if defective.
age.
(1) Press
(2) Front arm
(3) Rear bushing
FS-00127
(1)
(2)
(3)
ST2
ST1
FS-23
Front Strut
FRONT SUSPENSION
7. Front Strut
A: REMOVAL
wheels.
2) Place an alignment mark on the camber adjust-
ing bolt and strut.
3) Remove the bolt securing the brake hose from
the strut.
4) Remove the bolt securing the ABS wheel speed
sensor harness.
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.
6) Remove the three nuts securing strut mount to
body.
B: INSTALLATION
1) Install the strut mount at the upper side of strut to
body, and tighten it with new self-locking nuts.
Tightening torque:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
2) Align alignment marks on the camber adjusting
bolt and strut.
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:
152 Nm (15.5 kgf-m, 112.1 ft-lb)
3) Secure the ABS wheel speed sensor harness to
the strut.
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
4) Install the bolts which secure the brake hose to
the strut.
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
sary.
FS-00037
FS-00038
FS-00039
FS-24
Front Strut
FRONT SUSPENSION
C: DISASSEMBLY
1) Using a coil spring compressor, compress the
coil spring.
2) Using the ST, remove the self-locking nut.
ST 20399AG000 STRUT MOUNT SOCKET
3) Remove the strut mount, spacer and upper
spring seat from strut.
4) Gradually decrease the compression force of
compressor, and remove the coil spring.
5) Remove the dust cover and helper spring.
D: ASSEMBLY
1) Before installing the coil spring, strut mount, etc.
on strut, check for the presence of air in the damp-
ening force generating mechanism of the strut
since air prevents proper dampening force produc-
tion.
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 fin-
gers, move the rod up and down.
(4) If the piston rod moves 10 mm (0.39 in) or
more 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 ver-
tically.
(4) Fully retract the piston rod.
(5) Repeat 3 or 4 times from the step (1).
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 ac-
cordance with Checking for presence of air
4) Using a coil spring compressor, compress the
coil spring.
NOTE:
Make sure that the vertical install direction of the
coil spring is as shown in the figure.
5) Set the coil spring correctly so that its end face
seats well in the spring seat as shown in the figure.
6) Install the helper and dust cover to the piston
rod.
FS-00040
FS-00041
ST
(1) Diameter is small (Upper part)
(2) Identification paint
(3) Diameter is large (Bottom part)
(1) Coil spring end face
(2)
(1)
(3)
FS-00231
FS-00043
(1)
FS-25
Front Strut
FRONT SUSPENSION
7) Pull the piston rod fully upward, and install the
spring seat.
NOTE:
Position the upper spring seat as shown in the fig-
ure.
8) Install spacer and the strut mount to piston rod,
and tighten a new self-locking nut temporarily.
9) Using a hexagon wrench to prevent strut rod
from turning, tighten the new self-locking nut with
ST.
ST 20399AG000 STRUT MOUNT SOCKET
Tightening torque:
55 Nm (5.6 kgf-m, 41 ft-lb)
10) Loosen the coil spring compressor carefully.
E: INSPECTION
Check the removed part for wear, damage and
cracks, and then repair or replace it if defective.
1. DAMPER STRUT
1) Check for oil leaks.
2) Move the piston rod up and down to check that it
operates smoothly without any hitch.
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 P
1
while ap-
plying 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 P
2
.
Play limit (P
1
+ P
2
):
0.8 mm (0.031 in)
If the play exceeds limit, replace the strut.
2. STRUT MOUNT
Check the rubber part for deformation, cracks or
deterioration, and then replace it with a new part if
defective.
3. DUST COVER
If major cracks or damage are found, replace it with
a new part.
4. COIL SPRING
If a permanent strain is found, replaced it with a
new part.
5. HELPER
If major cracks or damage are found, replace it with
a new part.
(1) Outside of body
FS-00128
(1)
FS-00041
ST
FS-00046
W
L
FS-26
Front Strut
FRONT SUSPENSION
F: DISPOSAL
1. EXCEPT FOR BILSTEIN STRUT
CAUTION:
Before handling struts, be sure to wear gog-
gles to protect eyes from gas, oil and cutting
powder.
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 strut on a level surface with the piston
rod fully expanded.
2) Using a 2 3 mm (0.08 0.12 in) dia. drill,
make holes in areas shown in the figure.
2. BILSTEIN STRUT
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 damping tube fully extended.
2) Using a 2 3 mm (0.08 0.12 in) dia. drill,
make the holes at (1) first, and then (2).
(1) 40 mm (1.57 in)
FS-00047
(1)
(1) 20 mm (0.78 in)
(2) 10 mm (0.39 in)
(3) Strut
(4) Damping tube
FS-00096
(1)
(4)
(2)
(3)
FS-27
Front Crossmember
FRONT SUSPENSION
8. Front Crossmember
A: REMOVAL
wheels.
2) Remove the front exhaust pipe.
Support Plate.>
4) Remove the front stabilizer. <Ref. to FS-17, RE-
MOVAL, Front Stabilizer.>
5) Disconnect the tie-rod end from housing.
6) Remove the front arm. <Ref. to FS-20, REMOV-
AL, Front Arm.>
7) Remove the nuts attaching the engine mount
cushion rubber to crossmember.
8) Remove the steering universal joint.
9) Disconnect the power steering hose from steer-
ing gearbox.
10) Lift the engine approx. 10 mm (0.39 in) using a
chain block.
11) Support the crossmember with a jack, remove
the bolts securing crossmember to body, and then
gradually lower the crossmember with steering
gearbox as a unit.
CAUTION:
When removing the crossmember downward,
be careful that the tie-rod end does not interfere
with drive shaft boot.
B: INSTALLATION
NOTE:
Use a new bolt and self-locking nut. For parts
which are not reusable, refer to COMPONENT.
<Ref. to FS-4, COMPONENT, General Descrip-
tion.>
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.
Tightening torque:
Crossmember to body:
95 Nm (9.7 kgf-m, 70.1 ft-lb)
Engine mounting to Crossmember:
75 Nm (7.6 kgf-m, 55.3 ft-lb)
Front arm to Crossmember:
95 Nm (9.7 kgf-m, 70.1 ft-lb)
Front arm to Support plate:
88 Nm (9.0 kgf-m, 64.9 ft-lb)
Support plate to Body:
150 Nm (15.3 kgf-m, 110.6 ft-lb)
Tie-rod end to Housing:
27.0 Nm (2.75 kgf-m, 19.9 ft-lb)
After tightening to the specified torque, tighten the
castle nut further but within 60 until the hole in the
ball stud is aligned with a slot in castle nut
Universal joint:
24 Nm (2.4 kgf-m, 17.7 ft-lb)
Stabilizer bracket:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Stabilizer link:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
Power steering hose to Steering gearbox:
15 Nm (1.5 kgf-m, 11 ft-lb)
2) Purge air from the power steering system.
sary.
C: INSPECTION
Check the crossmember for wear, damage or
cracks, and then repair or replace if faulty.
FS-00118
FS-00119
FS-28
FRONT SUSPENSION
9. General Diagnostic Table
A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
2. POOR RIDE COMFORT
1) Large rebound shock
2) Rocking of the vehicle continues too long after running over bump and hump.
3) Excessive shock in bumping
3. NOISE
Possible cause Corrective action
(1) Permanent distortion or damage of the coil spring Replace.
(2) Rough operation of damper strut or shock absorber Replace.
(3) Improper installation of strut or shock absorber Replace with appropriate parts.
(4) Installation of the wrong coil spring Replace with appropriate parts.
(1) Damaged coil spring Replace.
(2) Overinflation of tires Adjust.
(3) Improper wheel arch height Adjust or replace the coil springs with new parts.
(4) Fault in operation of damper strut or shock absorber Replace.
(5) Damage or deformation of strut mount or shock absorber mount Replace.
(6) Unsuitable length (maximum or minimum) of damper strut or shock
absorber
Replace with appropriate parts.
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly or shock absorber Replace.
(9) Oil leakage from the damper strut or shock absorber Replace.
(1) Wear or damage of damper strut or shock absorber component parts Replace.
(2) Loosening of the suspension link installing bolt Tighten to the specified torque.
absorber
(6) Wear or damage of the ball joint Replace.
(7) Deformation of the stabilizer clamp Replace.
RS-2
General Description
REAR SUSPENSION
A: SPECIFICATION
Refer to FS section for rear suspension specifica-
tions. <Ref. to FS-2, SPECIFICATION, General
Description.>
NOTE:
Front and rear toe-in and front camber can be
adjusted. Adjust if the toe-in or camber tolerance
exceeds specifications.
Other items indicated in the specifications table
cannot be adjusted. If other items exceed specifica-
tions, check the suspension parts and connections
for deformation, and replace with new parts as re-
quired.
(1) Front
A B = Positive: Toe-in, Negative: Toe-out
= Individual toe angles
FS-00001
B
A
(1)
RS-3
General Description
REAR SUSPENSION
B: COMPONENT
1. REAR SUSPENSION
(1) Shock absorber (14) Rear arm bracket Tightening torque:Nm (kgf-m, ft-lb)
(2) Self-locking nut (15) Helper T1: 30 (3.1, 22.4)
(3) Stabilizer (16) Upper link T2: 32 (3.3, 24)
(4) Stabilizer bushing (17) Upper link bushing (inner side) T3: 38 (3.9, 28)
(5) Bracket (18) Upper link bushing (outer side) T4: 44 (4.5, 32.5)
(6) Stabilizer link (19) Front link T5: 57 (5.8, 42)
(7) Rear link (20) Rear sub frame T6: 60 (6.1, 44)
(8) Adjusting bolt (21) Sub frame support arm T7: 62 (6.3, 46)
(9) Rear link bushing (22) Sub frame lower stopper T8: 65 (6.6, 48)
(10) Adjusting washer (23) Spacer T9: 120 (12.2, 89)
(11) Rear arm (24) Stabilizer link bracket
(model with aluminum rear arm)
T10: 125 (12.7, 92)
(12) Rear arm rear bushing T11: 150 (15.3, 111)
(13) Rear arm front bushing T12: 175 (17.8, 129)
(1)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(22)
(22)
(21)
T5
T10
T10
T12
T11
T5
T8
T9
T2
T12
T12
T5
T7
T1
T3
T4
(23)
(24)
T6
RS-00238
RS-4
General Description
REAR SUSPENSION
2. SHOCK ABSORBER
C: CAUTION
forming any work.
Before disposing of shock absorbers, be sure to
bleed the gas out completely. Also, do not expose
to flames or fire.
ufacturers.
points.
(1) Mount (4) Coil spring Tightening torque:Nm (kgf-m, ft-lb)
(2) Upper rubber sheet (5) Shock absorber T1: 30 (3.1, 22.4)
(3) Dust cover (6) Self-locking nut T2: 35 (3.6, 26)
T3: 62 (6.3, 46)
RS-00037
(4)
(5)
(6)
(6)
(6)
(3)
(2)
(1)
T3
T2
T1
RS-5
General Description
REAR SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOL
20099AE000 INSTALLER
& REMOVER
Used for replacing the rear link bushing.
& REMOVER
Used for replacing the upper link bushing.
& REMOVER SET
Used for replacing the rear arm front bushing.
& REMOVER SET
Used for replacing the rear arm rear bushing.
ST20099AE000
ST20099AE010
ST20099AE020
ST20099AE040
RS-6
General Description
REAR SUSPENSION
2. GENERAL TOOL
20099AE030 HELPER SOCKET
WRENCH
Used for replacing helper.
20399AG000 STRUT MOUNT
SOCKET
Used for removing and installing shock mount.
28099PA090 OIL SEAL PROTEC-
TOR
Used for installing the rear drive shaft to the
rear differential.
For oil seal protection
28099PA100 REMOVER Used for removal of DOJ.
ST20099AE030
ST20399AG000
ST28099PA090
ST28099PA100
TOOL NAME REMARKS
Alignment gauge Used for measuring wheel alignment.
Alignment gauge adapter Used for measuring wheel alignment.
Turning radius gauge Used for measuring wheel alignment.
Toe-in gauge Used for toe-in measurement.
Transmission jack Used for removing and installing suspension.
Bearing puller Used for removing bushings.
Coil spring compressor Used for disassembling and assembling shock absorber.
RS-7
Wheel Alignment
REAR SUSPENSION
2. Wheel Alignment
A: INSPECTION
NOTE:
Measure and adjust the front and rear wheel align-
ment at a time. Refer to FS section for measure-
ment and adjustment of wheel alignment. <Ref. to
FS-8, INSPECTION, Wheel Alignment.>
RS-8
Rear Stabilizer
REAR SUSPENSION
3. Rear Stabilizer
A: REMOVAL
1) Lift up the vehicle, and then remove the rear
wheels.
3) Remove the stabilizer bracket.
B: INSTALLATION
NOTE:
Ensure the stabilizer bushing and stabilizer have
the same identification colors.
To install the stabilizer bushing, align the paint
mark end of stabilizer to the end of stabilizer bush-
ing.
The stabilizer bracket has a set orientation. In-
stall it with the arrow mark facing the upper side of
the vehicle.
2) Always tighten the stabilizer bushing in the state
Tightening torque:
Stabilizer link
44 Nm (4.5 kgf-m, 32.5 ft-lb)
Stabilizer bracket
38 Nm (3.9 kgf-m, 28 ft-lb)
C: INSPECTION
age.
2) Check the stabilizer link for damage.
RS-00038
RS-00217
(1) Paint mark
(1)
RS-00218
RS-9
Rear Arm
REAR SUSPENSION
4. Rear Arm
A: REMOVAL
wheels.
2) Remove the sub frame support arm.
<Ref. to RS-20, REMOVAL, Sub Frame Support
Arm.>
3) Remove the bearing unit.
<Ref. to DS-19, REMOVAL, Rear Hub Unit Bear-
ing.>
4) Hang the back plate from sub frame.
5) Remove the bolt which secures the parking
brake cable clamp to the rear arm bracket.
6) Remove the bolt which holds the brake hose
bracket and ABS wheel speed sensor bracket to
the rear arm.
7) Remove the bolts which secure the brake hose
bracket to the rear arm. Remove the bolts which
secure the ABS wheel speed sensor to the rear
arm.
8) Remove the stabilizer link from the rear arm.
9) Remove the shock absorber from the rear arm.
10) Support the rear arm horizontally using a trans-
mission jack.
RS-00043
RS-00040
RS-00041
RS-00124
RS-00044
RS-00045
RS-00046
RS-10
Rear Arm
REAR SUSPENSION
11) Remove the nuts which hold the rear arm to
bracket. Remove the bolts and then remove the
rear frame bracket.
12) Loosen the nut which holds the front link to the
rear arm.
13) Loosen the nut which holds the rear link to the
rear arm.
14) Loosen the nut which holds the upper link to the
rear arm.
15) Remove the bolt which secures the rear arm to
the link, and then remove the rear arm.
B: INSTALLATION
NOTE:
Use a new bolt and self-locking nut. For parts which
are not reusable, refer to COMPONENT. <Ref. to
RS-3, REAR SUSPENSION, COMPONENT, Gen-
eral Description.>
1) Support the rear arm using a transmission jack.
2) Install the rear arm and temporarily tighten the
bolts which hold the rear arm to the link.
3) Install the bearing unit.
<Ref. to DS-20, INSTALLATION, Rear Hub Unit
Bearing.>
4) Install the bolts which secure the ABS wheel
speed sensor to rear arm.
5) Install the bolts which secure the brake hose to
the rear arm.
6) Install bolts which secure the parking brake ca-
ble clamp to the rear arm bracket.
7) Set the vehicle equipped jack upside down, be-
tween the rear link and sub frame. Align the loca-
tion of the jack, and with the rear shock absorber
and rear arm attachment locations matched, tem-
porarily tighten the bolt and nut.
CAUTION:
Protect the rear link and sub frame from being
damaged by putting a waste cloth between the
contact surface with the jack.
RS-00118
RS-00048
RS-00049
RS-00050
RS-00051
RS-11
Rear Arm
REAR SUSPENSION
mission jack.
9) Tighten the nuts and bolts which hold the rear
arm, front link, rear link, upper link and shock ab-
sorber.
NOTE:
Always tighten the stabilizer bushing in the state
10) Install the sub frame support arm.
Tightening torque:
Refer to COMPONENT of General Descrip-
tion for the tightening torque. <Ref. to RS-3,
REAR SUSPENSION, COMPONENT, General
Description.>
11) Inspect the wheel alignment and adjust if nec-
essary.
C: DISASSEMBLY
1. FRONT BUSHING
1) Set the ST A with the larger side of its inner di-
ameter turned upward.
2) Set the rear arm with the protruding side of bush-
ing turned upward.
3) Place the ST B on bushing, and push the bush-
ing out.
ST A 20099AE020INSTALLER & REMOVER SET
ST B 20099AE020INSTALLER & REMOVER SET
2. REAR BUSHING
Using the ST C and bearing puller, press the rear
bushing out.
ST C 20099AE040INSTALLER & REMOVER SET
(1) Rear arm
(2) Transmission jack
RS-00052
(1)
(2)
(1) Bushing
(1) Bearing puller
RS-00119
(1)
ST-B
ST-A
RS-00054
ST-C
(1)
RS-12
Rear Arm
REAR SUSPENSION
D: ASSEMBLY
1. FRONT BUSHING
1) Set the ST A with the larger side of its inner di-
ameter turned upward.
2) Set the rear arm with the vehicle inner side of
arm turned downward.
3) Place the bushing on rear arm as shown in the
figure.
4) Place the ST B on the bushing, and press-fit until
each edge surface of bushing and rear arm is
aligned.
ST A 20099AE020INSTALLER & REMOVER SET
ST B 20099AE020INSTALLER & REMOVER SET
2. REAR BUSHING
1) Insert the bushing into the bore of ST D.
2) Set the ST C, ST D and bearing puller in the
specified positions as shown in the figure, and then
press-fit the bushing until the outer end of bushing
and rear end of rear arm is flat.
ST C 20099AE040INSTALLER & REMOVER SET
ST D 20099AE040INSTALLER & REMOVER SET
E: INSPECTION
Check the rear arm for bending, corrosion or dam-
age.
(1) 05
(2) Rubber protrusion: Assemble with the
rubber protrusion side facing the arm
inner side.
RS-00221
ST-B
ST-A
(1)
(2)
RS-00056
ST-C ST-D
RS-13
Upper Link
REAR SUSPENSION
5. Upper Link
A: REMOVAL
wheels.
mission jack.
3) Remove the bolt which secures the upper link to
sub frame.
4) Remove the bolts which secure the upper link to
the rear arm, and then remove the upper link.
B: INSTALLATION
mission jack.
2) Using new self-locking nuts, install the upper
link.
NOTE:
Inspect the wheel alignment and adjust if neces-
sary.
Tightening torque:
Upper link-to-Sub frame
57 Nm (5.8 kgf-m, 42 ft-lb)
Upper link-to-Rear arm
65 Nm (6.6 kgf-m, 48 ft-lb)
C: DISASSEMBLY
Using the ST, press the bushing out.
ST 20099AE010 INSTALLER & REMOVER
(1) Rear arm
RS-00052
(1)
(2)
RS-00058
RS-00059
(1) Rear arm
RS-00052
(1)
(2)
RS-00061
ST
RS-14
Upper Link
REAR SUSPENSION
D: ASSEMBLY
Using the ST, press the bushing into place.
ST 20099AE010 INSTALLER & REMOVER
CAUTION:
Outer side bushing has an orientation. Assem-
ble it with the longer protrusion faced to the
rear side of vehicle.
E: INSPECTION
1) Visually check the upper link for abnormal fa-
tigue or damage.
2) Visually check the bushing for abnormal fatigue
or damage.
(1) Rear arm
(2) Rear sub frame
(3) Rear side of vehicle
RS-00090
ST
RS-00121
(3)
(1)
(2)
RS-15
Rear Shock Absorber
REAR SUSPENSION
6. Rear Shock Absorber
A: REMOVAL
1) Remove the luggage floor mat. (Wagon model)
2) Roll up the trunk side trim. (Sedan model)
wheels.
4) Remove the bolts which secure the shock ab-
sorber to rear arm.
5) Support the shock absorber using a jack.
6) Remove the nuts which secure the shock ab-
sorber mount to vehicle.
7) Remove the shock absorber.
B: INSTALLATION
1) Support the shock absorber using a jack.
2) Using new self-locking nuts, secure the shock
absorber to vehicle.
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
3) Set the vehicle equipped jack upside down, be-
tween the rear link and sub frame. Adjust the posi-
tion of the jack, and align the attachment position of
the rear shock absorber and rear arm. Using new
self-locking nuts, temporary tighten the bolt.
CAUTION:
Protect the rear link and sub frame from being
damaged by putting a waste cloth between the
contact surface with the jack.
mission jack.
5) Using new self-locking nuts, tighten the bolt and
nut which secures the shock absorber.
Tightening torque:
62 Nm (6.3 kgf-m, 46 ft-lb)
6) Install the luggage floor mat. (Wagon model)
7) Set the trunk side trim. (Sedan model)
8) Check the wheel alignment and adjust it if nec-
essary.
RS-00065
RS-00066
(1) Rear arm
RS-00051
RS-00052
(1)
(2)
RS-16
Rear Shock Absorber
REAR SUSPENSION
C: DISASSEMBLY
Refer to Front Strut for disassembly procedure.
<Ref. to FS-24, DISASSEMBLY, Front Strut.>
D: ASSEMBLY
Refer to Front Strut for installation procedures.
<Ref. to FS-24, ASSEMBLY, Front Strut.>
E: INSPECTION
Refer to Front Strut for inspection procedures.
<Ref. to FS-25, INSPECTION, Front Strut.>
F: DISPOSAL
CAUTION:
Before handling the shock absorber, be sure
to wear goggles to protect eyes from gas, oil
and cutting powder.
Do not disassemble the shock absorber or
place it into a fire.
Drill a hole into shock absorbers in case of
discarding shock absorbers filled with gas.
1) Place the shock absorber on a level surface with
the piston rod fully expanded.
2) Make a hole into the specified position 30 mm
(1.18 in) deep using a drill with 2 3 mm (0.08
0.12 in) diameter.
(1) 40 mm (1.57 in)
RS-00135
(1)
RS-17
Front Link
REAR SUSPENSION
7. Front Link
A: REMOVAL
wheels.
mission jack.
3) Remove the bolt which secures the front link to
the sub frame.
4) Remove the bolt which secures the front link to
rear arm, then remove the front link.
B: INSTALLATION
mission jack.
2) Using new self-locking nuts, install the front link.
CAUTION:
Install the front link with the protruding side
facing the front side of the vehicle.
NOTE:
Inspect the wheel alignment and adjust if neces-
sary.
Tightening torque:
57 Nm (5.8 kgf-m, 42 ft-lb)
C: INSPECTION
Visually check the front link for damage and defor-
mation.
(1) Rear arm
RS-00052
(1)
(2)
RS-00072
RS-00073
(1) Rear arm
(1) Front
RS-00052
(1)
(2)
RS-00075
(1)
RS-18
Rear Link
REAR SUSPENSION
8. Rear Link
A: REMOVAL
wheels.
2) Remove the rear stabilizer. <Ref. to RS-8, RE-
MOVAL, Rear Stabilizer.>
mission jack.
4) Remove the bolts which secures the rear link to
the rear arm.
5) Place alignment marks on the rear link adjusting
bolt and sub frame.
6) Remove the bolt which secures the rear link to
the sub frame, then remove the rear link.
CAUTION:
When loosening the adjusting bolt, make sure
to fix the bolt head in place when loosening the
nut.
B: INSTALLATION
mission jack.
2) Using new self-locking nuts, install the rear link.
NOTE:
Tighten the self-locking nut with the bolt head fixed
in place when installing the adjusting bolt.
Tightening torque:
Rear link-to-Sub frame
120 Nm (12.2 kgf-m, 89 ft-lb)
Rear link-to-Rear arm
57 Nm (5.8 kgf-m, 42 ft-lb)
sary.
C: DISASSEMBLY
Using the ST A and ST B, press the bushing out.
STA 20099AE000 INSTALLER & REMOVER
STB 20099AE000 INSTALLER & REMOVER
(1) Rear arm
RS-00052
(1)
(2)
RS-00080
RS-00081
(1) Rear arm
RS-00052
(1)
(2)
RS-00083
ST-A
ST-B
RS-19
Rear Link
REAR SUSPENSION
D: ASSEMBLY
Using the ST A and ST B, press-fit the bushing.
STA 20099AE000 INSTALLER & REMOVER
STB 20099AE000 INSTALLER & REMOVER
E: INSPECTION
1) Visually check the rear link for abnormal fatigue
or damage.
2) Visually check the bushing for abnormal fatigue
or damage.
RS-00083
ST-A
ST-B
RS-20
Sub Frame Support Arm
REAR SUSPENSION
9. Sub Frame Support Arm
A: REMOVAL
1) Lift up the vehicle and support the rear sub
frame with a support stand.
B: INSTALLATION
Tightening torque:
Sub frame support arm-to-Rear arm bracket
125 Nm (12.7 kgf-m, 92 ft-lb)
Sub frame support arm-to-Rear sub frame
175 Nm (17.8 kgf-m, 129 ft-lb)
C: INSPECTION
Visually check the sub frame support arm for dam-
age and deformation.
RS-00088
RS-21
Rear Sub Frame
REAR SUSPENSION
10.Rear Sub Frame
A: REMOVAL
1) Separate the front exhaust pipe and rear ex-
haust pipe.
3) Remove the rear differential.
T-type
<Ref. to DI-31, REMOVAL, Rear Differential (T-
type).>
VA-type
<Ref. to DI-60, REMOVAL, Rear Differential (VA-
type).>
4) Remove the rear stabilizer. <Ref. to RS-8, RE-
MOVAL, Rear Stabilizer.>
5) Remove the bolts which secure the rear shock
absorber to the rear arm.
6) Support the sub frame using a transmission jack.
7) Remove the front link from sub frame.
<Ref. to RS-17, REMOVAL, Front Link.>
8) Remove the rear link from the sub frame.
<Ref. to RS-18, REMOVAL, Rear Link.>
9) Remove the upper link from the sub frame.
<Ref. to RS-13, REMOVAL, Upper Link.>
11) Remove the sub frame.
B: INSTALLATION
2) Follow the procedure below for the rear differen-
tial installation and tightening torque.
T-type
<Ref. to DI-32, INSTALLATION, Rear Differential
(T-type).>
VA-type
(VA-type).>
mission jack. Tighten the nuts and bolts which hold
the rear arm, front link, rear link, upper link and
shock absorber.
Tightening torque:
Refer to COMPONENT of General Descrip-
tion for tightening torque. <Ref. to RS-3,
REAR SUSPENSION, COMPONENT, General
Description.>
4) Check the wheel alignment and adjust it if nec-
essary.
C: INSPECTION
Check the removed parts for wear, damage and
crack, and repair or replace them if faulty.
RS-00085
(1) Rear arm
RS-00052
(1)
(2)
RS-22
Helper
REAR SUSPENSION
11.Helper
A: REMOVAL
wheels.
2) Remove the helper using the ST.
ST 20099AE030 HELPER SOCKET WRENCH
B: INSTALLATION
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
C: INSPECTION
Check the helper for major cracks or damages.
RS-00087
ST
RS-23
REAR SUSPENSION
A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
2. POOR RIDE COMFORT
1) Large rebound shock
2) Rocking of the vehicle continues too long after running over bump and hump.
3) Excessive shock in bumping
3. NOISE
(1) Permanent distortion or damaged coil spring Replace.
(2) Rough operation of damper strut or shock absorber Replace.
(3) Improper installation of strut or shock absorber Replace with proper parts.
(4) Installation of the wrong coil spring Replace with proper parts.
(2) Overinflation of tires Adjust.
(3) Improper wheel arch height Adjust or replace the coil springs with new parts.
(4) Fault in operation of damper strut or shock absorber Replace.
(5) Damage or deformation of strut mount or shock absorber mount Replace.
absorber
(8) Deformation or damage of helper in strut assembly or shock absorber Replace.
(9) Oil leakage from the damper strut or shock absorber Replace.
(1) Wear or damage of damper strut or shock absorber component parts Replace.
(2) Loosening of the suspension link installing bolt Tighten to the specified torque.
absorber
(6) Wear or damage of the ball joint Replace.
(7) Deformation of the stabilizer clamp Replace.
RS-24
REAR SUSPENSION
WT-2
General Description
WHEEL AND TIRE SYSTEM
A: SPECIFICATION
1. WHEEL AND TIRE SIZE
2. SERVICE DATA
(1) Offset
(2) P.C.D.
WT-00001
Specification Tire size Wheel size
Offset
mm (in)
P.C.D.
mm (in)
Tire inflation pressure kPa
(kgf/cm
2
, psi)
Front wheel Rear wheel
Sedan
2.5 i, LTD
P205/55 R16 89H 16 6
1
/
2
JJ
55 (2.17)
100
(3.94)
220 (2.2, 32) 210 (2.1, 30)
P205/50 R17 88V
17 7JJ
230 (2.3, 33) 220 (2.2, 32)
2.5 GT LTD 215/45 R17 91W 240 (2.4, 35) 230 (2.3, 33)
2.5 GT spec. B 215/45 R18 89Y 18 7JJ
230 (2.3, 33) 220 (2.2, 32)
3.0 R LTD P215/45 R18 89W 18 7JJ
Wagon
2.5 i, LTD
P205/55 R16 89H 16 6
1
/
2
JJ
220 (2.2, 32) 210 (2.1, 30)
P205/50 R17 88V
17 7JJ
2.5 GT LTD 215/45 R17 91W 240 (2.4, 35) 230 (2.3, 33)
OUTBACK 2.5 i Base P225/60 R16 97H 16 6
1
/
2
JJ
48 (1.89) 220 (2.2, 32) 210 (2.1, 30)
OUTBACK 2.5 i, LTD,
OUTBACK 2.5 XT LTD
P225/55 R17 95V 17 7JJ
OUTBACK 3.0 R,
LTD, LLB
T-type Tire
2.5 i, LTD T135/80R16 101M 16 4T 50 (1.97)
420 (4.2, 60)
2.5 GT LTD T135/70D17 102M 17 4T 40 (1.57)
OUTBACK,
2.5 GT spec.B,
3.0 R LTD
T155/70D17 110M 17 4T 40 (1.57)
Part Axial runout Radial runout
Steel wheel 1.5 mm (0.059 in)
Aluminum wheel 1.0 mm (0.039 in)
WT-3
General Description
3. ADJUSTING PARTS
Wheel balancing Standard: Service limit
Dynamic unbalance 10 g (0.35 oz) or less
Balance weight part number
(Knock-on type weight
for steel wheels)
Weight
28101AA001 5 g (0.18 oz)
28101AA011 10 g (0.35 oz)
28101AA021 15 g (0.53 oz)
28101AA031 20 g (0.71 oz)
28101AA041 25 g (0.88 oz)
28101AA051 30 g (1.06 oz)
28101AA061 35 g (1.23 oz)
28101AA071 40 g (1.41 oz)
28101AA081 45 g (1.59 oz)
28101AA091 50 g (1.76 oz)
28101AA101 55 g (1.94 oz)
28101AA111 60 g (2.12 oz)
for aluminum wheel)
Weight
23141GA462 5 g (0.18 oz)
23141GA472 10 g (0.35 oz)
23141GA482 15 g (0.53 oz)
23141GA492 20 g (0.71 oz)
23141GA502 25 g (0.88 oz)
23141GA512 30 g (1.06 oz)
23141GA522 35 g (1.23 oz)
23141GA532 40 g (1.41 oz)
23141GA542 45 g (1.59 oz)
23141GA552 50 g (1.76 oz)
23141GA562 55 g (1.94 oz)
23141GA572 60 g (2.12 oz)
(Adhesive type weight
for aluminum wheel)
Weight
28101AE00B 5 g (0.18 oz)
28101AE01B 7.5 g (0.26 oz)
28101AE02B 10 g (0.35 oz)
28101AE03B 12.5 g (0.44 oz)
28101AE04B 15 g (0.53 oz)
28101AE05B 17.5 g (0.62 oz)
28101AE06B 20 g (0.71 oz)
28101AE07B 22.5 g (0.79 oz)
28101AE08B 25 g (0.88 oz)
28101AE09B 27.5 g (0.97 oz)
28101AE10B 30 g (1.06 oz)
28101AE11B 32.5 g (1.15 oz)
28101AE12B 35 g (1.23 oz)
28101AE13B 37.5 g (1.32 oz)
28101AE14B 40 g (1.41 oz)
28101AE15B 42.5 g (1.50 oz)
28101AE16B 45 g (1.59 oz)
28101AE17B 47.5 g (1.68 oz)
28101AE18B 50 g (1.76 oz)
28101AE19B 52.5 g (1.85 oz)
28101AE20B 55 g (1.94 oz)
28101AE21B 57.5 g (2.03 oz)
28101AE22B 60 g (2.12 oz)
28101AE23B 62.5 g (2.20 oz)
28101AE24B 65 g (2.29 oz)
28101AE25B 67.5 g (2.38 oz)
28101AE26B 70 g (2.47 oz)
28101AE27B 72.5 g (2.56 oz)
28101AE28B 75 g (2.65 oz)
28101AE29B 77.5 g (2.73 oz)
28101AE30B 80 g (2.82 oz)
28101AE31B 82.5 g (2.91 oz)
28101AE32B 85 g (3.00 oz)
28101AE33B 87.5 g (3.09 oz)
28101AE34B 90 g (3.17 oz)
28101AE35B 92.5 g (3.26 oz)
28101AE36B 95 g (3.35 oz)
28101AE37B 97.5 g (3.44 oz)
28101AE38B 100 g (3.53 oz)
28101AG50B 102.5 g (3.62 oz)
28101AG51B 105 g (3.70 oz)
28101AG52B 107.5 g (3.79 oz)
28101AG53B 110 g (3.88 oz)
28101AG54B 112.5 g (3.97 oz)
28101AG55B 115 g (4.06 oz)
28101AG56B 117.5 g (4.14 oz)
28101AG57B 120 g (4.23 oz)
for aluminum wheel)
Weight
WT-4
General Description
B: COMPONENT
C: PREPARATION TOOL
1. GENERAL TOOL
(1) Transmitter (Clamp in type) (6) Screw Tightening torque:Nm (kgf-m, ft-lb)
(2) Grommet (7) Transmitter (Snap in type) T1: 1.4 (0.1, 1)
(3) Nut (8) Valve T2: 7.5 (0.76, 5.53)
(4) Cap T3: 8 (0.8, 5.8)
(5) Tire pressure monitoring control
module
WT-00124
(4)
(3)
(2)
(1)
T2
T3
T3
(5)
(7)
(8)
T1
(6)
TOOL NAME REMARKS
Air pressure gauge Used for measuring tire air pressure.
Dial gauge with
magnet stand
Used for measuring wheel runout.
Wheel balancer Used for adjusting wheel balance.
WT-5
Tire
2. Tire
A: INSPECTION
1) Take stones, glass, nails etc. out of the tread
groove.
2) Replace tires in the following cases.
CAUTION:
When replacing a tire, make sure to use only
tires of the same size, construction and load
range as originally installed.
Use a tire changer when removing the tire
from the wheel.
On models equipped with tire pressure mon-
itoring systems, do not use the bead breaker in
a 90 area centered on the transmitter to pre-
vent damaging the transmitter.
To prevent damaging the transmitter, set the
tire changer boom in the position as shown in
the figure.
(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) When a crack on tire valve is found, replace the
tire valve.
1. TIRE ROTATION
Rotate tires periodically (12,500 km/7,500 miles) as
shown in the figure, in order to prevent them from
uneven wear and to prolong their life.
Without instruction for the direction of tire rotation.
With instruction for the direction of tire rotation
(1) Transmitter
(2) 90
(use of a bead breaker is prohibited in this area.)
(1) Transmitter
(2) Direction of turn table rotation
(3) 90
(4) Tire changer boom
(1)
WT-00070
(2)
(1)
WT-00071
(3)
(4)
(2)
(1) Tread wear indicator
(2) Tire tread
(1) Front
(1) Front
WT-00002
WT-00113
1
WT-00115
1
WT-6
Tire
NOTE:
Vehicles equipped with tire pressure monitoring
systems will require re-registration of transmitter
ID. <Ref. to TPM(diag)-10, REGISTER TRANS-
MITTER ID, OPERATION, Subaru Select Moni-
tor.>
WT-7
Steel Wheel
3. Steel Wheel
A: REMOVAL
1) Apply the parking brake, and position select le-
ver to P.
2) Set the shop jacks or a lift to the specified points,
and support the vehicle with its wheels slightly con-
tacting 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 up-
ward to prevent wheels from being damaged.
B: INSTALLATION
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 SUBA-
RU 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 the wheel nuts in a diagonal selection to
the specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
CAUTION:
Tighten the wheel nuts in two or three steps
by gradually increasing the torque on opposing
nuts, until they reach the specified torque.
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 re-
pair of a puncture, retighten the wheel nuts to the
specified torque after driving 1,000 km (600 miles).
C: INSPECTION
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 neces-
sary.
2) Jack-up the vehicle until wheels clear the floor.
3) Slowly rotate the wheel to check rim runout us-
ing a dial gauge.
Rim runout:
4) If the rim runout exceeds specifications, remove
the tire from the wheel and check runout with the
dial gauge attached to positions shown in the fig-
ure.
5) If the measured runout still exceeds specifica-
tions, replace the wheel.
Axial runout limit Vertical run out limit
1.5 mm (0.059 in)
(1) Approx. 7 mm (0.28 in)
WT-00004
WT-00005
(1)
(1)
(1)
WT-8
Aluminum Wheel
4. Aluminum Wheel
A: REMOVAL
Refer to Steel Wheels for removal procedure of
aluminum wheels. <Ref. to WT-7, REMOVAL,
Steel Wheel.>
B: INSTALLATION
Refer to Steel Wheels for installation procedure of
aluminum wheels. <Ref. to WT-7, INSTALLATION,
Steel Wheel.>
C: INSPECTION
Refer to Steel Wheels for inspection procedure of
aluminum wheels. <Ref. to WT-7, INSPECTION,
Steel Wheel.>
Rim runout:
D: CAUTION
Aluminum wheels are easily scratched. To main-
tain their appearance and safety, be careful of the
following:
1) Do not damage the aluminum wheels during re-
moval, installation, wheel balancing, etc. After re-
moving aluminum wheels, place them on a rubber
mat etc.
2) When washing the aluminum wheel, use neutral
synthetic detergent and water. Avoid using cleans-
ers containing abrasives, hard brushes or an auto-
matic car washer.
Axial runout limit Vertical run out limit
1.0 mm (0.039 in)
WT-9
Wheel Balancing
5. Wheel Balancing
A: ADJUSTMENT
NOTE:
Because an adhesive type weight is adopted for
the outside balance weight of 17-inch and 18-inch
wheels, change the setting of the wheel balancer to
adhesive type weight.
1) Remove the balance weights.
CAUTION:
Be careful not to damage the wheel.
Completely remove the double-sided tape of
the adhesive weight from the wheel.
2) Using the wheel balancer, measure wheel bal-
ance.
3) Select a weight close to the value measured by
wheel balancer.
CAUTION:
Use SUBARU genuine balance weights.
for steel wheels)
Weight
28101AA001 5 g (0.18 oz)
28101AA011 10 g (0.35 oz)
28101AA021 15 g (0.53 oz)
28101AA031 20 g (0.71 oz)
28101AA041 25 g (0.88 oz)
28101AA051 30 g (1.06 oz)
28101AA061 35 g (1.23 oz)
28101AA071 40 g (1.41 oz)
28101AA081 45 g (1.59 oz)
28101AA091 50 g (1.76 oz)
28101AA101 55 g (1.94 oz)
28101AA111 60 g (2.12 oz)
for aluminum wheel)
Weight
23141GA462 5 g (0.18 oz)
23141GA472 10 g (0.35 oz)
23141GA482 15 g (0.53 oz)
23141GA492 20 g (0.71 oz)
23141GA502 25 g (0.88 oz)
23141GA512 30 g (1.06 oz)
23141GA522 35 g (1.23 oz)
23141GA532 40 g (1.41 oz)
23141GA542 45 g (1.59 oz)
23141GA552 50 g (1.76 oz)
23141GA562 55 g (1.94 oz)
23141GA572 60 g (2.12 oz)
for aluminum wheel)
Weight
28101AE00B 5 g (0.18 oz)
28101AE01B 7.5 g (0.26 oz)
28101AE02B 10 g (0.35 oz)
28101AE03B 12.5 g (0.44 oz)
28101AE04B 15 g (0.53 oz)
28101AE05B 17.5 g (0.62 oz)
28101AE06B 20 g (0.71 oz)
28101AE07B 22.5 g (0.79 oz)
28101AE08B 25 g (0.88 oz)
28101AE09B 27.5 g (0.97 oz)
28101AE10B 30 g (1.06 oz)
28101AE11B 32.5 g (1.15 oz)
28101AE12B 35 g (1.23 oz)
28101AE13B 37.5 g (1.32 oz)
28101AE14B 40 g (1.41 oz)
28101AE15B 42.5 g (1.50 oz)
28101AE16B 45 g (1.59 oz)
28101AE17B 47.5 g (1.68 oz)
28101AE18B 50 g (1.76 oz)
28101AE19B 52.5 g (1.85 oz)
28101AE20B 55 g (1.94 oz)
28101AE21B 57.5 g (2.03 oz)
28101AE22B 60 g (2.12 oz)
28101AE23B 62.5 g (2.20 oz)
28101AE24B 65 g (2.29 oz)
28101AE25B 67.5 g (2.38 oz)
28101AE26B 70 g (2.47 oz)
28101AE27B 72.5 g (2.56 oz)
28101AE28B 75 g (2.65 oz)
28101AE29B 77.5 g (2.73 oz)
28101AE30B 80 g (2.82 oz)
28101AE31B 82.5 g (2.91 oz)
28101AE32B 85 g (3.00 oz)
28101AE33B 87.5 g (3.09 oz)
28101AE34B 90 g (3.17 oz)
28101AE35B 92.5 g (3.26 oz)
28101AE36B 95 g (3.35 oz)
28101AE37B 97.5 g (3.44 oz)
28101AE38B 100 g (3.53 oz)
28101AG50B 102.5 g (3.62 oz)
28101AG51B 105 g (3.70 oz)
28101AG52B 107.5 g (3.79 oz)
28101AG53B 110 g (3.88 oz)
28101AG54B 112.5 g (3.97 oz)
28101AG55B 115 g (4.06 oz)
28101AG56B 117.5 g (4.14 oz)
28101AG57B 120 g (4.23 oz)
WT-10
Wheel Balancing
4) Install the selected weight to the point designat-
ed by the wheel balancer.
CAUTION:
Degrease the wheel surface where the adhe-
sive type weight will be applied.
Press the adhesive type weight by 25 N
(2.5 kgf, 5.6 lb) or more per 5 g (0.18 oz) for
2 seconds or more and attain full adhesion.
Total application of the adhesive type weight
should be 100 g (3.53 oz) or less.
The total weight of all adhesive weight on
models with transmitters (tire pressure sensor)
is to be 120 g (4.23 oz) or less.
5) Using the wheel balancer, measure the wheel
balance again. Check that wheel balance is cor-
rectly adjusted.
NOTE:
Knock-on type balance weights for aluminum
wheels can be used on any 15 to 18 inch aluminum
wheels.
Service limit A:
Knock-on type weight for steel wheel:
5 25 g (0.18 0.88 oz) 2.0 mm (0.08 in)
30 g (1.06 oz) or more 1.8 mm (0.07 in)
Knock-on type weight for aluminum wheel:
5 25 g (0.18 0.88 oz) 5.0 mm (0.20 in)
30 g (1.06 oz) or more 4.5 mm (0.177 in)
(1) Knock-on type weight for aluminum wheel
(2) Knock-on type weight for steel wheel
WT-00006
A
A
WT-11
T-type Tire
6. T-type Tire
A: NOTE
T-type tire for temporary use is equipped as a
spare tire.
CAUTION:
Do not drive at a speed greater than 80 km/h
(50 MPH).
For the model with tire pressure monitoring
system, the indicator light may blink when run-
ning with the T-type tire.
B: REPLACEMENT
Refer to Steel Wheels for removal and installation
procedures of the T-type tire. <Ref. to WT-7, RE-
MOVAL, Steel Wheel.>
CAUTION:
The T-type tire is only for temporary use. Re-
place with a conventional tire as soon as possi-
ble.
C: INSPECTION
1) Check the tire air pressure.
Specifications:
420 kPa (4.2 kg/cm
2
, 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 defective.
WT-12
Tire Pressure Monitoring System
7. Tire Pressure Monitoring
System
A: REMOVAL
1. TRANSMITTER (CLAMP IN TYPE)
1) Remove the wheels from the vehicle. <Ref. to
WT-7, REMOVAL, Steel Wheel.>
2) Bleed air from tire valve.
3) Remove the nut, and drop the transmitter in the
tire.
4) Remove the tires from wheels.
CAUTION:
Use a tire changer when removing the tire from
the wheel.
5) Remove the nut to take out transmitter.
NOTE:
Replace the grommet with a new part when reusing
transmitter.
2. TRANSMITTER (SNAP IN TYPE)
1) Remove the wheels from the vehicle. <Ref. to
WT-7, REMOVAL, Steel Wheel.>
2) Remove the tires from wheels.
CAUTION:
Use a tire changer when removing the tire from
the wheel.
3) Loosen the screw to remove the transmitter from
the valve.
NOTE:
Replace the valve and screw with a new part when
reusing transmitter.
4) Remove the valve stems from the wheel.
3. TIRE PRESSURE MONITORING
CONTROL MODULE
1) Remove the drivers seat. <Ref. to SE-9, RE-
MOVAL, Front Seat.>
2) Turn up the floor mat in the drivers seat area.
3) Remove the connector to remove tire pressure
monitoring control module.
(1) Transmitter
(2) Nut
(3) Wheel
(4) Tire
(5) Push
(1)
(4)
(5)
(2)
WT-00098
(3)
(1) Wheel
(2) Transmitter
(3) Screw
(4) Valve
WT-00125
(1)
(2)
(4)
(3)
WT-00073
WT-13
B: INSTALLATION
1. TRANSMITTER (CLAMP IN TYPE)
1) Install the transmitter to the wheel by aligning it
with valve hole, and then tighten with nuts.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.53 ft-lb)
2) Install the tires to wheels.
CAUTION:
Use a tire changer when installing tire to
wheel.
the figure.
3) Install the wheels to vehicle. <Ref. to WT-7, IN-
STALLATION, Steel Wheel.>
4) Register the transmitter ID to the tire pressure
monitoring control module. <Ref. to TPM(diag)-10,
REGISTER TRANSMITTER ID, OPERATION, Sub-
(1) Transmitter
(2) Grommet
(3) Nut
(4) Wheel
WT-00072
(2)
(3)
(4)
(1)
(3) (2) (1) (4)
(1) Transmitter
(3) 90
(1)
WT-00071
(3)
(4)
(2)
WT-14
2. TRANSMITTER (SNAP IN TYPE)
CAUTION:
Use the new transmitter assembly or replace
the new valve and screw, when installing.
1) Replace the valve and screw with a new part
when reusing transmitter.
Tightening torque:
1.4 Nm (0.1 kgf-m, 1 ft-lb)
2) Install the transmitter to the wheel by aligning it
with valve hole.
3) Install the tires to wheels.
CAUTION:
Use a tire changer when installing tire to
wheel.
the figure.
4) Install the wheels to vehicle. <Ref. to WT-7, IN-
STALLATION, Steel Wheel.>
5) Register the transmitter ID to the tire pressure
monitoring control module. <Ref. to TPM(diag)-10,
REGISTER TRANSMITTER ID, OPERATION, Sub-
3. TIRE PRESSURE MONITORING
CONTROL MODULE
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
C: ADJUSTMENT
Re-register the transmitter ID when transmitter has
been replaced or tires have been rotated. <Ref. to
TPM(diag)-10, REGISTER TRANSMITTER ID,
(1) Screw
(2) Transmitter
(3) Valve
(1) Transmitter
(3) 90
WT-00126
(2)
(3)
(1)
(1)
WT-00071
(3)
(4)
(2)
WT-15
A: INSPECTION
Wheel is out of balance. Improperly inflated tire. Adjust the tire pressure.
Uneven wear Check the tire referring to Abnormal
tire wear in this table, carry out the
procedure and replace the tire.
Front wheel alignment Check the front wheel alignment.
<Ref. to FS-8, INSPECTION, Wheel
Alignment.>
Rear wheel alignment Check the rear wheel alignment.
<Ref. to RS-7, INSPECTION, Wheel
Alignment.>
Front strut Check the front strut. <Ref. to FS-
25, INSPECTION, Front Strut.>
Rear shock absorber Check the rear shock absorber.
<Ref. to RS-16, INSPECTION, Rear
Shock Absorber.>
Front axle Check the front axle. <Ref. to DS-
16, INSPECTION, Front Axle.>
Front hub unit bearing Check the front hub unit bearing.
<Ref. to DS-18, INSPECTION, Front
Hub Unit Bearing.>
Rear hub unit bearing Check the rear hub unit bearing.
<Ref. to DS-22, INSPECTION, Rear
Hub Unit Bearing.>
Vehicle is abnormally out of
balance.
Improperly inflated tire. Adjust the tire pressure.
Front stabilizer Inspect the front stabilizer. <Ref. to
FS-17, INSPECTION, Front Stabi-
lizer.>
Alignment.>
Alignment.>
Abnormal wheel vibration Improperly inflated tire. Adjust the tire pressure.
Improper wheel balancing Check the wheel balance. <Ref. to
WT-9, ADJUSTMENT, Wheel Bal-
ancing.>
Front axle Check the front axle. <Ref. to DS-
16, INSPECTION, Front Axle.>
Front hub unit bearing Check the front hub unit bearing.
<Ref. to DS-18, INSPECTION, Front
Hub Unit Bearing.>
Rear hub unit bearing Check the rear hub unit bearing.
<Ref. to DS-22, INSPECTION, Rear
Hub Unit Bearing.>
WT-16
Abnormal tire wear Improperly inflated tire. Adjust the tire pressure.
Improper wheel balancing Check the wheel balance. <Ref. to
WT-9, ADJUSTMENT, Wheel Bal-
ancing.>
Alignment.>
Alignment.>
TPM(diag)-2
TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)
A: PROCEDURE
CAUTION:
Remove foreign matter (dust, water, oil etc.) from the tire pressure monitoring control module con-
nector when removing or installing.
NOTE:
To check harness for broken wires or short circuits, shake the suspected trouble spot or connector.
Step Check Yes No
1) Check with the user regarding when the
warning light lit or started blinking.
2) Before performing diagnostics, check all
components which may adversely affect the tire
pressure monitor system. <Ref. to TPM(diag)-
3, INSPECTION, General Description.>
Is the component that might
affect the tire pressure monitor
system normal?
each component.
2 CHECK DIAGNOSTIC TROUBLE CODE
(DTC).
2) Connect the Subaru Select Monitor to data
link connector.
NOTE:
If the communication function of the Subaru Se-
lect Monitor cannot be executed normally,
check the communication circuit. <Ref. to
TPM(diag)-11, COMMUNICATION FOR INI-
TIALIZING IMPOSSIBLE, INSPECTION, Sub-
4) Read the DTC. <Ref. to TPM(diag)-16,
OPERATION, Read Diagnostic Trouble Code
(DTC).>
Is DTC displayed? Go to step 4. Go to step 3.
1) Perform the inspection by referring to Gen-
eral Diagnostic Table. <Ref. to TPM(diag)-38,
General Diagnostic Table.>
2) Perform Clear Memory Mode. <Ref. to
TPM(diag)-10, CLEAR MEMORY, OPERA-
3) Perform Inspection Mode. <Ref. to
TPM(diag)-17, Inspection Mode.>
4) Read the DTC. <Ref. to TPM(diag)-8, READ
DIAGNOSTIC TROUBLE CODE (DTC),
Check that there is no DTC displayed.
Does the tire pressure warning
light illuminates for about 2 sec-
onds and then foes off after
turning on the ignition switch,
and then go out?
Finish the diagno-
sis.
Check by referring
to Diagnostic Pro-
cedure for TPM.
<Ref. to
TPM(diag)-14,
WITHOUT DTC,
INSPECTION,
Subaru Select
Monitor.>
1) Refer to List of Diagnostic Trouble Code
(DTC).
2) Correct the cause of trouble.
4) Perform the drive test.
Drive the vehicle at 40 km/h (25 MPH) or faster
for at least 10 minutes.
Is DTC displayed? Repeat steps 1 to 4
until DTC is not
shown.
Finish the diagno-
sis.
TPM(diag)-3
General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM
AIRBAG
Airbag system wiring harness is routed near the
TPM control module.
CAUTION:
All airbag system wiring harnesses are yel-
low. Do not use the electrical test equipment on
these circuits.
wiring harness when servicing the tire pressure
monitoring control module.
2. TIRE PRESSURE MONITORING CON-
TROL MODULE
If the transmitter is replaced, ID registration for the
transmitter is required. <Ref. to TPM(diag)-10, REG-
ISTER TRANSMITTER ID, OPERATION, Subaru
Select Monitor.>
When adjusting tire pressure indoors in winter,
there is a big temperature difference between the
indoor facilities and outside. Once the car is outside
where the temperature is lower, the air pressure in
the tires will drop, causing the tire pressure warning
light to illuminate, even if the pressure in the tires
was adjusted to standard values indoors. To avoid
this, it is necessary to adjust the tire pressure to the
high side in consideration of the difference in tem-
perature between inside and outside according to
the following table.
a. 215/45ZR17
b. 215/45R18 and P215/45R18, P205/50R17
c. P225/60R16 and P225/55R17
B: INSPECTION
Before performing diagnosis, check the following
item which might affect the quality of the tire pres-
sure monitoring system.
1. TIRE
Inspect that the tire pressure is within the speci-
fication while the tire is cool. (Refer to Tire Caution
Label.)
Check the tires for damage or the insertion of for-
eign matters.
2. BATTERY
Check that amount of battery fluid, gravity and volt-
age are within the specifications.
Standard voltage: 12 V or more
Temperature
C (F)
Indoor
temperature
15.5 (60)
Ambient
temperature
1 (30) 12 (10) 23 (10)
Air pressure
kPa (psi)
Front 265 (38) 280 (40) 295 (42)
Rear 250 (36) 265 (38) 280 (40)
Temperature
C (F)
Indoor
temperature
15.5 (60)
Ambient
temperature
1 (30) 12 (10) 23 (10)
Air pressure
kPa (psi)
Front 250 (36) 265 (38) 280 (40)
Rear 240 (35) 255 (37) 270 (39)
Temperature
C (F)
Indoor
temperature
15.5 (60)
Ambient
temperature
1 (30) 12 (10) 23 (10)
Air pressure
kPa (psi)
Front 240 (35) 255 (37) 270 (39)
Rear 230 (33) 245 (35) 260 (37)
TPM(diag)-4
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
MONITOR III KIT
TOOL NAME REMARKS
Transmitter registration tool Used to register the transmitter ID. Manufacturer: Kent-Moore
Item number: J45295
ST1B021XU0
TPM(diag)-5
A: LOCATION
module
(2) Tire pressure warning light (4) Snap-in type transmitter
(3) Clamp-in type transmitter
TPM00029
(2)
(1)
(3)
(3)
(1)
TPM00002 TPM00003
(2)
(3)
TPM00004
(4)
TPM00045
TPM(diag)-6
Control Module I/O Signal
4. Control Module I/O Signal
Terminal
No.
Measured value Measuring condition Remarks
1 Select monitor communication Serial communication
2 Tire pressure warning light output
Illuminate when malfunction occurs, or
tire pressure decreases
System failure: blinks 25 times
illuminates
Tire pressure decreases: turns on
4 Speed sensor signal While driving (Pulse signal)
Change according to vehicle
speed
5 Ignition power supply IG switch ON (Battery voltage)
6 Battery power supply Battery voltage Always
8
Body integrated unit (Hazard output
signal)
When hazard turns on.
9 GND 0 V (Always) Always
TPM(diag)-7
B: WIRING DIAGRAM
(1) Battery power supply (4) Antenna (8) Vehicle speed signal
(2) Ignition power supply (5) GND (9) Subaru Select Monitor
module
(6) Transmitter (10) Body integrated unit
(7) Combination meter
TPM00005
(6)
(6)
(6)
(6)
(1)
(2)
(7)
(9)
(5)
(8)
(10)
(3)
6
5
4
8
2
1
9
(4)
1 2 3 4 5 6
7 8 9 10 11 12
TPM(diag)-8
A: OPERATION
(DTC)
TPM(diag)-4, SPECIAL TOOL, PREPARATION
TOOL, General Description.>
2) Connect the diagnosis cable to the Subaru Se-
lect Monitor.
link connector.
(1) The data link connector is located in the low-
er portion of the instrument panel (on the driv-
ers side).
(2) Connect the diagnosis cable to the data link
connector.
CAUTION:
ru Select Monitor.
run the Subaru Select Monitor.
Check}.
6) On the System Selection Menu, select {Tire
Pressure Monitor}.
7) After {Model Year} is displayed, select [OK].
8) On the Tire Pressure Monitor Diagnosis, se-
lect {DTC Display}.
NOTE:
refer to the help file for Subaru Select Monitor.
For details concerning DTCs, refer to List of Di-
agnostic Trouble Codes (DTC). <Ref. to TPM(di-
All DTCs detected will be displayed.
If a particular DTC is not properly stored in mem-
ory (due to a voltage drop of the tire air pressure
monitor control module power supply, etc.) when a
problem occurs, a DTC suffixed with a question
mark will appears on the Subaru Select Monitor
display. This shows it may be an unreliable read-
ing.
9) If communication is not possible between the tire
pressure monitoring control module and the Suba-
ru Select Monitor, check the communication circuit.
<Ref. to TPM(diag)-11, COMMUNICATION FOR
INITIALIZING IMPOSSIBLE, INSPECTION, Suba-
ru Select Monitor.>
10) When DTC is not displayed, check the indicator
circuit and communication circuit. <Ref. to TPM(di-
ag)-14, WITHOUT DTC, INSPECTION, Subaru
Select Monitor.>
ABS00465
(1)
TPM(diag)-9
2. DATA DISPLAY
2) On the System Selection Menu, select {Tire Pressure Monitor}.
3) After the {Tire Pressure Monitor} is displayed, select [OK].
4) On the Tire Pressure Monitor Diagnosis, select the {Data Display}, and then necessary data will be dis-
played.
1. Data monitor (Analog)
Display Contents to be monitored Unit of measure
FR FN Code
LEARN, LOW BAT, OFF, WAKE, RE ME,
NORMAL
LEARN: Transmitted transmitter ID using the
transmitter registration tool
LOW BAT: Transmitter battery voltage running
low
OFF: Transmitter function stops (no data trans-
mission)
RE ME: Tire air changes 8.4 kPa
WAKE: When data transmission is started from a
stopped state.
NORMAL: Conditions other than above
FL FN Code
RR FN Code
RL FN Code
FR tire pressure
Value converted to tire pressure from data
delivered from transmitter is displayed.
(The figure may differ from the actual mea-
sured values.)
kPa, psig, mmHg, inHg
FL tire pressure kPa, psig, mmHg, inHg
RR tire pressure kPa, psig, mmHg, inHg
RL tire pressure kPa, psig, mmHg, inHg
Vehicle Speed
Vehicle speed signal which is input in control
module.
km/h, MPH
Pressure warning
Threshold where tire pressure warning light
illuminates
Return pressure
Threshold where tire pressure warning light
goes out
TPM(diag)-10
3. CLEAR MEMORY
1) On the Main Menu, select {2. Each System
Check}.
Pressure Monitor}.
3) After the {Tire Pressure Monitor} is displayed,
select [OK].
lect {Clear Memory}.
are shown on the display screen, end the Subaru
Select Monitor and turn the ignition switch to OFF.
NOTE:
For details concerning the operation procedure, re-
fer to the SUBARU SELECT MONITOR OPERA-
TION MANUAL.
4. REGISTER TRANSMITTER ID
Perform the procedures below to register the transmitter.
Transmitter replaced.
Replaced the tire pressure monitoring control
module.
NOTE:
If registration of the transmitter ID is not possible
after 2 attempts, replace the tire pressure monitor-
ing control module. <Ref. to WT-12, TIRE PRES-
SURE MONITORING CONTROL MODULE,
REMOVAL, Tire Pressure Monitoring System.>
<Ref. to WT-14, TIRE PRESSURE MONITORING
CONTROL MODULE, INSTALLATION, Tire Pres-
sure Monitoring System.>
During the registration, turn the ignition switch to
OFF and end the Subaru Select Monitor. Or if the
registration is not performed for 5 minutes or more,
the registration mode is cancelled.
When rotating tires, there is no affect on the per-
formance or functions of the tire pressure monitor-
ing control module even if the transmitter (ID) is not
registered, however, the tire position displayed on
the Subaru Select Monitor will be incorrect.
1) Adjust all tire pressures to the specifications.
2) Connect Subaru Select Monitor and select {2.
Each System Check} on the Main Menu.
Pressure Monitor}.
select [OK].
lect {Transmitter ID regist confirm}.
6) {When ID registration mode execute, Registered
ID is deleted Proceed?} is displayed, select [OK].
7) Touch the transmitter registration tool to the side
wall area near the air valve on the front left tire, and
press the switch. The transmitter ID is sent to the
tire pressure monitoring control module. (At that
time, the tire pressure warning light blinks to con-
firm that the registration has started.)
NOTE:
The registration order of transmitter ID is not
specified.
The transmitter registration tool is used by touch-
ing the side wall area near the transmitter.
When registration of each tire is completed, the
hazard light will blink and {ID registration complet-
ed} is displayed on the Select Monitor screen.
If registration procedure stop in the halfway
(turning ignition switch to OFF, wrong registration
order, etc), proceed from step 5)
8) When ID registration is completed, the tire pres-
sure warning light remains lit for approximately 2
seconds, to end the registration. Switch to the
screen displaying the transmitter ID on the Subaru
Select Monitor display. <Ref. to TPM(diag)-10, DIS-
PLAY TRANSMITTER (ID)., OPERATION, Subaru
Select Monitor.>
9) Check the transmitter ID that was registered,
then perform a driving test. <Ref. to TPM(diag)-17,
PROCEDURE, Inspection Mode.>
5. DISPLAY TRANSMITTER (ID).
Check}.
Pressure Monitor}.
select [OK].
lect {Transmitter ID regist confirm}.
5) Select the {Transmitter ID Data Monitor} and
then select [OK] to display the transmitter ID.
(1) Air valve (transmitter)
(2) Transmitter registration tool
(1)
(2)
TPM00006
TPM(diag)-11
B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
TROUBLE SYMPTOM:
Communication is impossible between the tire pressure monitoring control module and the Subaru Select
Monitor.
WIRING DIAGRAM:
B40
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
S
B
F
-
1
S
B
F
-
8
N
o
.
4
B40
R211
E
16
7
19 5
IGNITION
RELAY
BATTERY
DATA LINK
CONNECTOR
N
o
.
1
3
TPM CONTROL MODULE
R211
1 2 3 4 5 6
7 8 9 10 11 12
1
2
B97
R1
B97
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
TPM00024
TPM(diag)-12
Step Check Yes No
1 CHECK IGNITION SWITCH. Is the ignition switch ON? Go to step 2. Turn the ignition
switch to ON, and
select TPM mode
using Subaru
Select Monitor.
2 CHECK BATTERY. Is the voltage 11 V or more? Go to step 3. Charge or replace
the battery.
3 CHECK BATTERY TERMINAL. Is there poor contact at battery
terminal?
Repair or tighten the
battery terminal.
Go to step 4.
COMMUNICATION.
whether communication to other systems can
be performed normally.
Is the system name displayed
COMMUNICATION.
2) Disconnect the tire pressure monitoring
control module connector.
4) Check whether communication to other sys-
tems can be executed normally.
Is the system name displayed
Replace the tire
pressure monitor-
ing control module.
<Ref. to WT-12,
TIRE PRESSURE
MONITORING
CONTROL MOD-
ULE, REMOVAL,
Tire Pressure Mon-
itoring System.>
Go to step 6.
CONNECTOR.
control module.
3) Measure the resistance between data link
more?
and connector
between each con-
trol module and data
link connector.
7 CHECK THE TIRE PRESSURE MONITORING
CONTROL MODULE OUTPUT SIGNAL.
2) Measure the voltage between tire pressure
monitoring control module and chassis ground.
and connector
between each con-
link connector.
TIRE PRESSURE MONITORING CONTROL
MODULE AND DATA LINK CONNECTOR.
Measure the resistance between tire pressure
monitoring control module and data link con-
nector.
(R211) No. 1 (B40) No. 7:
Is resistance less than 0.5 ? Go to step 9. Repair the harness
and connector
between tire pres-
sure monitoring con-
link connector.
9 CHECK TIRE PRESSURE MONITORING
CONTROL MODULE CONNECTOR.
Is the tire pressure monitoring
control module connector
inserted in the tire pressure
monitoring control module until
it locks?
Go to step 10. Insert the tire pres-
sure monitoring con-
trol module
connector into the tire
pressure monitoring
control module.
TPM(diag)-13
10 CHECK POWER SUPPLY CIRCUIT.
2) Measure the ignition power voltage
between tire pressure monitoring control mod-
ule connector and chassis ground.
Is the voltage 10 15 V? Go to step 11. Repair open circuit
of the harness
between the tire
pressure monitor-
ing control module
and battery.
TIRE PRESSURE MONITORING CONTROL
MODULE AND CHASSIS GROUND.
2) Disconnect the connector from the tire pres-
sure monitoring control module.
tire pressure monitoring control module and
chassis ground.
Is the resistance less than 0.5 ? Go to step 12. Repair open circuit
of the harness of
the tire pressure
monitoring control
module.
12 CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in tire
pressure monitoring control
module power supply, ground
circuit and data link connector?
Repair the connec-
tor.
Replace the tire
pressure monitor-
ing control module.
<Ref. to WT-12,
TIRE PRESSURE
MONITORING
CONTROL MOD-
ULE, REMOVAL,
Tire Pressure Mon-
itoring System.>
Step Check Yes No
TPM(diag)-14
2. WITHOUT DTC
Defective combination meter
Defective harness
TROUBLE SYMPTOM:
TIRE PRESSURE WARNING LIGHT DOES NOT GO OFF
NO TROUBLE CODE will be displayed on the Subaru Select Monitor.
NOTE:
When the tire pressure warning light is OFF and NO TROUBLE CODE is displayed on Subaru Select Mon-
itor, the system is in a normal condition.
WIRING DIAGRAM:
FB-36
F/B FUSE NO.5
(IG)
26
A: i10
B: i11
A
3
B
6
FB-17
F/B FUSE NO. 7
(B)
i102
R167
R211
FB-48
F/B FUSE NO. 4
(IG)
1
6
5
9
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B: i11
i102
1 2 3
8 9 10
4
11 12 13 14 15 16
5 6 7
A: i10
1 2 3 4 5 6 7 8 9 10
11 12 19 20 21 13 14 15 16 17 18 22
R211
1 2 3 4 5 6
7 8 9 10 11 12
TPM00042
TO POWER SUPPLY CIRCUIT
COMBINATION
METER
TIRE INFLATION
PRESSURE
WARNING LIGHT
DRIVE CIRCUIT
MICRO COMPUTER
TPM CONTROL MODULE
TPM(diag)-15
Step Check Yes No
1 CHECK SUBARU SELECT MONITOR DATA.
1) Select {Current Data Display & Save} in
2) Read the data of the Tire pressure warning
light.
Is ON indicated? Replace the tire
pressure monitor-
ing control module.
<Ref. to WT-12,
TIRE PRESSURE
MONITORING
CONTROL MOD-
ULE, REMOVAL,
Tire Pressure Mon-
itoring System.>
Go to step 2.
2 CHECK WIRING HARNESS.
Measure the resistance between tire pressure
monitoring control module and combination
meter connector.
(i11) No. 6 (R211) No. 2:
Is the resistance less than 0.5 ? Go to step 3. Repair the harness
and connector
between tire pres-
sure monitoring
control module and
combination meter.
3 CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in the tire
pressure monitoring control
module connector and combi-
Repair the connec-
tor.
Check the combi-
nation meter.
TPM(diag)-16
Code (DTC)
A: OPERATION
For details regarding reading of DTCs, refer to
Subaru Select Monitor. <Ref. to TPM(diag)-8,
TPM(diag)-17
Inspection Mode
7. Inspection Mode
A: PROCEDURE
Reproduce the malfunction occurrence condition
as much as possible. Drive the vehicle at 40 km/h
(25 MPH) or faster for at least ten minutes.
TPM(diag)-18
Clear Memory Mode
A: OPERATION
For details concerning DTC clear operation, refer to
Subaru Select Monitor. <Ref. to TPM(diag)-8,
TPM(diag)-19
Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern
9. Tire Pressure Warning Light / Trouble Indicator Light Illumination
Pattern
A: INSPECTION
(1) Ignition switch (8) Tire pressure warning light (14) Tire pressure warning light
(2) OFF (9) Light OFF (15) Light OFF
(3) ON (10) Light ON (16) Blink
(4) Start (11) System status (17) 1 second
(5) Tire pressure (12) Normal (18) Blinks 25 times
(6) Meet the specification (13) Malfunction (19) 2 seconds
(7) 180 kPa (1.8 kgf/cm
2
, 26 psi),
or less
TPM00043
(2)
(3)
(4)
(3)
(5)
(6)
(7)
(8)
(9)
(10)
(2)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(19)
(10)
(9)
(19)
(1)
(18)
TPM(diag)-20
1) When the tire pressure warning light does not illuminate in accordance with this illumination pattern, there
must be an electrical malfunction.
2) If the tire pressure warning light does not go off, check the tire pressure monitoring control module/warning
light circuit and the combination meter circuit. <Ref. to TPM(diag)-22, TIRE PRESSURE WARNING LIGHT
DOES NOT COME OFF, Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern.>
NOTE:
If the problem is fixed while driving at approximately 40 km/h (25 MPH) after the tire pressure warning light
blinks/lights, the warning light goes out and the tire pressure monitor system operates normally. (If there is
a decrease in tire pressure, or a malfunction of the system, the malfunction history is displayed.)
TPM(diag)-21
B: TIRE PRESSURE WARNING LIGHT DOES NOT COME ON
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), the tire pressure warning light does not come on (for
approximately 2 seconds).
WIRING DIAGRAM:
Step Check Yes No
(DTC).
Connect the Subaru Select Monitor, and read
the Diagnostic Trouble Code. <Ref. to
TPM(diag)-8, READ DIAGNOSTIC TROUBLE
Monitor.>
Is diagnostics code (DTC)
displayed?
Perform the diag-
nosis according to
the DTC. <Ref. to
TPM(diag)-26, List
of Diagnostic Trou-
ble Code (DTC).>
Replace the com-
bination meter.
<Ref. to IDI-19,
REMOVAL, Com-
bination Meter.>
FB-36
F/B FUSE NO.5
(IG)
26
A: i10
B: i11
A
3
B
6
FB-17
F/B FUSE NO. 7
(B)
i102
R167
R211
FB-48
F/B FUSE NO. 4
(IG)
1
6
5
9
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B: i11
i102
1 2 3
8 9 10
4
11 12 13 14 15 16
5 6 7
A: i10
1 2 3 4 5 6 7 8 9 10
11 12 19 20 21 13 14 15 16 17 18 22
R211
1 2 3 4 5 6
7 8 9 10 11 12
TPM00042
COMBINATION
METER
TIRE INFLATION
PRESSURE
WARNING LIGHT
DRIVE CIRCUIT
MICRO COMPUTER
TPM CONTROL MODULE
TPM(diag)-22
C: TIRE PRESSURE WARNING LIGHT DOES NOT COME OFF
Tires pressure drop
Transmitter ID not registered
TROUBLE SYMPTOM:
Tire pressure warning light remains illuminating after engine starts.
WIRING DIAGRAM:
FB-36
F/B FUSE NO.5
(IG)
26
A: i10
B: i11
A
3
B
6
FB-17
F/B FUSE NO. 7
(B)
i102
R167
R211
FB-48
F/B FUSE NO. 4
(IG)
1
6
5
9
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B: i11
i102
1 2 3
8 9 10
4
11 12 13 14 15 16
5 6 7
A: i10
1 2 3 4 5 6 7 8 9 10
11 12 19 20 21 13 14 15 16 17 18 22
R211
1 2 3 4 5 6
7 8 9 10 11 12
TPM00042
COMBINATION
METER
TIRE INFLATION
PRESSURE
WARNING LIGHT
DRIVE CIRCUIT
MICRO COMPUTER
TPM CONTROL MODULE
TPM(diag)-23
Step Check Yes No
(DTC).
Monitor.>
nosis according to
the DTC. <Ref. to
TPM(diag)-26, List
of Diagnostic Trou-
ble Code (DTC).>
Go to step 2.
2 CHECK TRANSMITTER (ID).
Display the transmitter ID of the tire pressure
monitor system.
Is the transmitter ID registered? Go to step 3. Register the trans-
mitter ID. <Ref. to
TPM(diag)-10,
REGISTER
TRANSMITTER
ID, OPERATION,
Subaru Select
Monitor.>
3 CHECK TRANSMITTER DATA OUTPUT.
1) Select data display of the tire pressure
monitoring.
2) Start the engine and check the tire pressure
warning light output.
Is the warning light output ON? Replace the tire
pressure monitor-
ing control module.
<Ref. to WT-12,
TIRE PRESSURE
MONITORING
CONTROL MOD-
ULE, REMOVAL,
Tire Pressure Mon-
itoring System.>
Replace the com-
bination meter.
<Ref. to IDI-19,
REMOVAL, Com-
bination Meter.>
TPM(diag)-24
D: TIRE PRESSURE WARNING LIGHT IS 25 TIMES BLINKING AND TURN ON
Tire pressure monitoring control module is faulty.
Defective harness
Transmitter is faulty.
TROUBLE SYMPTOM:
Every time the engine starts, tire pressure warning light blinks 25 times and then illuminates.
WIRING DIAGRAM:
FB-36
F/B FUSE NO.5
(IG)
26
A: i10
B: i11
A
3
B
6
FB-17
F/B FUSE NO. 7
(B)
i102
R167
R211
FB-48
F/B FUSE NO. 4
(IG)
1
6
5
9
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B: i11
i102
1 2 3
8 9 10
4
11 12 13 14 15 16
5 6 7
A: i10
1 2 3 4 5 6 7 8 9 10
11 12 19 20 21 13 14 15 16 17 18 22
R211
1 2 3 4 5 6
7 8 9 10 11 12
TPM00042
COMBINATION
METER
TIRE INFLATION
PRESSURE
WARNING LIGHT
DRIVE CIRCUIT
MICRO COMPUTER
TPM CONTROL MODULE
TPM(diag)-25
Step Check Yes No
(DTC).
Monitor.>
Is diagnostics code (DTC)
displayed?
Perform the diag-
nosis according to
the DTC. <Ref. to
TPM(diag)-26, List
of Diagnostic Trou-
ble Code (DTC).>
Go to step 2.
2 CHECK HARNESS.
terminal No. 2 of the tire pressure monitoring
control module connector (R211).
2) Turn the ignition switch to ON, and select
Oscilloscope from the Main Menu of Subaru
Select Monitor.
3) Check the voltage displayed.
3 CHECK HARNESS.
1) Check the output waveform displayed in the
oscilloscope of Subaru Select Monitor.
Is the pattern the same output
waveform as shown in the figure?
(1) 40020 ms Duty 50 %
High: Battery voltage
Low:1.5 V or less
Check the combi-
nation meter.
Replace the tire
pressure monitor-
ing control module.
<Ref. to WT-12,
REMOVAL, Tire
Pressure Monitor-
ing System.>
4 CHECK HARNESS.
control module connector.
terminal No. 2 of the tire pressure monitoring
control module connector (R211).
Oscilloscope from the Main Menu of Subaru
Select Monitor.
4) Check the voltage displayed.
Is the voltage 10 V or more? Replace the tire
pressure monitor-
ing control module.
<Ref. to WT-12,
REMOVAL, Tire
Pressure Monitor-
ing System.>
The harness
between the com-
bination meter
connector and the
tire pressure moni-
toring control mod-
ule connector is
shorted or open.
Repair or replace
the harness.
TPM00044
High
Low
(1)
TPM(diag)-26
A: LIST
DTC Item Contents of diagnosis Remarks
11 Tire 1 Air Pressure Decrease Tire pressure of tire 1 is reduced.
<Ref. to TPM(diag)-28, DTC 11 TIRE
1 AIR PRESSURE DECREASE, Diag-
nostic Procedure with Diagnostic Trou-
ble Code (DTC).>
ble Code (DTC).>
ble Code (DTC).>
ble Code (DTC).>
21 Transmitter 1 No Data Data cannot be received from transmitter 1.
<Ref. to TPM(diag)-29, DTC 21
TRANSMITTER 1 NO DATA, Diagnos-
tic Procedure with Diagnostic Trouble
Code (DTC).>
Code (DTC).>
Code (DTC).>
Code (DTC).>
31
Transmitter 1 Pressure Data
Abnormal
Transmitter 1 data contents are abnormal.
TRANSMITTER 1 PRESSURE DATA
ABNORMAL, Diagnostic Procedure
32
Abnormal
33
Abnormal
34
Abnormal
41
Transmitter 1 Function Code
Abnormal
Function code has error.
TRANSMITTER 1 FUNCTION CODE
TPM(diag)-27
42
Abnormal
43
Abnormal
44
Abnormal
51
Transmitter 1 Battery Voltage
Decrease
Transmitter battery voltage is low.
TRANSMITTER 1 BATTERY VOLT-
AGE DECREASE, Diagnostic Proce-
dure with Diagnostic Trouble Code
(DTC).>
52
Decrease
(DTC).>
53
Decrease
(DTC).>
54
Decrease
(DTC).>
61 Vehicle Speed Is Abnormal
Vehicle speed signal is not input to the
control module when the vehicle speed is
6 km/h (3.7 MPH) or more.
<Ref. to TPM(diag)-36, DTC 61 VEHI-
CLE SPEED IS ABNORMAL, Diag-
nostic Procedure with Diagnostic
DTC Item Contents of diagnosis Remarks
TPM(diag)-28
A: DTC 11 TIRE 1 AIR PRESSURE DECREASE
NOTE:
Refer to DTC 14 for the diagnostic procedure. <Ref. to TPM(diag)-28, DTC 14 TIRE 4 AIR PRESSURE DE-
CREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
B: DTC 12 TIRE 2 AIR PRESSURE DECREASE
NOTE:
C: DTC 13 TIRE 3 AIR PRESSURE DECREASE
NOTE:
D: DTC 14 TIRE 4 AIR PRESSURE DECREASE
Inflation pressure of tires dropped under specifications (180 kPs (1.8 kgf/cm
2
, 26.1 psi) or less).
TROUBLE SYMPTOM:
Tire pressure warning light illuminates.
CAUTION:
When driving vehicle to perform driving test, there should be always 2 persons (driver and checker)
to check.
Step Check Yes No
1 CHECK THE TIRES.
Lift up the vehicle and check for damage in the
tires.
Are there cracks or damage? Replace the tire.
<Ref. to WT-5,
Tire.>
Go to step 2.
2 CHECK THE TIRES.
Check the tire air pressure.
Is the tire pressure in the
specifications?
Go to step 3. Adjust the air
pressure.
3 CHECK TRANSMITTER.
Drive the vehicle at 40 km/h (25 MPH) or faster
and compare the data from the transmitter on
the four wheels.
Is there a transmitter with
different data?
Replace the trans-
mitter (tire pres-
sure sensor). <Ref.
to WT-12, Tire
Pressure Monitor-
ing System.>.
Go to step 4.
4 PERFORM DRIVING TEST.
2) Perform a driving test. <Ref. to TPM(diag)-
17, PROCEDURE, Inspection Mode.>
Is DTC displayed? Inspect by refer-
ring to Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).
<Ref. to
TPM(diag)-28,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
Finish the diagnosis.
TPM(diag)-29
E: DTC 21 TRANSMITTER 1 NO DATA
NOTE:
Refer to DTC 24 for the diagnostic procedure. <Ref. to TPM(diag)-30, DTC 24 TRANSMITTER 4 NO DATA,
F: DTC 22 TRANSMITTER 2 NO DATA
NOTE:
G: DTC 23 TRANSMITTER 3 NO DATA
NOTE:
TPM(diag)-30
H: DTC 24 TRANSMITTER 4 NO DATA
Data from each transmitter is not received for 8 minutes.
TROUBLE SYMPTOM:
Tire pressure warning light blinks 25 times and then illuminates.
CAUTION:
When driving vehicle to perform driving test, there should be always 2 persons (driver and checker)
to check.
Step Check Yes No
1 START FL TRANSMITTER.
1) Connect the Subaru Select Monitor and
then turn the ignition switch to ON.
2) Select Transmitter ID. <Ref. to TPM(diag)-
10, DISPLAY TRANSMITTER (ID)., OPERA-
3) Use the transmitter registration tool and
transmit the ID from the FL transmitter to check
Latest Received ID.
Is Latest Received ID
updated?
Go to step 2. Replace front left
transmitter.
2 CHECK FL TRANSMITTER ID.
Check the ID displayed in the updated ID dis-
play and the tire 1 registered ID.
Are the two IDs same? Go to step 3. Record the
received ID update
as the FL transmit-
ter. Go to step 3.
3 START FR TRANSMITTER.
Use the transmitter registration tool and trans-
mit the ID from the FR transmitter to check Lat-
est Received ID.
updated?
right transmitter.
4 CHECK FR TRANSMITTER ID.
received ID update
as the FR transmit-
ter. Go to step 5.
5 START RR TRANSMITTER.
mit the ID from the RR transmitter to check Lat-
est Received ID.
updated?
Go to step 6. Replace the RR
transmitter.
6 CHECK RR TRANSMITTER ID.
received ID update
as the RR transmit-
ter. Go to step 7.
7 START RL TRANSMITTER.
mit the ID from the RL transmitter to check Lat-
est Received ID.
updated?
Go to step 8. Replace the RL
transmitter.
8 CHECK RL TRANSMITTER ID.
received ID update
as the RL transmit-
ter. Go to step 9.
9 CHECK MALFUNCTION TRANSMITTER. Is ID recorded by this procedure? Go to step 10. Go to step 1.
10 CHECK MALFUNCTION TRANSMITTER.
Check the registered ID of the transmitter indi-
cated by DTC.
Is there checked ID in the
record?
Replace the trans-
mitter of the
recorded position.
Replace the trans-
mitter showing the
latest ID that is not
included in the reg-
istered IDs.
TPM(diag)-31
I: DTC 31 TRANSMITTER 1 PRESSURE DATA ABNORMAL
NOTE:
Refer to DTC 34 for the diagnostic procedure. <Ref. to TPM(diag)-32, DTC 34 TRANSMITTER 4 PRES-
SURE DATA ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
J: DTC 32 TRANSMITTER 2 PRESSURE DATA ABNORMAL
NOTE:
K: DTC 33 TRANSMITTER 3 PRESSURE DATA ABNORMAL
NOTE:
TPM(diag)-32
L: DTC 34 TRANSMITTER 4 PRESSURE DATA ABNORMAL
When comparing the data from each transmitter to the previous data, the change is large.
The pressure exceeds what the transmitter can measure. (Excessive pressure)
TROUBLE SYMPTOM:
Step Check Yes No
Latest Received ID.
updated?
transmitter.
received ID update
as the FL transmit-
ter. Go to step 3.
est Received ID.
updated?
right transmitter.
received ID update
as the FR transmit-
ter. Go to step 5.
est Received ID.
updated?
transmitter.
received ID update
as the RR transmit-
ter. Go to step 7.
est Received ID.
updated?
transmitter.
received ID update
as the RL transmit-
ter. Go to step 9.
9 CHECK MALFUNCTION TRANSMITTER. Is ID recorded by this proce-
dure?
cated by DTC.
record?
Replace the trans-
mitter of the
recorded position.
Replace the trans-
mitter showing the
latest ID that is not
included in the reg-
istered IDs.
TPM(diag)-33
M: DTC 41 TRANSMITTER 1 FUNCTION CODE ABNORMAL
NOTE:
Refer to DTC 44 for the diagnostic procedure. <Ref. to TPM(diag)-34, DTC 44 TRANSMITTER 4 FUNCTION
CODE ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
N: DTC 42 TRANSMITTER 2 FUNCTION CODE ABNORMAL
NOTE:
O: DTC 43 TRANSMITTER 3 FUNCTION CODE ABNORMAL
NOTE:
TPM(diag)-34
P: DTC 44 TRANSMITTER 4 FUNCTION CODE ABNORMAL
Unexpected function codes received from each transmitter.
TROUBLE SYMPTOM:
Step Check Yes No
Latest Received ID.
updated?
transmitter.
received ID update
as the FL transmit-
ter. Go to step 3.
est Received ID.
updated?
right transmitter.
received ID update
as the FR transmit-
ter. Go to step 5.
est Received ID.
updated?
transmitter.
received ID update
as the RR transmit-
ter. Go to step 7.
est Received ID.
updated?
transmitter.
received ID update
as the RL transmit-
ter. Go to step 9.
9 CHECK MALFUNCTION TRANSMITTER. Is ID recorded by this proce-
dure?
mitter indicated by
DTC.
cated by DTC.
record?
Replace the trans-
mitter of the
recorded position.
Replace the trans-
mitter indicated by
DTC.
TPM(diag)-35
Q: DTC 51 TRANSMITTER 1 BATTERY VOLTAGE DECREASE
NOTE:
Refer to DTC 54 for the diagnostic procedure. <Ref. to TPM(diag)-35, DTC 54 TRANSMITTER 4 BATTERY
VOLTAGE DECREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
R: DTC 52 TRANSMITTER 2 BATTERY VOLTAGE DECREASE
NOTE:
S: DTC 53 TRANSMITTER 3 BATTERY VOLTAGE DECREASE
NOTE:
T: DTC 54 TRANSMITTER 4 BATTERY VOLTAGE DECREASE
Low battery signals received 20 times from each transmitter.
TROUBLE SYMPTOM:
Step Check Yes No
1 CHECK TRANSMITTER.
1) Replace all transmitters and register their IDs.
<Ref. to TPM(diag)-10, REGISTER TRANSMIT-
TER ID, OPERATION, Subaru Select Monitor.>
2) Perform the Clear Memory Mode, and per-
form driving test.
Is the fault eliminated? Internal battery of
the transmitter had
worn out.
Replace the tire
pressure monitor-
ing control module.
<Ref. to WT-12,
REMOVAL, Tire
Pressure Monitor-
ing System.>
TPM(diag)-36
U: DTC 61 VEHICLE SPEED IS ABNORMAL
Vehicle speed function codes were received from the transmitter, but the vehicle speed signal was not input
to the module.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
4
A: i10
A
1
A
1
9
i102
R167
R211
I/F
1
2
9
i102
1 2 3
8 9 10
4
11 12 13 14 15 16
5 6 7
A: i10
1 2 3 4 5 6 7 8 9 10
11 12 19 20 21 13 14 15 16 17 18 22
R211
18
B301
B310
FB-17
F/B FUSE NO. 7
(B)
i3 B38
B301
4 5 6 7 8 9
16 17 18 19 20
2 3 1
21 22 23 24 25 26
10 11
13 14 12 15
B310
B38
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
2
3
3
3
1 2 3 4 5 6
7 8 9 10 11 12
A
B
S
VDC
ABS
VDC
12 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
13 4 5 6 7 8 9 2 3 1 10 11
43 44 45 46
TPM00027
MICRO
COMPUTER
SPEEDOMETER
COMBINATION
METER
: MODEL WITH VDC
: MODEL WITHOUT VDC
ABS
CONTROL MODULE
VDC
CONTROL MODULE
TPM CONTROL MODULE
TPM(diag)-37
Step Check Yes No
1 CHECK TIRE PRESSURE MONITORING
CONTROL MODULE.
1) Connect an oscilloscope to the terminal No.
4 of the tire pressure monitoring control module
connector (R211).
2) Drive the vehicle at 40 km/h (25 MPH) and
check the vehicle speed signal at that time.
Is the vehicle speed being
input?
Replace the tire
pressure monitor-
ing control module.
<Ref. to WT-12,
Tire Pressure
Monitoring Sys-
tem.>
Go to step 2.
2 CHECK HARNESS.
1) Disconnect the combination meter connec-
tor (i10).
2) Connect the tire pressure monitoring control
module connector (R211) and combination meter
connector (i10) and measure the resistance.
Is the resistance less than 0.5 ? Check the combi-
nation meter. <Ref.
to IDI-19,
REMOVAL, Com-
bination Meter.>
Repair or replace
the open circuit of
the harness.
TPM(diag)-38
A: INSPECTION
Tire pressure warning light illuminates. Tire pressure is reduced.
Improper tire pressure adjustment.
Punctured tire
Tire pressure warning light blinks
25 times and then illuminates.
Tire pressure monitoring system
has malfunction.
Air pressure sensor malfunction
Air pressure sensor is out of battery.
Defective vehicle harness
Tire pressure is dropping but the
warning light does not illuminate.
Tire pressure warning light does
not illuminate.
Air pressure sensor is faulty.
DI-2
General Description
DIFFERENTIALS
A: SPECIFICATION
1. REAR DIFFERENTIAL
When replacing a rear differential assembly, select the correct one 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.
For option code, refer to ID section. <Ref. to ID-2, IDENTIFICATION, Identification.>
Model
Sedan, Wagon
2.5 L Non-turbo 2.5 L Turbo
5MT AT 6MT 5MT AT
Rear differential type T-type VA1-type T-type T-type VA2-type
Identification T1 XJ T2 HY EW XZ
LSD type Torsen Viscous coupling
Type of gear Hypoid gear
Gear ratio (Number of gear teeth) 3.900 (39/10) 4.111 (37/9) 3.545 (39/11) 3.900 (39/10) 3.083 (37/12)
Oil capacity 0.8 2 (0.8 US qt, 0.7 Imp qt)
1.0 2
(1.1 US qt,
0.9 Imp qt)
0.8 2 (0.8 US qt, 0.7 Imp qt)
Model
OUTBACK
2.5 L Non-turbo 2.5 L Turbo
3.0 L
5MT AT 5MT AT
Rear differential type T-type VA2-type
Identification JE T2 CD TP CF XU
LSD type
Viscous
Coupling

Viscous
Coupling
Viscous coupling
Type of gear Hypoid gear
Gear ratio (Number of gear teeth) 4.111 (37/9) 4.444 (40/9) 3.272 (36/11)
Oil capacity 0.8 2 (0.8 US qt, 0.7 Imp qt)
DI-3
General Description
DIFFERENTIALS
2. IDENTIFICATION
Identification label positions are shown in the fol-
lowing figures. For details concerning identification,
refer to the ID section.
T-type
VA1-type
VA2-type
3. REAR DIFFERENTIAL GEAR OIL
GL5 (75W90)
CAUTION:
(1) Identification
(1) Identification
(1) Identification
ID-00056
(1)
DI-00396
(1)
DI-00397
(1)
(1) Item
(2) Rear differential gear oil
(3) API classification
(1)
(4)
GL-5
(3)
(2)
( C)
( F)
-30 -26 -15 15
90
85W
80W
75W -90
25 30 -5 0
-22 -15 23 32 86 59 77 5
MT-00001
DI-4
General Description
DIFFERENTIALS
4. SERVICE DATA
Drive pinion bear-
ing preload (For
new bearing)
Measure with spring measurement. (Measured
from the companion flange bolt) N (kgf, lbf)
T-type
(Except for GT
spec. B 6MT
model)
17.7 38.8 (1.8 4.0, 4.0 8.7)
T-type
(GT spec. B 6MT
model)
24.1 38.6 (2.5 3.9, 5.4 8.7)
VA-type 12.7 32.2 (1.3 3.3, 2.9 7.2)
Measure with torque wrench Nm (kgf-m, ft-lb)
T-type
(Except for GT
spec. B 6MT
model)
0.67 1.47 (0.07 0.15, 0.49 1.08)
T-type
(GT spec. B 6MT
model)
0.91 1.46 (0.09 0.15, 0.67 1.08)
VA-type 0.48 1.22 (0.05 0.12, 0.35 0.90)
Side gear backlash mm (in) T-type 0.10 0.20 (0.004 0.008)
VA-type 0.05 0.15 (0.002 0.006)
Side bearing standard width mm (in) 20.00 (0.7874)
Hypoid driven gear to drive pinion backlash mm (in)
T-type 0.10 0.20 (0.004 0.008)
VA-type 0.10 0.15 (0.004 0.006)
Hypoid driven gear runout on its back surface mm (in) 0.05 (0.002)
DI-5
General Description
DIFFERENTIALS
5. ADJUSTING PARTS
T-type (except for GT spec. B 6MT model)
Part No. Length mm (in)
Preload adjusting collar
383695201 56.2 (2.213)
383695202 56.4 (2.220)
383695203 56.6 (2.228)
383695204 56.8 (2.236)
383695205 57.0 (2.244)
383695206 57.2 (2.252)
Preload adjusting washer
383705200 2.59 (0.1020)
383715200 2.57 (0.1012)
383725200 2.55 (0.1004)
383735200 2.53 (0.0996)
383745200 2.51 (0.0988)
383755200 2.49 (0.0980)
383765200 2.47 (0.0972)
383775200 2.45 (0.0965)
383785200 2.43 (0.0957)
383795200 2.41 (0.0949)
383805200 2.39 (0.0941)
383815200 2.37 (0.0933)
383825200 2.35 (0.0925)
383835200 2.33 (0.0917)
383845200 2.31 (0.0909)
Pinion height adjusting washer
383495200 3.09 (0.1217)
383505200 3.12 (0.1228)
383515200 3.15 (0.1240)
383525200 3.18 (0.1252)
383535200 3.21 (0.1264)
383545200 3.24 (0.1276)
383555200 3.27 (0.1287)
383565200 3.30 (0.1299)
383575200 3.33 (0.1311)
383585200 3.36 (0.1323)
383595200 3.39 (0.1335)
383605200 3.42 (0.1346)
383615200 3.45 (0.1358)
383625200 3.48 (0.1370)
383635200 3.51 (0.1382)
383645200 3.54 (0.1394)
383655200 3.57 (0.1406)
383665200 3.60 (0.1417)
383675200 3.63 (0.1429)
383685200 3.66 (0.1441)
Side gear thrust washer
(Model without LSD)
383445201 0.75 0.80 (0.0295 0.0315)
383445202 0.80 0.85 (0.0315 0.0335)
383445203 0.85 0.90 (0.0335 0.0354)
DI-6
General Description
DIFFERENTIALS
Side bearing retainer shim
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
Drive pinion bearing preload
Measure with spring measurement.
(Measured from the companion
flange bolt)
N (kgf, lb) 17.7 38.8 (1.8 4.0, 4.0 8.7)
Measure with torque wrench
Nm (kgf-m,
ft-lb)
0.67 1.47 (0.07 0.15, 0.49 1.08)
Side gear backlash mm (in) 0.10 0.20 (0.004 0.008)
Hypoid driven gear to drive pinion backlash limit mm (in) 0.10 0.20 (0.004 0.008)
Hypoid driven gear runout limit on its back surface mm (in) 0.05 (0.002)
DI-7
General Description
DIFFERENTIALS
T-type (GT spec. B 6MT model)
Drive pinion bearing preload (For new bearing)
(Measured from the companion flange
bolt) N (kgf, lbf)
24.1 38.6 (2.5 3.9, 5.4 8.7)
Measure with torque wrench
Nm (kgf-m, ft-lb)
0.91 1.46 (0.09 0.15, 0.67 1.08)
Preload adjusting spacer
31454AA130 52.2 (2.055)
31454AA140 52.4 (2.063)
31454AA150 52.6 (2.071)
31454AA160 52.8 (2.079)
31454AA170 53.0 (2.087)
31454AA180 53.2 (2.094)
383705200 2.59 (0.1020)
383715200 2.57 (0.1012)
383725200 2.55 (0.1004)
383735200 2.53 (0.0996)
383745200 2.51 (0.0988)
383755200 2.49 (0.0980)
383765200 2.47 (0.0972)
383775200 2.45 (0.0965)
383785200 2.43 (0.0957)
383795200 2.41 (0.0949)
383805200 2.39 (0.0941)
383815200 2.37 (0.0933)
383825200 2.35 (0.0925)
383835200 2.33 (0.0917)
383845200 2.31 (0.0909)
38336AA230 3.09 (0.1217)
38336AA240 3.12 (0.1228)
38336AA250 3.15 (0.1240)
38336AA260 3.18 (0.1252)
38336AA270 3.21 (0.1264)
38336AA280 3.24 (0.1276)
38336AA290 3.27 (0.1287)
38336AA300 3.30 (0.1299)
38336AA310 3.33 (0.1311)
38336AA320 3.36 (0.1323)
38336AA330 3.39 (0.1335)
38336AA340 3.42 (0.1346)
38336AA350 3.45 (0.1358)
38336AA360 3.48 (0.1370)
38336AA370 3.51 (0.1382)
38336AA380 3.54 (0.1394)
38336AA390 3.57 (0.1406)
38336AA400 3.60 (0.1417)
38336AA410 3.63 (0.1429)
38336AA420 3.66 (0.1441)
Side bearing standard width mm (in) 20.00 (0.7874)
DI-8
General Description
DIFFERENTIALS
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
Hypoid driven gear to drive pinion backlash
Limit mm (in)
0.10 0.20 (0.004 0.008)
Driven gear rear face runout limit 0.05 (0.002)
DI-9
General Description
DIFFERENTIALS
VA1-type
32288AA040 52.3 (2.059)
32288AA050 52.5 (2.067)
31454AA100 52.6 (2.071)
32288AA060 52.7 (2.075)
31454AA110 52.8 (2.079)
32288AA070 52.9 (2.083)
31454AA120 53.0 (2.087)
32288AA080 53.1 (2.091)
32288AA090 53.3 (2.098)
38336AA000 1.500 (0.0591)
38336AA120 1.513 (0.0596)
38336AA010 1.525 (0.0600)
38336AA130 1.538 (0.0606)
38336AA020 1.550 (0.0610)
38336AA140 1.563 (0.0615)
38336AA030 1.575 (0.0620)
38336AA150 1.588 (0.0625)
38336AA040 1.600 (0.0630)
38336AA160 1.613 (0.0635)
38336AA050 1.625 (0.0640)
38336AA170 1.638 (0.0645)
38336AA060 1.650 (0.0650)
38336AA180 1.663 (0.0655)
38336AA070 1.675 (0.0659)
38336AA190 1.688 (0.0665)
38336AA080 1.700 (0.0669)
38336AA200 1.713 (0.0674)
38336AA090 1.725 (0.0679)
38336AA210 1.738 (0.0684)
38336AA100 1.750 (0.0689)
38336AA220 1.763 (0.0694)
38336AA110 1.775 (0.0699)
32295AA200 0.150 (0.0059)
32295AA210 0.175 (0.0069)
32295AA220 0.200 (0.0079)
32295AA230 0.225 (0.0089)
32295AA240 0.250 (0.0098)
32295AA250 0.275 (0.0108)
803135011 0.925 0.950 (0.0364 0.0374)
803135012 0.950 0.975 (0.0374 0.0384)
803135013 0.975 1.000 (0.0384 0.0394)
803135014 1.000 1.025 (0.0394 0.0404)
803135015 1.025 1.050 (0.0404 0.0413)
DI-10
General Description
DIFFERENTIALS
flange bolt)
N (kgf, lb) 12.7 32.2 (1.3 3.3, 2.9 7.2)
Measure with torque wrench Nm (kgf-m, ft-lb) 0.48 1.22 (0.05 0.12, 0.35 0.90)
Side gear backlash mm (in) 0.05 0.15 (0.002 0.006)
DI-11
General Description
DIFFERENTIALS
VA2-type
31454AA250 51.05 (2.010)
31454AA260 51.25 (2.018)
31454AA270 51.35 (2.022)
31454AA280 51.45 (2.026)
31454AA290 51.55 (2.030)
31454AA300 51.65 (2.033)
31454AA310 51.75 (2.037)
31454AA320 51.85 (2.041)
31454AA330 52.05 (2.049)
38336AA430 1.500 (0.0591)
38336AA440 1.513 (0.0596)
38336AA450 1.525 (0.0600)
38336AA460 1.538 (0.0606)
38336AA470 1.550 (0.0610)
38336AA480 1.563 (0.0615)
38336AA490 1.575 (0.0620)
38336AA500 1.588 (0.0625)
38336AA510 1.600 (0.0630)
38336AA520 1.613 (0.0635)
38336AA530 1.625 (0.0640)
38336AA540 1.638 (0.0645)
38336AA550 1.650 (0.0650)
38336AA560 1.663 (0.0655)
38336AA570 1.675 (0.0659)
38336AA580 1.688 (0.0665)
38336AA590 1.700 (0.0669)
38336AA600 1.713 (0.0674)
38336AA610 1.725 (0.0679)
38336AA620 1.738 (0.0684)
38336AA630 1.750 (0.0689)
38336AA640 1.763 (0.0694)
38336AA650 1.775 (0.0699)
32295AA350 0.150 (0.0059)
32295AA360 0.175 (0.0069)
32295AA370 0.200 (0.0079)
32295AA380 0.225 (0.0089)
32295AA390 0.250 (0.0098)
32295AA400 0.275 (0.0108)
flange bolt)
N (kgf, lb) 12.7 32.2 (1.3 3.3, 2.9 7.2)
Measure with torque wrench Nm (kgf-m, ft-lb) 0.48 1.22 (0.05 0.12, 0.35 0.90)
DI-12
General Description
DIFFERENTIALS
B: COMPONENT
1. REAR DIFFERENTIAL WITHOUT LSD (T-TYPE)
(1) Hypoid driven gear and drive pin-
ion set
(14) O-ring (27) Oil filler plug
(15) Side bearing retainer shim (28) Oil drain plug
(2) Pinion height adjusting washer (16) Side bearing retainer (29) Rear cover
(3) Rear bearing (17) Side oil seal (30) Differential case
(4) Bearing preload adjusting collar (18) Side gear thrust washer (31) Gasket
(5) Bearing preload adjusting washer (19) Side gear
(6) Differential carrier (20) Pinion mate gear Tightening torque:Nm (kgf-m, ft-lb)
(7) Front bearing (21) Pinion mate gear washer T1: 10.5 (1.1, 7.7)
(8) Collar (22) Pinion shaft lock pin T2: 29.5 (3.0, 21.8)
(9) Pilot bearing (23) Snap ring T3: 49 (5.0, 36.2)
(10) Front oil seal (24) Pinion mate shaft T4: 103 (10.5, 76.0)
(11) Companion flange (25) Air breather cap T5: 181.5 (18.5, 134.0)
(12) Self-locking nut (26) Stud bolt
(13) Side bearing
(1)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(13)
(14)
(14)
(15)
(15)
(16)
(16)
(17)
(17)
(18)
(18)
(19)
(19)
(20)
(20)
(23)
(21)
(21)
(22)
(24)
(30)
(23)
(25)
(26)
(27)
(28)
(29)
(31)
T1
T2
T3
T3
T4
T5
T1
DI-00260
DI-13
General Description
DIFFERENTIALS
2. REAR DIFFERENTIAL WITH LSD (T-TYPE)
ion set
(13) Side bearing Tightening torque:Nm (kgf-m, ft-lb)
(14) O-ring T1: 10.5 (1.1, 7.7)
(2) Pinion height adjusting washer (15) Side bearing retainer shim T2: 29.5 (3.0, 21.8) (Except for GT
spec. B 6MT model)
44 (4.5, 32.5) (GT spec. B 6MT
model)
(3) Rear bearing (16) Side bearing retainer
(4) Bearing preload adjusting collar (17) Side oil seal
(5) Bearing preload adjusting washer (18) Gasket
(6) Differential carrier (19) Differential case ASSY T3: 49 (5.0, 36.2) (Except for GT
spec. B 6MT model)
60 (6.1, 44.3) (GT spec. B 6MT
model)
(7) Front bearing (20) Rear cover
(8) Collar (21) Air breather cap
(9) Pilot bearing (22) Stud bolt
(10) Front oil seal (23) Oil filler plug T4: 103 (10.5, 76.0)
(11) Companion flange (24) Oil drain plug T5: 181.5 (18.5, 134.0)
(12) Self-locking nut (25) Gasket (GT spec. B 6MT model)
DI-00497
T4
T1
T2
T3
T3
(18)
(14)
(5)
(4)
(1)
(21)
(22)
(23)
(24) (20)
(19)
(6)
(13)
(16)
(3)
(2)
(1)
(17)
(15)
T1
T5
(13)
(16)
(17)
(12)
(11)
(10)
(9)
(8)
(7)
(14)
(15)
(25)
T3
(25)
DI-14
General Description
DIFFERENTIALS
3. REAR DIFFERENTIAL (VA1-TYPE)
ion set
(13) Lock plate (25) Stud bolt
(14) Side bearing (26) Gasket
(2) Pinion height adjusting washer (15) O-ring (27) Oil filler plug
(3) Rear bearing (16) Axle shaft holder (28) Oil drain plug
(4) Bearing preload adjusting collar (17) Side oil seal (29) Rear cover
(5) Bearing preload adjusting washer (18) Side gear thrust washer (30) Gasket
(6) Differential carrier (19) Side gear
(7) Front bearing (20) Pinion mate gear Tightening torque:Nm (kgf-m, ft-lb)
(8) Collar (21) Pinion shaft lock pin T1: 25 (2.5, 18.5)
(9) Pilot bearing (22) Differential case T2: 34 (3.5, 25.1)
(10) Front oil seal (23) Pinion mate shaft T3: 62 (6.3, 45.8)
(11) Companion flange (24) Air breather cap T4: 191 (19.5, 141.0)
(12) Self-locking nut
DI-00296
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(13)
(14)
(15)
(16)
(17)
(29)
(26)
(28)
(27)
(26)
(25)
(22)
(23)
(21)
(24)
(14)
(30)
(15)
(16)
(17)
(18)
(18)
(19)
(19)
(20)
T1
T1
T1
T2
T3
T4
DI-15
General Description
DIFFERENTIALS
4. REAR DIFFERENTIAL (VA2-TYPE)
ion set
(12) Self-locking nut (23) Oil drain plug
(13) Lock plate (24) Rear cover
(2) Pinion height adjusting washer (14) Side bearing (25) Gasket
(3) Rear bearing (15) O-ring
(4) Bearing preload adjusting collar (16) Axle shaft holder Tightening torque:Nm (kgf-m, ft-lb)
(5) Bearing preload adjusting washer (17) Side oil seal T1: 25 (2.5, 18.5)
(6) Differential carrier (18) Differential case ASSY T2: 29 (3.0, 21.4)
(7) Front bearing (19) Air breather cap T3: 34 (3.5, 25.1)
(8) Collar (20) Stud bolt T4: 62 (6.3, 45.8)
(9) Pilot bearing (21) Gasket T5: 191 (19.5, 141.0)
(10) Front oil seal (22) Oil filler plug
(11) Companion flange
DI-00349
T4
T3
(14)
(5)
(4)
(1)
(24)
(20)
(18)
(19)
(25)
(16)
(3)
(2)
(17)
(15)
(21)
(21)
(22)
(23)
T1
T1
T5
(13)
(16)
(17)
(12)
(11)
(10)
(9)
(8)
(7)
(14)
(15)
(13)
T2
(6)
DI-16
General Description
DIFFERENTIALS
5. REAR DIFFERENTIAL MOUNTING SYSTEM
(1) Rear differential front member (5) Self-locking nut Tightening torque:Nm (kgf-m, ft-lb)
(2) Rear differential member plate T1: 50 (5.1, 36.9)
(3) Rear differential ASSY T2: 70 (7.1, 51.6)
(4) Sub frame T3: 110 (11.2, 81)
DI-00350
(4)
T2
T3
T1
(3)
(2)
(1)
(5)
(5)
(5)
DI-17
General Description
DIFFERENTIALS
C: CAUTION
forming any work.
points.
Before installing the O-ring or snap ring, apply a
sufficient amount of gear oil to avoid damage and
deformation.
DI-18
General Description
DIFFERENTIALS
D: PREPARATION TOOL
1. SPECIAL TOOL
398477701 HANDLE Used for installing the front and rear bearing
cones.
398477702 DRIFT Used for press-fitting the bearing cone of dif-
ferential carrier (front).
For T-type
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-19
General Description
DIFFERENTIALS
498427200 FLANGE WRENCH Used for stopping rotation of companion flange
when removing and tightening self-lock nut.
398467700 DRIFT Used for removing pinion, pilot bearing and
front bearing cone.
For T-type and VA1-type
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-20
General Description
DIFFERENTIALS
498247001 MAGNET BASE Used for measuring backlash between side
gear and pinion, and hypoid gear.
(498247100).
498247100 DIAL GAUGE Used for measuring backlash between side
gear and pinion, and hypoid gear.
(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.
For T-type
ST-498247001
ST-498247100
ST-398507704
ST-398177700
ST-398457700
DI-21
General Description
DIFFERENTIALS
398477703 DRIFT 2 Used for press-fitting bearing race (rear) of dif-
ferential carrier.
398437700 DRIFT Used for installing the side oil seal.
398507702 DUMMY SHAFT Used for adjusting pinion height and preload.
For T-type
398507703 DUMMY COLLAR Used for adjusting pinion height and preload.
For T-type
398517700 REPLACER Used for removing rear bearing cone.
ST-398477703
ST-398437700
ST-398507702
ST-398507703
ST-398517700
DI-22
General Description
DIFFERENTIALS
398487700 DRIFT Used for press-fitting side bearing cone.
398507701 DIFFERENTIAL
CARRIER GAUGE
Used for adjusting pinion height.
For T-type
398527700 PULLER ASSY Used for removing front oil seal.
Used for removing side bearing cup. (T-type)
28099PA090 OIL SEAL
PROTECTOR
rear differential.
For oil seal protection
28099PA100 DRIVE SHAFT
REMOVER
Used for removing the rear drive shaft from
rear differential.
For T-type
ST-398487700
ST-398507701
ST-398527700
ST28099PA090
ST28099PA100
DI-23
General Description
DIFFERENTIALS
399703600 PULLER ASSY Used for removing companion flange.
899874100 INSTALLER Used for installing the companion flange.
498077000 REMOVER Used for removing the differential side bearing
cone.
For VA2-type
899864100 REMOVER Used for removing the differential side bearing.
499277200 INSTALLER Used for installing the front bearing cone.
For VA2-type
ST-399703600
ST-899874100
ST-498077000
ST-899864100
ST-499277200
DI-24
General Description
DIFFERENTIALS
18758AA000 PULLER Used for removing side bearing cup.
For VA2-type
18759AA000 PULLER ASSY Used for removing the differential side bearing
cone.
For T-type
18678AA000 DUMMY SHAFT Used for adjusting pinion height and preload.
For VA2-type
CARRIER GAUGE
For VA2-type
RETAINER
Used for removing and installing the side oil
seal holder.
For VA-type
be used.
ST18758AA000
ST18759AA000
ST18678AA000
ST18831AA010
ST18630AA010
DI-25
General Description
DIFFERENTIALS
498175500 INSTALLER Used for installing the rear bearing cone.
For VA1-type
498447100 INSTALLER Used for installing the oil seal.
For VA1-type and T-type
399520105 SEAT Used for removing the side bearing cone.
Used together with the PULLER SET
(899524100).
For VA-type
498485400 DRIFT Used for installing side bearing cone.
For VA1-type
498505501 DIFFERENTIAL
CARRIER GAUGE
For VA1-type
ST-498175500
ST-498447100
ST-399520105
ST-498485400
ST-498505501
DI-26
General Description
DIFFERENTIALS
498447110 DRIFT Used for press-fitting the bearing race (front)
of the differential carrier.
For VA1-type
498447150 DUMMY SHAFT Used for adjusting pinion height and preload.
For VA1-type
899524100 PULLER SET Used for removing the differential side bearing
cone.
(1) Puller
(2) Cap
498515500 REPLACER Used for removing rear bearing cone.
For VA1-type
32285AA000 DUMMY COLLAR Used for adjusting pinion height and preload.
For VA1-type
ST-498447110
ST-498447150
ST-899524100
(1)
(2)
ST-498515500
ST32285AA000
DI-27
General Description
DIFFERENTIALS
2. GENERAL TOOL
499705404 SEAT Used for removing the side bearing race.
Used together with PULLER ASSY
(499705401).
For VA1-type
499705401 PULLER ASSY Used for removing the side bearing race.
Used together with SEAT (499705404).
For VA-type
TOOL NAME REMARKS
Transmission jack Used for assembly/disassembly of the rear differential.
Puller Used for removing the side bearing retainer.
Thickness gauge Used for measuring clearance.
Hexagon wrench Used for installing and removing the filler and drain plug.
Tire lever Used for removing the front drive shaft. (VA-type)
ST-499705404
ST-499705401
DI-28
DIFFERENTIALS
A: INSPECTION
1) Remove the filler plug, and then check the gear
oil. Replace the gear oil if it is contaminated or de-
teriorated. <Ref. to DI-28, REPLACEMENT, Differ-
ential Gear Oil.>
2) Check that the gear oil level is up to the bottom
of the filler plug hole. If the level is low, refill up to
the bottom of filler plug.
Except for VA2-type
VA2-type
B: REPLACEMENT
2) Remove the oil drain plug and filler plug, and
drain the gear oil.
CAUTION:
Be careful not to burn your hands, because
gear oil becomes extremely hot after running.
Except for VA2-type
VA2-type
(A) Filler plug
(B) Drain plug
(A) Filler plug
(B) Drain plug
DI-00354
(A)
(B)
(B)
DI-00355
(A)
(A) Filler plug
(B) Drain plug
(A) Filler plug
(B) Drain plug
DI-00356
(A)
(B)
(A)
DI-00357
(B)
DI-29
DIFFERENTIALS
3) Tighten the oil drain plug.
NOTE:
Apply liquid gasket to the drain plug for the T-
type (except for GT spec. B 6MT model).
Liquid gasket:
equivalent
Use a new copper gasket for the VA1-type and
T-type (GT spec. B 6MT model).
Use a new metal gasket for the VA2-type.
Tightening torque:
T-type (except for GT spec.B 6MT model):
49 Nm (5.0 kgf-m, 36.2 ft-lb)
T-type (GT spec. B 6MT model):
60 Nm (6.1 kgf-m, 44.3 ft-lb)
VA1-type:
34 Nm (3.5 kgf-m, 25.1 ft-lb)
VA2-type:
29 Nm (3.0 kgf-m, 21.4 ft-lb)
4) Fill the differential carrier with gear oil to the bot-
tom of filler plug.
NOTE:
Carefully refill oil while watching the level. Exces-
sive or insufficient oil must be avoided.
<Ref. to DI-2, SPECIFICATION, General
Description.>
Oil capacity:
Except for GT spec. B 6MT model:
0.8 2 (0.8 US qt, 0.7 Imp qt)
GT spec. B 6MT model:
1.0 2 (1.1 US qt, 0.9 Imp qt)
Except for VA2-type
VA2-type
5) Install the filler plug.
NOTE:
Apply liquid gasket to the filler plug for the T-type
(except for GT spec. B 6MT model).
Liquid gasket:
equivalent
Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
60 Nm (6.1 kgf-m, 44.3 ft-lb)
VA1-type:
34 Nm (3.5 kgf-m, 25.1 ft-lb)
VA2-type:
29 Nm (3.0 kgf-m, 21.4 ft-lb)
(A) Filler plug
(B) Drain plug
DI-00391
(A)
(B)
(A) Filler plug
(B) Drain plug
(B)
DI-00355
(A)
DI-30
DIFFERENTIALS
3. Front Differential Assembly
A: NOTE
1. AT MODEL
4AT
For front differential of 4AT model, refer to 4AT
section. <Ref. to 4AT-104, Front Differential As-
sembly.>
5AT
For front differential of 5AT model, refer to 5AT
section. <Ref. to 5AT-92, Front Differential Assem-
bly.>
2. MT MODEL
5MT
For front differential of the 5MT model, refer to
5MT section. <Ref. to 5MT-68, Front Differential
Assembly.>
6MT
For front differential of the 6MT model, refer to
6MT section. <Ref. to 6MT-98, Front Differential
Assembly.>
DI-31
Rear Differential (T-type)
DIFFERENTIALS
4. Rear Differential (T-type)
A: REMOVAL
2) Shift the select lever or gear shift lever to neutral.
3) Release the parking brake.
2.5 L SOHC Non-turbo
Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.>
2.5 L DOHC turbo model
AL, Muffler.>
8) Prepare the transmission jack and band.
9) Loosen the self-lock nuts which hold the rear dif-
ferential to rear crossmember.
10) Remove the DOJ of rear drive shaft from rear
differential using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
11) Remove the rear differential front member.
12) Support the rear differential with the transmis-
sion jack.
13) Secure the rear differential using band.
14) Remove the self-lock nuts which hold the rear
differential to the crossmember.
AT-01331
DI-00268
DI-00269
(A) Bolt
DI-00270
(A)
ST
DI-00358
DI-00273
DI-32
DIFFERENTIALS
15) Remove the rear differential stud bolt from rear
crossmember bushing.
NOTE:
When removing the stud bolt, carefully adjust the
angle and location of transmission jack and jack
stand, if necessary
16) Lower the transmission jack stand after remov-
ing the rear differential stud bolt from the rear
crossmember. Rear drive shaft should not come
into contact with the lateral link bolt.
17) Pull out the axle shaft from rear differential.
NOTE:
If it is difficult to remove the axle shaft from the rear
differential, remove it using a ST.
ST 28099PA100 DRIVE SHAFT REMOVER
19) Secure the rear drive shaft to lateral link using
wire.
20) Remove the rear differential member plate from
rear differential.
B: INSTALLATION
1) Install the rear differential member plate to the
rear differential.
2) Set the rear differential to transmission jack.
NOTE:
Secure the rear differential to transmission jack us-
ing band.
DI-00400
DI-00392
DI-00276
(A) Rear differential member plate
DI-00277
DI-00359
(A)
DI-00359
(A)
DI-33
DIFFERENTIALS
3) Attach the ST to rear differential.
ST 28099PA090 OIL SEAL PROTECTOR
4) Insert the spline shaft until the spline portion
comes inside the side oil seal.
5) Remove ST from rear differential.
6) Push the rear differential to insert the axle shaft
into rear differential.
7) Adjust the transmission jack, if necessary, and
insert the rear differential stud bolt into rear cross-
member bushing properly.
8) After inserting the rear differential stud bolt into
the rear crossmember bushing, lift up the transmis-
sion jack and align the rear differential to its attach-
ment position.
9) Tighten a new self-locking nut temporarily to rear
crossmember.
10) Remove the band from rear differential. Lift up
the rear differential until the rear differential is sep-
arated from the transmission jack.
11) Install the rear differential front member with a
new self-locking nut.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 110 Nm (11.2 kgf-m, 81 ft-lb)
DI-00279
ST
DI-00280
DI-00281
DI-00393
DI-00283
DI-00269
DI-00284
T2
T1
DI-34
DIFFERENTIALS
12) Tighten the self-locking nut.
Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
2.5 L SOHC Non-turbo
TION, Muffler.>
17) After installing the rear differential carrier to the
vehicle, remove the filler plug, and refill with gear oil
up to the lower lip of the plug hole.
Oil capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
1.0 2 (1.1 US qt, 0.9 Imp qt)
18) Tighten the filler plug.
NOTE:
Apply liquid gasket to the filler plug. (Except for
GT spec. B 6MT model)
Liquid gasket:
equivalent
Use a new copper gasket. (GT spec. B 6MT
model)
Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
60 Nm (6.1 kgf-m, 44.3 ft-lb)
C: DISASSEMBLY
To detect the real cause of trouble, inspect the fol-
lowing items before disassembling.
Tooth contact and backlash of hypoid driven
gear and drive pinion.
Hypoid driven gear runout on its back surface
Total preload of drive pinion
1) Set the ST on vise and install the differential as-
sembly to ST.
ST 398217700 ATTACHMENT SET
drain the gear oil.
(A) Filler plug
(B) Drain plug
DI-00269
DI-00285
(A)
(B)
ST
DI-00061
DI-35
DIFFERENTIALS
3) Remove the air breather cap.
NOTE:
Do not attempt to replace the air breather cap un-
less necessary.
Whenever the air breather cap is removed, re-
place it with a new part.
4) Remove the bolts, and then remove the rear
cover.
NOTE:
Remove it by tapping with a plastic hammer.
5) Keep the side bearing retainers separate to
make it possible to identify RH and LH sides. Re-
move the side bearing retainer attaching bolts, set
the ST to differential case, and extract the side
bearing retainers RH and LH with a puller.
NOTE:
Each shim, which is installed to adjusted the side
bearing preload, should be kept together with its
mating retainer.
ST 398457700 ATTACHMENT
6) Pull out the differential case assembly from dif-
ferential carrier.
NOTE:
Be careful so that the teeth do not hit against the
case.
7) When replacing the side bearing, remove the
bearing cup from the side bearing retainer using
ST.
(A) Air breather cap
(B) Rear cover
(A) Rear cover
(B) Differential carrier
(A)
(B)
DI-00062
(A)
(B)
DI-00063
ST
DI-00064
DI-00065
ST
DI-00066
DI-36
DIFFERENTIALS
8) 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.
Store so that the right and left side bearing races
and cones are not mixed together.
ST 18759AA000 PULLER ASSY
9) Remove the hypoid driven gear by loosening hy-
poid driven gear bolts.
10) Drive out the pinion shaft lock pin from the hy-
poid driven gear side. (Model without LSD)
NOTE:
The lock pin is staked at the pin hole end on the dif-
ferential carrier. Do not drive it out forcibly before
removing the stake.
11) Draw out the pinion mate shaft and remove pin-
ion 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.
12) Remove the self-locking nut while holding the
companion flange with ST.
ST 498427200 FLANGE WRENCH
13) Extract the companion flange with a puller.
DI-00316
ST
DI-00068
DI-00237
ST
(A) Side gear
(B) Pinion mate gear
(C) Thrust washer
(D) Differential case
(E) Pinion mate shaft
(A) Companion flange
(B) Puller
DI-00238
ST
DI-00071
(B)
(A)
DI-00142
DI-37
DIFFERENTIALS
14) Press the end of drive pinion shaft and extract it
together with rear bearing cone, pinion height ad-
justing washer and washer.
NOTE:
Hold the drive pinion so as not to drop it.
ST 398467700 DRIFT
15) Remove the rear bearing cone from drive pin-
ion by supporting the cone with ST.
NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
16) Remove the front oil seal from differential carri-
er using ST.
17) Remove the pilot bearing together with the front
bearing cone and collar using the ST.
ST 398467700 DRIFT
18) When replacing the bearings, hit out the front
bearing cup and rear bearing cup in this order using
a brass bar.
(A) Differential carrier
(B) Front oil seal
ST
DI-00073
ST
DI-00074
(B)
(A)
DI-00145
(A) Pilot bearing
(B) Collar
(C) Front bearing
(D) Rear bearing cup
(A) 2 cutout portions along diagonal lines
(B) Tap alternately with brass bar.
ST
(B)
(A) (C)
(D)
DI-00076
(B)
(A)
DI-00077
DI-38
DIFFERENTIALS
D: ASSEMBLY
1. EXCEPT FOR GT SPEC. B 6MT MODEL
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 dis-
assembly.
Apply grease to the oil seal lip.
Be careful not to mix up the differential oil seal
RH and LH.
1) Adjusting preload for front and rear bearings
NOTE:
Adjust the bearing preload between front and rear
bearings with collar and washer. Pinion height ad-
justing 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 the
differential carrier using ST1 and ST2.
ST2 398477703 DRIFT 2
(2) Install the rear bearing race (front) into the
differential carrier using ST1 and ST2.
ST2 398477702 DRIFT
(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 de-
formed, and then re-use the used washer.
Use new rear bearing cone.
(4) Install the preload adjusting collar & washer,
front bearing cone, ST2, companion flange, and
washer & self-locking nut.
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
DI-00078
ST2
ST1
DI-00079
(A) Pinion height adjusting washer
(B) Preload adjusting collar
(C) Preload adjusting washer
(B)
(A)
(C)
ST2 ST1
DI-00080
DI-39
DIFFERENTIALS
(5) Turn the ST1 by hand to smooth the bear-
ing, and tighten the self-locking nut while mea-
suring the initial load or initial torque with a
spring scale or torque wrench. Select the pre-
load adjusting washer and collar so that the
specified preload is obtained when nut is tight-
ened 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
Tightening torque:
181.5 Nm (18.5 kgf-m, 134.0 ft-lb)
Initial load:
17.7 38.8 N (1.8 4.0 kgf, 4.0 8.7 lb)
Initial torque:
0.67 1.47 Nm (0.07 0.15 kgf-m,
0.49 1.08 ft-lb)
ST1
ST2
DI-00081
DI-00117
383705200 2.59 (0.1020)
383715200 2.57 (0.1012)
383725200 2.55 (0.1004)
383735200 2.53 (0.0996)
383745200 2.51 (0.0988)
383755200 2.49 (0.0980)
383765200 2.47 (0.0972)
383775200 2.45 (0.0965)
383785200 2.43 (0.0957)
383795200 2.41 (0.0949)
383805200 2.39 (0.0941)
383815200 2.37 (0.0933)
383825200 2.35 (0.0925)
383835200 2.33 (0.0917)
383845200 2.31 (0.0909)
383695201 56.2 (2.213)
383695202 56.4 (2.220)
383695203 56.6 (2.228)
383695204 56.8 (2.236)
383695205 57.0 (2.244)
383695206 57.2 (2.252)
DI-00481
DI-40
DIFFERENTIALS
2) Adjusting drive pinion height:
Adjust the drive pinion height with washer installed
between the rear bearing cone and the back of pin-
ion gear.
(1) Attach the ST2.
ST2 398507701 DIFFERENTIAL CARRIER
GAUGE
(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
(3) Obtain the thickness of pinion height adjust-
ing washer to be inserted from the following for-
mula, and replace the temporarily installed
washer with this one.
T = To + N (H 0.01) 0.20 mm (0.008 in)
NOTE:
Use copies of this page.
(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 WASHER 383605200.
RH
LH
N
(A)
ST2 ST3 ST1
DI-00083
ST2
ST1
DI-00084
T Thickness of pinion height adjusting
washer mm (in)
To Thickness of washer temporally
inserted mm (in)
N Clearance of thickness gauge mm (in)
H Figure marked on drive pinion head
Memo:
383495200 3.09 (0.1217)
383505200 3.12 (0.1228)
383515200 3.15 (0.1240)
383525200 3.18 (0.1252)
383535200 3.21 (0.1264)
383545200 3.24 (0.1276)
383555200 3.27 (0.1287)
383565200 3.30 (0.1299)
383575200 3.33 (0.1311)
383585200 3.36 (0.1323)
383595200 3.39 (0.1335)
383605200 3.42 (0.1346)
383615200 3.45 (0.1358)
383625200 3.48 (0.1370)
383635200 3.51 (0.1382)
383645200 3.54 (0.1394)
383655200 3.57 (0.1406)
383665200 3.60 (0.1417)
383675200 3.63 (0.1429)
383685200 3.66 (0.1441)
DI-41
DIFFERENTIALS
3) Install the selected pinion height adjusting wash-
er on drive pinion, and press the rear bearing cone
into position with ST.
4) Insert the drive pinion into the differential carrier,
and install the preselected bearing preload adjust-
ing collar and washer.
5) Press-fit the front bearing cone into case with
ST1, ST2 and ST3.
6) Insert the collar, then press-fit the pilot bearing
with ST1 and ST2.
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.
8) Press-fit the companion flange with ST1 and
ST2.
NOTE:
Be careful not to damage the bearing.
(A) Drive pinion
(B) Bearing preload adjusting collar
(C) Bearing preload adjusting washer
(D) Differential carrier
ST
DI-00085
(A)
(B)
(C)
(D)
DI-00086
ST3
ST1
ST2
DI-00087
ST2
ST1
DI-00088
ST
DI-00089
ST1
ST2
DI-00090
DI-42
DIFFERENTIALS
9) Attach a new self-locking nut and tighten using
the ST.
Tightening torque:
181.5 Nm (18.5 kgf-m, 134.0 ft-lb)
10) Check the initial torque and initial load.
Initial load:
17.7 38.8 N (1.8 4.0 kgf, 4.0 8.7 lb)
Initial torque:
0.67 1.47 Nm (0.07 0.15 kgf-m,
0.49 1.08 ft-lb)
11) Install the driven gear to the differential case.
NOTE:
Before installing bolts, apply seal material to bolt
threads.
SEAL MATERIAL
equivalent
NOTE:
Tighten diagonally while tapping the bolt heads.
Tightening torque:
103 Nm (10.5 kgf-m, 76.0 ft-lb)
12) Press the side bearing into differential case us-
ing ST.
ST 398487700 DRIFT
13) Press the side bearing race into side bearing
retainer using the ST.
ST 398417700 DRIFT PUNCH
14) Adjusting the side bearing retainer shims
(1) The driven gear backlash and side bearing
preload can be adjusted by the side bearing re-
tainer shim thickness.
ST
DI-00091
DI-00117
DI-00481
DI-00068
ST
DI-00095
DI-43
DIFFERENTIALS
(2) Install the differential case assembly into dif-
ferential carrier in the reverse order of disas-
sembly.
(3) Install the side bearing retainer shims to re-
tainers RH and LH from which they were in-
stalled.
NOTE:
Replace broken or corroded side retainer shims
and O-rings with a new part of the same thickness.
(4) Align the arrow mark on differential carrier
with the mark on side retainer during installa-
tion.
NOTE:
Replace the broken or cracked O-ring with a new
part.
Be careful that side bearing race is not damaged
by the bearing roller.
(5) Tighten the side bearing retainer bolts.
Tightening torque:
10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
(6) Measure the driven gear to drive pinion
backlash. 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 rear face 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 rear face shim
thickness and reduce the tooth surface side
shim thickness.
Backlash:
0.10 0.20 mm (0.004 0.008 in)
(7) At the same time, measure the preload in-
crease amount of the drive pinion. Compared
with the resistance when differential case is not
installed, if the total preload is not within speci-
fication, adjust the thickness of side bearing re-
tainer 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)
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
(A) Arrow mark
DI-00065
(A)
DI-00097
DI-00487
DI-00099
DI-44
DIFFERENTIALS
15) Recheck the driven gear to pinion backlash.
Backlash:
0.10 0.20 mm (0.004 0.008 in)
16) Check the driven gear runout on its back sur-
face, and make sure that the pinion and driven gear
rotate smoothly.
Driven gear rear face runout limit:
0.05 mm (0.002 in)
17) Checking and adjusting the tooth contact of
driven gear
(1) Apply lead-free red dye evenly to the surfac-
es of three or four teeth on the driven gear.
Check the contact pattern after rotating the driv-
en gear several revolutions back and forth until
a definite contact pattern appears on the driven
gear.
(2) When the contact pattern is not correct, re-
adjust.
NOTE:
Be sure to wipe off the lead-free red dye after the
adjustment is completed.
Check item: Tooth contact pattern is slightly
shifted towards the toe side under no-load
rotation. (When driving, it moves towards
the heel side.)
DI-00099
DI-00101
(A) Toe side
(B) Heel side
(A)
(B)
MT-01401
DI-45
DIFFERENTIALS
Face contact
Contact pattern
Corrective action: Increase the thickness of pin-
ion height adjusting washer according to the
procedure for bringing the drive pinion close to
the driven gear.
Flank contact
Contact pattern
Adjustment: Reduce the thickness of pinion
dure for bringing drive the pinion away from
driven gear.
AT-00208
AT-00212
AT-00209
AT-00213
DI-46
DIFFERENTIALS
Toe contact (inner side contact)
Check item: Contact area is too small.
Contact pattern
driven gear.
Contact pattern
dures for moving the drive pinion closer to the
driven gear.
18) 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 hy-
poid gear backlash.
(1) Drive pinion height
GAUGE
T = To + N (H 0.01) 0.20 (mm)
Place:
T = Thickness of pinion height adjusting washer
(mm)
To = Thickness of washer temporally inserted
(mm)
N = Clearance of thickness gauge (mm)
H = Figure marked on drive pinion head
AT-00210
AT-00213
AT-00211
AT-00212
ST2
ST1
DI-00084
DI-47
DIFFERENTIALS
(2) Hypoid gear backlash
Backlash:
0.10 0.20 mm (0.004 0.008 in)
19) Remove the RH and LH side bearing retainer.
20) Install O-rings and side bearing retainer shims
to side bearing retainers of both sides.
21) Install oil seals to side bearing retainers of both
sides. <Ref. to DI-92, REPLACEMENT, Rear Dif-
ferential Side Oil Seal.>
22) Align the arrow mark on differential carrier with
the mark on side retainer during installation.
23) Apply liquid gasket to the bolts indicated by the
arrows, and tighten the side bearing retainer bolts.
Liquid gasket:
equivalent
Tightening torque:
10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
24) Install the new gasket and rear cover, and tight-
Tightening torque:
29.5 Nm (3.0 kgf-m, 21.8 ft-lb)
25) Install the air breather cap.
26) Install the oil drain plug and filler plug.
Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
(A) Arrow mark
DI-00099
(A)
DI-00097
DI-00461
(B) Rear cover
DI-00113
(A)
(B)
DI-00062
DI-48
DIFFERENTIALS
2. GT SPEC. B 6MT MODEL
1) Assembling instructions:
thrust washers.
races.
assembly.
Apply chassis grease between the lips.
Adjust the bearing preload between front and
rear bearings with spacer and washer. Pinion
height adjusting washer is not affected by this ad-
justment. The adjustment must not be carried out
with oil seal inserted.
2) Using the ST, press-fit the rear bearing race to
the differential carrier.
3) Using the ST, press-fit the front bearing race to
ST 398477702 DRIFT
4) Selection of pinion height adjusting washer
(1) Measure the thickness of the inserted pinion
height adjusting washer.
(2) Read the stamps of the attached drive pin-
ion gear and a new part.
NOTE:
When there is no stamp, it indicates 0 (zero).
DI-00078
ST
DI-00318
DI-00319
0
0
5
5
1 0
1 0
1 5
DI-00320
+2
DI-00321
DI-49
DIFFERENTIALS
mula, and replace the installed washer with this
one.
T = T1 + (T2 0.01 T3 0.01)
T1 = 3.30, T2 = +2, T3 = 1
T = 3.30 + {(2 0.01) (1 0.01)} = 3.33
A washer to be used is 38336AA310.
and install the originally attached bearing preload
adjusting spacer and washer.
7) Insert the spacer, then press-fit the pilot bearing
with the ST.
ST4 498937110 HOLDER DRIVE PINION
T mm Thickness of the selected pinion height adjusting
washer
T1 mm Thickness of the inserted pinion height adjusting
washer
T2 mm Numbers stamped on the attached drive pinion
gear
T3 mm Numbers stamped on a new drive pinion gear
38336AA230 3.09 (0.1217)
38336AA240 3.12 (0.1228)
38336AA250 3.15 (0.1240)
38336AA260 3.18 (0.1252)
38336AA270 3.21 (0.1264)
38336AA280 3.24 (0.1276)
38336AA290 3.27 (0.1287)
38336AA300 3.30 (0.1299)
38336AA310 3.33 (0.1311)
38336AA320 3.36 (0.1323)
38336AA330 3.39 (0.1335)
38336AA340 3.42 (0.1346)
38336AA350 3.45 (0.1358)
38336AA360 3.48 (0.1370)
38336AA370 3.51 (0.1382)
38336AA380 3.54 (0.1394)
38336AA390 3.57 (0.1406)
38336AA400 3.60 (0.1417)
38336AA410 3.63 (0.1429)
38336AA420 3.66 (0.1441)
(A) Drive pinion
(B) Bearing preload adjusting spacer
ST
DI-00085
(A)
(B)
(C)
(D)
DI-00086
ST2
ST3
ST1
ST4
ST1
ST4
DI-00322
DI-50
DIFFERENTIALS
8) Press-fit the companion flange with ST1, ST2
and ST3.
NOTE:
9) Install the self-locking nut. Tighten using the ST.
Tightening torque:
181.5 Nm (18.5 kgf-m, 134.0 ft-lb)
10) Turn the drive pinion shaft 10 or more times to
make it fit in each taper roller bearing, and measure
the initial load or initial torque.
Initial load:
24.1 38.6 N (2.5 3.9 kgf, 5.4 8.7 lb)
Initial torque:
0.91 1.46 Nm (0.09 0.15 kgf-m,
0.67 1.08 ft-lb)
ST3
ST1
ST2
ST2
DI-00323
ST
DI-00091
DI-00117
DI-00481
DI-51
DIFFERENTIALS
11) If the bearing preload is outside the specifica-
tion range, select a preload adjusting washer and
spacer from the table below to fit within the specifi-
cation range.
13) Draw out the companion flange with a puller.
NOTE:
Press-fit until the oil seal end comes 1 mm (0.04 in)
inward from end of carrier.
Apply grease between the oil seal lips.
15) Press-fit the companion flange with ST1, ST2
and ST3.
NOTE:
383705200 2.59 (0.1020)
383715200 2.57 (0.1012)
383725200 2.55 (0.1004)
383735200 2.53 (0.0996)
383745200 2.51 (0.0988)
383755200 2.49 (0.0980)
383765200 2.47 (0.0972)
383775200 2.45 (0.0965)
383785200 2.43 (0.0957)
383795200 2.41 (0.0949)
383805200 2.39 (0.0941)
383815200 2.37 (0.0933)
383825200 2.35 (0.0925)
383835200 2.33 (0.0917)
383845200 2.31 (0.0909)
31454AA130 52.2 (2.055)
31454AA140 52.4 (2.063)
31454AA150 52.6 (2.071)
31454AA160 52.8 (2.079)
31454AA170 53.0 (2.087)
31454AA180 53.2 (2.094)
ST
DI-00091
(B) Puller
(B)
(A)
DI-00142
ST
DI-00089
ST3
ST1
ST2
ST2
DI-00323
DI-52
DIFFERENTIALS
16) Install the self-locking nut. Tighten using the
ST.
Initial load:
24.1 38.6 N (2.5 3.9 kgf, 5.4 8.7 lb)
Initial torque:
0.91 1.46 Nm (0.09 0.15 kgf-m,
0.67 1.08 ft-lb)
18) Install the driven gear to the differential case.
NOTE:
threads.
SEAL MATERIAL
equivalent
NOTE:
Tighten diagonally while gently tapping the bolt
heads.
Tightening torque:
103 Nm (10.5 kgf-m, 76.0 ft-lb)
ing ST.
ST 398487700 DRIFT
20) Assembling the side retainer
(1) Using the ST and a press, press-fit the side
bearing outer race.
ST 398417700 DRIFT
(2) Install the oil seal. <Ref. to DI-92, RE-
PLACEMENT, Rear Differential Side Oil Seal.>
ST
DI-00071
DI-00117
DI-00481
DI-00068
ST
DI-00095
DI-00324
ST
DI-53
DIFFERENTIALS
21) Adjusting the side bearing retainer shims
(1) The driven gear backlash and side bearing
preload can be adjusted by the side bearing re-
tainer shim thickness.
(2) Install the differential case assembly into differ-
ential carrier in the reverse order of disassembly.
(3) Install the side retainer shims and O-rings to re-
tainers RH and LH from which they were removed.
NOTE:
Replace the broken or cracked O-ring with a new
part.
Replace broken or corroded side retainer shims
with a new part of the same thickness.
(4) Align the arrow mark on differential carrier with
NOTE:
Be careful that side bearing outer race is not dam-
aged by the bearing roller.
(5) Tighten the side bearing retainer bolts.
Tightening torque:
10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
(6) Measure the driven gear to drive pinion
backlash. Set the magnet base on the differen-
tial 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.
Backlash:
0.10 0.20 mm (0.004 0.008 in)
(7) At the same time, measure the total preload
of the drive pinion. Compared with the time
when differential case is not installed, if the total
preload is not within specification, adjust the
thickness of side bearing retainer shims, in-
creasing/reducing both shims by an even
amount at a time.
Total preload:
27.0 54.0 N (2.8 5.5 kgf, 6.1 12.2 lb)
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
(A) Arrow mark
DI-00065
(A)
DI-00097
DI-00487
DI-00099
DI-54
DIFFERENTIALS
22) Measure the driven gear to drive pinion back-
lash again.
Backlash:
0.10 0.20 mm (0.004 0.008 in)
23) Check the driven gear runout on its back sur-
face, and make sure that the pinion and driven gear
rotate smoothly.
If the driven gear runout on its back surface ex-
ceeds the specification, check for any foreign ob-
jects between the hypoid driven gear and
differential case, and for any deformation of the
case or gear.
Driven gear rear face runout limit:
0.05 mm (0.002 in)
24) Checking and adjusting the tooth contact of
driven gear
(1) Apply lead-free red dye evenly to the both
side of three or four teeth on the driven gear.
Check the contact pattern after rotating the driv-
en gear several revolutions back and forth until
a definite contact pattern appears on the driven
gear.
(2) If the contact pattern is improper, readjust it
in accordance with the instruction in Contact
pattern.
NOTE:
the heel side.)
DI-00099
DI-00101
(A) Toe side
(B) Heel side
(A)
(B)
MT-01401
DI-55
DIFFERENTIALS
Face contact
Contact pattern
Corrective action: Increase the thickness of pin-
procedure for bringing the drive pinion close to
the driven gear.
Flank contact
Contact pattern
driven gear.
AT-00208
AT-00212
AT-00209
AT-00213
DI-56
DIFFERENTIALS
Contact pattern
driven gear.
Contact pattern
dures for moving the drive pinion closer to the
driven gear.
again adjust the drive pinion height by changing the
RH and LH side bearing retainer shims and the hy-
poid gear backlash.
26) Install oil seals to side bearing retainers of both
sides. <Ref. to DI-92, REPLACEMENT, Rear Dif-
ferential Side Oil Seal.>
27) Align the arrow mark on differential carrier with
AT-00210
AT-00213
(A) Arrow mark
AT-00211
AT-00212
(A)
DI-00097
DI-57
DIFFERENTIALS
28) Apply liquid gasket to the bolts indicated by the
arrows, and tighten the side bearing retainer bolts.
Liquid gasket:
equivalent
Tightening torque:
10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
29) Install the new gasket and rear cover, and tight-
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
30) Install the breather cap.
E: INSPECTION
Wash all the disassembled parts clean, and exam-
ine them for wear, damage and other defects. Re-
pair 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) Side gear and pinion mate gear
Replace if cracks, scoring or other defects are
evident on the tooth surface.
Replace if thrust washer contact surface is worn
or seized. Slight damages of the surface can be
corrected by oil stones or equivalent.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, noise or other defect is evident.
4) Thrust washer of the side gear and pinion mate
gear:
Replace if seized, flawed, abnormally worn or hav-
ing other defects.
5) Oil seal
Replace if deformed or damaged, and at every dis-
assembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal lip contact surface shows
cracking.
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 specifica-
tion, select the side gear thrust washer and adjust
the side gear backlash as specified.
(A) Side bearing retainer bolt
DI-00461
DI-00113
DI-00315
DI-58
DIFFERENTIALS
2. HYPOID DRIVEN GEAR BACKLASH
Using a dial gauge, check the backlash of hypoid
driven gear.
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 re-
pair if necessary.
3. HYPOID DRIVEN GEAR RUNOUT ON ITS
BACK SURFACE
Using a dial gauge, check the hypoid driven gear
back surface runout.
Hypoid driven gear back surface runout:
0.05 mm (0.002 in)
If the hypoid driven gear runout exceeds 0.05 mm
(0.002 in), replace the hypoid driven gear.
4. TOOTH CONTACT BETWEEN HYPOID
DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between the hypoid driv-
en gear and drive pinion. <Ref. to DI-38, ASSEM-
BLY, Rear Differential (T-type).>
5. TOTAL PRELOAD
Using a spring scale, check the total preload.
Total preload:
20.7 54.4 N (2.1 5.5 kgf, 4.7 12.2 lb)
GT spec. B 6MT model
27.0 54.0 N (2.8 5.5 kgf, 6.1 12.1 lb)
If the total preload is not within the specification,
adjust the side bearing retainer shims.
6. COMPANION FLANGE
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 (0.003 in)
DI-00099
DI-00101
DI-00117
DI-00360
DI-59
DIFFERENTIALS
3) Set the gauge inside of the companion flange,
and measure the runout.
Limit of runout:
0.08 mm (0.003 in)
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 even after chang-
ing 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 assem-
bled incorrectly or bearing is faulty.
F: ADJUSTMENT
Adjust the side gear backlash.
<Ref. to DI-38, ASSEMBLY, Rear Differential (T-
type).>
Adjust hypoid driven gear backlash.
type).>
Adjust the tooth contact between hypoid driven
gear and drive pinion gear.
type).>
4. TOTAL PRELOAD
Adjust the side bearing shim.
type).>
DI-00361
DI-60
Rear Differential (VA-type)
DIFFERENTIALS
5. Rear Differential (VA-type)
A: REMOVAL
2.5 L SOHC Non-turbo model
fler.>
AL, Muffler.>
3.0 L DOHC non-turbo model
8) Prepare the transmission jack and band.
9) Loosen the self-lock nuts which hold the rear dif-
ferential to rear crossmember.
10) Remove the DOJ of rear drive shaft from rear
differential.
11) Remove the nuts which hold the rear differen-
tial front member.
12) Support the rear differential with the transmis-
sion jack.
AT-01331
DI-00268
(A) Tire lever
(B) Bolt
DI-00269
DI-00287
(A)
(B)
DI-00362
DI-00273
DI-61
DIFFERENTIALS
13) Remove the rear differential front member.
14) Secure the rear differential using band.
15) Remove the self-lock nuts which hold the rear
differential to rear crossmember.
16) Remove the rear differential stud bolt from rear
crossmember bushing.
NOTE:
When removing the stud bolt, carefully adjust the
angle and location of transmission jack and jack
stand, if necessary
17) Lower the transmission jack stand after remov-
ing the rear differential stud bolt from the rear
crossmember. Rear drive shaft should not come
into contact with the lateral link bolt.
18) Pull out the axle shaft from rear differential.
NOTE:
If it is difficult to remove the axle shaft from rear dif-
ferential, remove it using tire lever.
20) Secure the rear drive shaft to lateral link using
wire.
21) Remove the rear differential member plate from
rear differential.
B: INSTALLATION
1) Insert the rear differential member plate into rear
differential.
2) Set the rear differential to transmission jack.
NOTE:
Secure the rear differential to transmission jack us-
ing band.
DI-00400
DI-00392
DI-00276
DI-00277
DI-00359
(A)
DI-00359
(A)
DI-62
DIFFERENTIALS
3) Attach the ST to rear differential.
4) Insert the spline shaft until the spline portion
comes inside the side oil seal.
5) Remove ST from rear differential.
6) Push the rear differential to insert the axle shaft
into rear differential.
7) Adjust the transmission jack, if necessary, and
insert the rear differential stud bolt into rear cross-
member bushing properly.
8) After inserting the rear differential stud bolt into
the rear crossmember bushing, lift up the transmis-
sion jack and align the rear differential to its attach-
ment position.
9) Tighten a new self-locking nut temporarily to rear
crossmember.
10) Remove the band from rear differential. Lift up
the rear differential until the rear differential is sep-
arated from the transmission jack.
11) Install the rear differential front member with a
new self-locking nut.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 110 Nm (11.2 kgf-m, 81 ft-lb)
DI-00300
ST
DI-00289
ST
DI-00281
DI-00393
DI-00283
DI-00269
DI-00395
T1
T2
DI-63
DIFFERENTIALS
12) Tighten the self-locking nut.
Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
14) Install the propeller shaft.
<Ref. to DS-11, INSTALLATION, Propeller Shaft.>
TION, Muffler.>
Exhaust Pipe.> <Ref. to EX(H4DOTC)-15, INSTAL-
LATION, Muffler.>
<Ref. to EX(H6DO)-8, INSTALLATION, Rear Ex-
TION, Muffler.>
C: DISASSEMBLY
1. VA1-TYPE
Tooth contact and backlash between hypoid
driven gear and drive pinion
sembly to ST.
ST 398217700 ATTACHMENT SET
drain the gear oil.
3) Remove the mounting bolts, and remove the
rear cover.
NOTE:
4) Remove the air breather cap.
NOTE:
Do not attempt to replace the air breather cap un-
less necessary.
Whenever the air breather cap is removed, re-
place it with a new part.
5) Remove the lock plate RH and LH.
DI-00269
ST
DI-00129
(B) Rear cover
DI-00130
(A)
(B)
DI-00131
DI-00132
DI-64
DIFFERENTIALS
6) Remove the holder RH and LH with ST.
ferential carrier.
NOTE:
case.
8) Remove the bearing race from holder RH and
LH with ST1 and ST2.
ST2 499705404 SEAT
9) Remove the oil seal from holder RH and LH us-
ing screwdriver.
NOTE:
Perform this operation only when changing oil seal.
10) Extract the bearing cone with ST1 and ST2.
NOTE:
necessary.
Set the puller so that its claws catch the edge of
the bearing cone.
Store so that the right and left side bearing races
and cones are not mixed together.
ST2 399520105 SEAT
11) Remove the hypoid driven gear by loosening
hypoid driven gear bolts.
(A) Bearing race
(B) Holder
DI-00133
ST
DI-00134
ST1
ST2
(B)
(A)
DI-00135
DI-00136
ST2
ST1
DI-00137
DI-00068
DI-65
DIFFERENTIALS
12) Drive out the pinion shaft lock pin from the hy-
poid driven gear side.
NOTE:
The lock pin is staked at the pin hole end on the dif-
ferential case. Do not drive it out forcibly before re-
moving the stake.
13) Draw out the pinion mate shaft and remove pin-
ion mate gears, side gears and thrust washers.
NOTE:
The gears should be marked or kept separated
right and left, and front and rear as well as thrust
washers.
16) Press the end of drive pinion shaft and extract it
together with rear bearing cone, pinion height ad-
justing washer and washer.
NOTE:
Hold the drive pinion so as not to drop it.
ST 398467700 DRIFT
NOTE:
(A) Side gear
(B) Pinion mate gear
(C) Thrust washer
(D) Differential case
(E) Pinion mate shaft
DI-00237
ST
DI-00238
ST
DI-00141
(B) Puller
(B)
(A)
DI-00142
ST
DI-00073
ST
DI-00074
DI-66
DIFFERENTIALS
er using ST.
19) Remove the pilot bearing together with the front
bearing cone and collar using the ST.
ST 398467700 DRIFT
a brass bar.
2. VA2-TYPE
Tooth contact and backlash between hypoid
driven gear and drive pinion
sembly to ST.
ST 398217700 ATTACHMENT
drain the gear oil.
3) Remove the mounting bolts, and remove the
rear cover.
NOTE:
4) Remove the lock plate RH and LH.
(A) Differential carrier
(B) Front oil seal
(A) Pilot bearing
(B) Collar
(C) Front bearing
(B)
(A)
DI-00145
ST
(B)
(A) (C)
(D)
DI-00076
(B)
(A)
DI-00077
ST
DI-00363
DI-00388
DI-00364
DI-67
DIFFERENTIALS
5) Remove the holder RH and LH with ST.
ferential carrier.
NOTE:
case.
7) Remove the bearing race from holder RH and
LH with ST and press.
NOTE:
Make sure the bolt of puller turn manually.
Set the puller so that its claws catch the groove
of holder.
8) Remove the oil seal from holder RH and LH us-
ing screwdriver.
NOTE:
Perform this operation only when changing oil seal.
ST
DI-00365
DI-00366
(A) Groove
(B) Claw
(A) Holder
ST
DI-00367
ST
(A)
(B)
(A)
ST
DI-00368
DI-00369
DI-68
DIFFERENTIALS
9) Extract the bearing cone with ST1, ST2 and ST3
NOTE:
necessary.
Never mix up the RH and LH bearing races and
cones.
ST2 399520105 SEAT
10) Remove the hypoid driven gear by loosening
hypoid driven gear bolts.
13) Removes the drive pinion shaft.
NOTE:
er using screwdriver.
16) Remove the pilot bearing, front bearing cone
and collar.
DI-00370
ST1
ST2
ST3
DI-00371
DI-00372
ST
(B) Puller
(A) Pilot bearing
(B) Collar
(C) Front bearing
(B)
(A)
DI-00394
DI-00373
ST
(B)
(A) (C)
(D)
DI-00374
DI-69
DIFFERENTIALS
a brass bar.
D: ASSEMBLY
1. VA1-TYPE
NOTE:
Use a new gasket.
thrust washers.
races.
assembly. Apply grease to the lips when installing
the oil seal.
RH and LH.
NOTE:
inserted.
(1) Install the rear bearing race into the differen-
tial carrier using ST1 and ST2.
ST2 398477702 DRIFT
(2) Install the front bearing race to the differen-
ST2 498447110 DRIFT
(3) Insert the front bearing cone.
NOTE:
Use new front bearing cone.
(4) Measure and record the thickness of the
pinion height adjusting washer.
NOTE:
If tooth contact (drive pinion, hypoid driven gear) is
normal in the inspection before disassembling, ver-
ify that the washer is not deformed, and then re-use
the used washer.
(5) Insert ST1 into the case with the pinion
fitted onto it.
NOTE:
front bearing cone, ST2, companion flange, and
washer & self-locking nut.
ST 498447150 DUMMY SHAFT
Part No. 32285AA000Collar
(B)
(A)
DI-00077
DI-00078
(D) Collar (SUBARU genuine part)
DI-00149
ST2
ST1
DI-00466
(B)
(A)
(C)
ST
(D)
DI-70
DIFFERENTIALS
(7) Turn the ST1 by hand to smooth the bear-
ing, and tighten the self-locking nut while mea-
suring the initial load or initial torque with a
spring scale or torque wrench. Select the pre-
load adjusting washer and collar so that the
specified preload is obtained when nut is tight-
ened to the specified torque.
NOTE:
Measure the preload in direction of tangent to the
flange.
When tightening the self-locking nut, lock ST1
with ST2 as shown in the figure.
ST1 398507704 BLOCK
Tightening torque:
191 Nm (19.5 kgf-m, 141.0 ft-lb)
Initial load:
12.7 32.2 N (1.3 3.3 kgf, 2.9 7.2 lb)
Initial torque:
0.48 1.22 Nm (0.05 0.12 kgf-m,
0.35 0.9 ft-lb)
ST1
ST2
DI-00081
DI-00152
38336AA000 1.500 (0.0591)
38336AA120 1.513 (0.0596)
38336AA010 1.525 (0.0600)
38336AA130 1.538 (0.0606)
38336AA020 1.550 (0.0610)
38336AA140 1.563 (0.0615)
38336AA030 1.575 (0.0620)
38336AA150 1.588 (0.0625)
38336AA040 1.600 (0.0630)
38336AA160 1.613 (0.0635)
38336AA050 1.625 (0.0640)
38336AA170 1.638 (0.0645)
38336AA060 1.650 (0.0650)
38336AA180 1.663 (0.0655)
38336AA070 1.675 (0.0659)
38336AA190 1.688 (0.0665)
38336AA080 1.700 (0.0669)
38336AA200 1.713 (0.0674)
38336AA090 1.725 (0.0679)
38336AA210 1.738 (0.0684)
38336AA100 1.750 (0.0689)
38336AA220 1.763 (0.0694)
38336AA110 1.775 (0.0699)
32288AA040 52.3 (2.059)
32288AA050 52.5 (2.067)
31454AA100 52.6 (2.071)
32288AA060 52.7 (2.075)
31454AA110 52.8 (2.079)
32288AA070 52.9 (2.083)
31454AA120 53.0 (2.087)
32288AA080 53.1 (2.091)
32288AA090 53.3 (2.098)
DI-00481
DI-71
DIFFERENTIALS
ion gear.
(1) Attach the ST2.
GAUGE
Part No. 32285AA000 Collar
thickness gauge.
NOTE:
and ST2.
GAUGE
NOTE:
Adjust it using 1 3 washers.
T = To + N 0.05 (mm)
To = 0.15 mm
N = 0.1 mm
T = 0.15 + 0.1 0.05 = 0.2 mm
Therefore use part number 32295AA220.
(B) Collar (SUBARU genuine part)
DI-00467
RH
LH
N
(A)
ST2 ST1 (B)
ST2
ST1
DI-00084
washer mm (in)
inserted mm (in)
Memo:
32295AA200 0.150 (0.0059)
32295AA210 0.175 (0.0069)
32295AA220 0.200 (0.0079)
32295AA230 0.225 (0.0089)
32295AA240 0.250 (0.0098)
32295AA250 0.275 (0.0108)
ST
DI-00085
DI-72
DIFFERENTIALS
5) Press-fit the front bearing cone into the carrier
with ST1, ST2 and collar.
Part No. 32285AA000 Collar
6) Insert the collar, then press-fit the pilot bearing
with ST1 and ST2.
NOTE:
8) Press-fit the companion flange with ST1 and
ST2.
NOTE:
(A) Drive pinion
(A) Collar (SUBARU genuine part)
(D)
(A)
(B)
(C)
DI-00156
DI-00468
ST2
ST1
(A)
ST2
ST1
DI-00088
ST
DI-00089
ST1
ST2
DI-00090
DI-73
DIFFERENTIALS
9) Attach a new self-locking nut and secure the
companion flange using ST, then tighten the nut.
NOTE:
Before installing lock nuts, apply seal material to
lock nut threads.
SEAL MATERIAL
equivalent
Tightening torque:
191 Nm (19.5 kgf-m, 141.0 ft-lb)
Initial load:
12.7 32.2 N (1.3 3.3 kgf, 2.9 7.2 lb)
Initial torque:
0.48 1.22 Nm (0.05 0.12 kgf-m,
0.35 0.90 ft-lb)
11) Assembling differential case
Install the side gears and pinion mate gears, with
their thrust washers and pinion mate shaft, into the
differential case.
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.
(1) Measure the side gear backlash.
Side gear backlash:
0.05 0.15 mm (0.002 0.006 in)
(2) Adjust the side gear backlash as specified
by selecting side gear thrust washer.
ST
DI-00161
DI-00152
DI-00481
803135011 0.925 0.950 (0.0364 0.0374)
803135012 0.950 0.975 (0.0374 0.0384)
803135013 0.975 1.000 (0.0384 0.0394)
803135014 1.000 1.025 (0.0394 0.0404)
803135015 1.025 1.050 (0.0404 0.0413)
DI-00239
DI-00240
DI-74
DIFFERENTIALS
(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.
12) Install the hypoid driven gear to differential
case.
NOTE:
threads.
SEAL MATERIAL
equivalent
Tightening torque:
62 Nm (6.3 kgf-m, 45.8 ft-lb)
ing ST.
ST 498485400 DRIFT
14) Assemble holders.
(1) Install the oil seal into holder RH and LH.
(2) Install the bearing race into holder RH and
LH.
ST 398477702 DRIFT
CAUTION:
Make sure that the RH and LH oil seals, bearing
outer races and cones are properly assembled.
(3) Install the differential assembly into differen-
tial carrier in the reverse order of disassembly.
NOTE:
case.
(4) Temporally tighten the side holders RH and
LH in differential carrier to install.
15) Perform the backlash adjustment between the
hypoid driven gear and drive pinion, and preload
adjustment of differential side bearing.
(1) Turn the drive pinion with ST for better fitting
of differential side bearing.
DI-00068
ST
DI-00095
ST
DI-00166
ST
DI-00167
DI-00134
ST
DI-00169
DI-75
DIFFERENTIALS
(2) Screw in the side holder LH until light con-
tact is made with ST.
(3) Back off the holder on the hypoid driven
gear side by approx.1 and 1/2 teeth, and tighten
the other side holder by approx. 2 teeth [amount
that the holder on hypoid driven gear side is
turned back (1 and 1/2) + 1/2 teeth)].
[Back off amount of side (hypoid driven gear
side) holder + 1/2 tooth.] This + 1/2 tooth gives
preload.
(4) Temporarily tighten the lock plate.
NOTE:
Turn over the lock plate to shift the holder by 1/2
tooth.
(5) Measure the hypoid driven gear-to-drive
pinion backlash. Set the magnet base on differ-
ential carrier. Align the contact point of dial
gauge with tooth face of hypoid driven gear,
and move hypoid driven gear while holding
drive pinion still. Read the value indicated on
dial gauge.
NOTE:
If measured value of backlash is not within the
specified range, repeat the procedures for pinion
driven gear set backlash adjustment and the differ-
ential side bearing preload adjustment.
Backlash:
0.10 0.15 mm (0.004 0.006 in)
16) Put alignment marks on both the differential
carrier and holder. Remove the holder side at a
time.
Replace them in the original position after inserting an
O-ring and applying grease to the threaded portion.
DI-00133
ST
DI-00132
(A) Alignment mark
(B) Holder
DI-00172
(A)
(B)
DI-00173
DI-76
DIFFERENTIALS
17) Tighten the bolt of lock plate to specified
torque.
Tightening torque:
25 Nm (2.5 kgf-m, 18.5 ft-lb)
18) Recheck the hypoid driven gear to pinion back-
lash.
Backlash:
0.10 0.15 mm (0.004 0.006 in)
19) Checking and adjusting the tooth contact of hy-
poid driven gear
side of three or four teeth on hypoid driven gear.
Check the contact pattern after rotating the hy-
poid driven gear several revolutions back and
forth until a definite contact pattern appears on
(2) When the contact pattern is not correct, readjust.
NOTE:
the heel side.)
DI-00132
DI-00172
(A) Toe side
(B) Heel side
(A)
(B)
MT-01401
DI-77
DIFFERENTIALS
Face contact
Contact pattern
Corrective action: Increase thickness of the pin-
procedures for moving the drive pinion closer to
Flank contact
Contact pattern
Corrective action: Reduce thickness of the pin-
procedures for moving the drive pinion away
from the hypoid driven gear.
AT-00208
AT-00212
AT-00209
AT-00213
DI-78
DIFFERENTIALS
Contact pattern
Contact pattern
again adjust the drive pinion height and the differ-
ential side bearing preload (already mentioned)
and the hypoid gear backlash.
21) Install the new gasket and rear cover to the dif-
ferential carrier, and tighten the bolts to specified
torque.
Tightening torque:
25 Nm (2.5 kgf-m, 18.5 ft-lb)
AT-00210
AT-00213
(A) Rear cover
AT-00211
AT-00212
(A)
DI-00189
DI-79
DIFFERENTIALS
2. VA2-TYPE
NOTE:
Use a new gasket.
thrust washers.
races.
assembly. Apply grease to the lips when installing
the oil seal.
RH and LH.
NOTE:
inserted.
(1) Install the rear bearing race into the differen-
ST2 398477703 DRIFT 2
(2) Using the ST, install the front bearing race to
(3) Insert the front bearing cone.
NOTE:
Use new front bearing cone.
(4) Measure and record the thickness of the
pinion height adjusting washer.
NOTE:
If tooth contact (drive pinion, hypoid driven gear) is
normal in the inspection before disassembling, ver-
ify that the washer is not deformed, and then re-use
the used washer.
(5) Insert the ST1 into carrier with the pinion
fitted onto it.
NOTE:
front bearing cone, collar, companion flange,
and washer & self-locking nut.
ST1 18678AA000 DUMMY SHAFT
DI-00078
DI-00375
ST2
ST1
(D) Collar
DI-00376
ST
ST1
DI-00377
(D)
(C)
(B)
(A)
DI-80
DIFFERENTIALS
(7) Turn ST1 by hand to seat the bearing, and
measure the initial load and initial torque with a
spring scale or a torque wrench while tightening
the selflocking nut. Select the preload adjusting
washer and collar so that the specified preload
is obtained when nut is tightened to the speci-
fied torque.
NOTE:
When tightening the self-locking nut, lock com-
panion flange with ST2 as shown in the figure.
Measure the preload in direction of tangent to the
flange.
ST2 498427200 FLANGE WRENCH
Tightening torque:
191 Nm (19.5 kgf-m, 141.0 ft-lb)
Initial load:
12.7 32.2 N (1.3 3.3 kgf, 2.9 7.2 lb)
Initial torque:
0.48 1.22 Nm (0.05 0.12 kgf-m,
0.35 0.90 ft-lb)
DI-00398
ST2
DI-00152
38336AA430 1.500 (0.0591)
38336AA440 1.513 (0.0596)
38336AA450 1.525 (0.0600)
38336AA460 1.538 (0.0606)
38336AA470 1.550 (0.0610)
38336AA480 1.563 (0.0615)
38336AA490 1.575 (0.0620)
38336AA500 1.588 (0.0625)
38336AA510 1.600 (0.0630)
38336AA520 1.613 (0.0635)
38336AA530 1.625 (0.0640)
38336AA540 1.638 (0.0645)
38336AA550 1.650 (0.0650)
38336AA560 1.663 (0.0655)
38336AA570 1.675 (0.0659)
38336AA580 1.688 (0.0665)
38336AA590 1.700 (0.0669)
38336AA600 1.713 (0.0674)
38336AA610 1.725 (0.0679)
38336AA620 1.738 (0.0684)
38336AA630 1.750 (0.0689)
38336AA640 1.763 (0.0694)
38336AA650 1.775 (0.0699)
31454AA250 51.05 (2.010)
31454AA260 51.25 (2.018)
31454AA270 51.35 (2.022)
31454AA280 51.45 (2.026)
31454AA290 51.55 (2.030)
31454AA300 51.65 (2.033)
31454AA310 51.75 (2.037)
31454AA320 51.85 (2.041)
31454AA330 52.05 (2.049)
DI-00481
DI-81
DIFFERENTIALS
ion gear.
(1) Attach the ST2.
ST2 18831AA010 DIFFERENTIAL CARRIER
GAUGE
(2) Install the side holder LH to the left side of
the differential carrier in reverse direction.
thickness gauge.
NOTE:
and ST2.
ST2 18831AA010 DIFFERENTIAL CARRIER
GAUGE
NOTE:
Adjust it using 1 3 washers.
T = To + N 0.05 (mm)
To = 0.15 mm
N = 0.1 mm
T = 0.15 + 0.1 0.05 = 0.2 mm
Therefore use part number 32295AA370.
RH
LH
N
(A)
ST2 ST1
DI-00379
DI-00380
DI-00381
ST2
ST1
washer mm (in)
inserted mm (in)
Memo:
32295AA350 0.150 (0.0059)
32295AA360 0.175 (0.0069)
32295AA370 0.200 (0.0079)
32295AA380 0.225 (0.0089)
32295AA390 0.250 (0.0098)
32295AA400 0.275 (0.0108)
ST
DI-00085
DI-82
DIFFERENTIALS
5) Set ST and differential carrier to the press and
install the front bearing cone.
ST 399780104 WEIGHT
NOTE:
Set the carrier to the press until the companion
flange is installed.
6) Insert the collar, then install the pilot bearing.
NOTE:
8) Press-fit the companion flange with ST.
NOTE:
9) Attach a new self-locking nut and secure the
companion flange using ST, then tighten the nut.
NOTE:
Before installing lock nuts, apply seal material to
lock nut threads.
SEAL MATERIAL
equivalent
Tightening torque:
191 Nm (19.5 kgf-m, 141.0 ft-lb)
(A) Drive pinion
(A) Pilot bearing
(B) Collar
(D)
(A)
(B)
(C)
DI-00382
ST
DI-00383
DI-00389
(A)
(B)
ST
DI-00089
DI-00384
ST
DI-00372
ST
DI-83
DIFFERENTIALS
10) Measure the initial torque and initial load.
Initial load:
12.7 32.2 N (1.3 3.3 kgf, 2.9 7.2 lb)
Initial torque:
0.48 1.22 Nm (0.05 0.12 kgf-m,
0.35 0.90 ft-lb)
11) Install the hypoid driven gear to differential
case.
NOTE:
Set a cushioning such as wooden block, alumi-
num plate or shop cloth between vise and differen-
tial case if the side gear comes into contact with
vise.
Tightening torque:
62 Nm (6.3 kgf-m, 45.8 ft-lb)
ing ST.
ST 398487700 DRIFT
13) Assemble holders.
(1) Install the new oil seal into holder RH and
LH.
(2) Install the bearing race into holder RH and
LH.
CAUTION:
Make sure that the RH and LH oil seals, bearing
outer races and cones are properly assembled.
(3) Install the differential assembly into differen-
tial carrier in the reverse order of disassembly.
NOTE:
case.
(4) Temporally tighten the side holders RH and
LH in differential carrier to install.
DI-00152
DI-00481
DI-00371
ST
DI-00095
ST
DI-00166
DI-00366
DI-84
DIFFERENTIALS
14) Perform the backlash adjustment between the
hypoid driven gear and drive pinion, and preload
adjustment of differential side bearing.
(1) Turn the drive pinion with ST for better fitting
of differential side bearing.
(2) Screw in the side holder LH until light con-
tact is made with ST.
(3) Back off the holder on the hypoid driven
gear side by approx.1 and 1/2 teeth, and tighten
the other side holder by approx. 2 teeth [amount
that the holder on hypoid driven gear side is
turned back (1 and 1/2) + 1/2 teeth)].
[Back off amount of side (hypoid driven gear
side) holder + 1/2 tooth.] This + 1/2 tooth gives
preload.
(4) Temporarily tighten the lock plate.
NOTE:
Turn over the lock plate to shift the holder by 1/2
tooth.
(5) Measure the hypoid driven gear-to-drive
pinion backlash. Set the magnet base on differ-
ential carrier. Align the contact point of dial
gauge with tooth face of hypoid driven gear,
and move hypoid driven gear while holding
drive pinion still. Read the value indicated on
dial gauge.
NOTE:
If measured value of backlash is not within the
specified range, repeat the procedures for pinion
driven gear set backlash adjustment and the differ-
ential side bearing preload adjustment.
Backlash:
0.10 0.15 mm (0.004 0.006 in)
15) Put alignment marks on both the differential
carrier and holder. Remove the holder side at a
time.
Replace them in the original position after inserting an
O-ring and applying grease to the threaded portion.
DI-00385
ST
ST
DI-00399
DI-00364
(A) Alignment mark
(B) Holder
DI-00172
DI-00386
(B)
(A)
DI-85
DIFFERENTIALS
16) Tighten the bolt of lock plate to specified
torque.
Tightening torque:
25 Nm (2.5 kgf-m, 18.5 ft-lb)
17) Recheck the hypoid driven gear to pinion backlash.
Backlash:
0.10 0.15 mm (0.004 0.006 in)
18) Checking and adjusting the tooth contact of hy-
poid driven gear
side of three or four teeth on hypoid driven gear.
Check the contact pattern after rotating the hy-
poid driven gear several revolutions back and
forth until a definite contact pattern appears on
(2) When the contact pattern is not correct, readjust.
NOTE:
the heel side.)
DI-00364
DI-00172
(A) Toe side
(B) Heel side
(A)
(B)
MT-01401
DI-86
DIFFERENTIALS
Face contact
Contact pattern
Flank contact
Contact pattern
AT-00208
AT-00212
AT-00209
AT-00213
DI-87
DIFFERENTIALS
Contact pattern
Contact pattern
again adjust the drive pinion height and the differ-
ential side bearing preload (already mentioned)
and the hypoid gear backlash.
20) Install the new gasket and rear cover to the dif-
ferential carrier, and tighten the bolts to specified
torque.
Tightening torque:
34 Nm (3.5 kgf-m, 25.1 ft-lb)
AT-00210
AT-00213
AT-00211
AT-00212
DI-00387
DI-88
DIFFERENTIALS
E: INSPECTION
Wash all the disassembled parts clean, and exam-
ine them for wear, damage or 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) Side gear and pinion mate gear
Replace if cracks, scoring or other defects are
evident on the tooth surface.
Replace if thrust washer contact surface is worn
or seized. Slight damages of the surface can be
corrected by oil stones or equivalent.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, noise or other defect is evident.
4) Thrust washer of the side gear and pinion mate
gear:
Replace if seized, flawed, abnormally worn or hav-
ing other defects.
5) Oil seal
Replace if deformed or damaged, and at every
disassembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal lip contact surface shows
cracking.
Using a dial gauge, check the backlash of side
gear. (VA1-type only)
Side gear backlash:
0.05 0.15 mm (0.002 0.006 in)
If the side gear backlash is not within the specifica-
tion, select the side gear thrust washer and adjust
the side gear backlash as specified.
Using a dial gauge, check the backlash of hypoid
driven gear.
Hypoid driven gear backlash:
0.10 0.15 mm (0.004 0.006 in)
If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or re-
pair if necessary.
Inspect the tooth contact between the hypoid driv-
en gear and drive pinion. <Ref. to DI-69, ASSEM-
BLY, Rear Differential (VA-type).>
DI-00240
DI-00099
DI-89
DIFFERENTIALS
4. COMPANION FLANGE
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 (0.003 in)
3) Set the gauge inside of the companion flange,
and measure the runout.
Limit of runout:
0.08 mm (0.003 in)
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 even after chang-
ing 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 assem-
bled incorrectly or bearing is faulty.
F: ADJUSTMENT
Adjust the side gear backlash. (VA1-type)
<Ref. to DI-69, ASSEMBLY, Rear Differential (VA-
type).>
Adjust hypoid driven gear backlash.
type).>
Adjust the tooth contact between hypoid driven
gear and drive pinion gear.
type).>
DI-00360
DI-00361
DI-90
Rear Differential Front Oil Seal
DIFFERENTIALS
6. Rear Differential Front Oil
Seal
A: INSPECTION
Make sure that there is no leakage from front oil
seal portion. If there is any leakage replace the oil
seal and inspect the propeller shaft.
B: REPLACEMENT
3) Remove the oil drain plug, and drain gear oil.
Except for VA2-type
VA2-type
4) Install the oil drain plug.
NOTE:
Apply liquid gasket to the drain plug for the T-
type (except for GT spec. B 6MT model).
Liquid gasket:
equivalent
Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
60 Nm (6.1 kgf-m, 44.3 ft-lb)
VA1-type:
34 Nm (3.5 kgf-m, 25.1 ft-lb)
VA2-type:
29 Nm (3.0 kgf-m, 21.4 ft-lb)
Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.>
AL, Muffler.>
7) Remove the heat shield cover. (When equipped)
(A) Filler plug
(B) Drain plug
(A) Filler plug
(B) Drain plug
DI-00356
(A)
(B)
(A)
DI-00357
(B)
DI-00194
ST
DI-91
Rear Differential Front Oil Seal
DIFFERENTIALS
10) Extract the companion flange using ST.
11) Remove the oil seal using ST or screwdriver.
13) Install the companion flange.
NOTE:
Use a plastic hammer to install companion flange.
14) Apply seal material on the drive pinion shaft
thread and new self-locking nut seat.
SEAL MATERIAL
equivalent
15) Tighten the self-locking nut within the specified
torque range so that the rotating resistance of com-
panion flange becomes the same as that of before
oil seal replacement.
NOTE:
Tightening torque:
T-type:
181.5 Nm (18.5 kgf-m, 134.0 ft-lb)
VA-type:
191 Nm (19.5 kgf-m, 141.0 ft-lb)
16) Hereafter, reassemble in the reverse order of
disassembly.
DI-00196
ST
DI-00197
ST
DI-00292
ST
DI-00194
ST
DI-92
Rear Differential Side Oil Seal
DIFFERENTIALS
7. Rear Differential Side Oil Seal
A: INSPECTION
Make sure that there is no leakage from side oil
seal. If there is any leakage, replace the oil seal.
B: REPLACEMENT
1) Remove the rear differential. <Ref. to DI-31, RE-
MOVAL, Rear Differential (T-type).> <Ref. to DI-60,
REMOVAL, Rear Differential (VA-type).>
2) Remove the rear differential side oil seal using a
screwdriver wrapped with vinyl tape to prevent the
side retainer from scratches.
3) Using the ST, install the oil seal to the side retainer.
T-type and VA2-type
ST 398437700 DRIFT
VA1-type
4) Install the rear differential. <Ref. to DI-32, IN-
STALLATION, Rear Differential (T-type).> <Ref. to
DI-61, INSTALLATION, Rear Differential (VA-
type).>
ST
DI-00209
ST
DI-00221
DI-93
Rear Differential Front Member
DIFFERENTIALS
8. Rear Differential Front Member
A: REMOVAL
3) Support the rear differential using transmission
jack, and then remove the rear differential front
member.
B: INSTALLATION
Using new self-locking nuts, install the rear differ-
ential front member.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 110 Nm (11.2 kgf-m, 81 ft-lb)
C: INSPECTION
1) Check the rear differential front member for
damage, bend and corrosion.
If damage, bend or corrosion is excessive, replace
the rear differential front member.
2) Check the bushings of rear differential member
for cracking, hardening and damage.
If cracking, hardening or damage is excessive, re-
place rear differential front member.
(A) Rear differential front member
DI-00293 (A)
DI-00294
T2
T1
DI-94
DIFFERENTIALS
A: INSPECTION
Symptom or trouble Possible cause Remedy
1. Oil leakage (1) Worn, scratched, or incorrectly seated
front or side oil seal. Scored, battered or
excessively worn sliding surface of com-
panion flange.
Correct or replace.
(2) Clogged or damaged air breather. Clean, repair or replace.
(3) Loose bolts on side retainer, or incor-
rectly fitted O-ring.
Tighten the bolts to specified torque.
Replace the O-ring.
(4) Loose rear cover attaching bolts or
damaged gasket.
Tighten the bolts to specified torque.
Replace gasket and apply liquid gasket.
(5) Loose oil filler or drain plug. Retighten and apply liquid gasket.
(6) Wear, damage or incorrect fitting of
side retainer or oil seal.
Correct or replace.
2. Seizure
NOTE:
Seized or damaged parts should be re-
placed, and also other parts should be thor-
oughly checked for any defect and should
be repaired or replaced as required.
(1) Insufficient backlash for hypoid gear. Readjust or replace.
(2) Excessive preload for side, rear or
front bearing.
Readjust or replace.
(3) Insufficient or improper oil used. Replace seized part and fill with specified
oil to specified level.
3. Damage
NOTE:
Damaged parts should be replaced, and
also other parts should be thoroughly
checked for any defect and should be re-
paired or replaced as required.
(1) Improper backlash for hypoid gear. Replace.
(2) Insufficient or excessive preload for
side, rear or front bearing.
Readjust or replace.
(3) Excessive backlash for differential
gear.
Replace gear or thrust washer.
(4) Loose bolts and nuts such as hypoid
driven gear bolt
Retighten.
(5) Damage due to overloading. Replace.
4. Noises when starting or shifting
gears
NOTE:
Noises may be caused by differential as-
sembly, universal joint, wheel bearing,
etc. Find out what is actually making noise
before disassembling.
(1) Excessive backlash for hypoid gear. Readjust.
(2) Excessive backlash for differential
gear.
Replace gear or thrust washer.
(3) Insufficient preload for front or rear
bearing.
Readjust.
(4) Loose drive pinion nut. Tighten to the specified torque.
(5) Loose bolts and nuts such as side
bearing retainer attaching bolt.
Tighten to the specified torque.
5. Noises when cornering (1) Damaged differential gear. Replace.
(2) Excessive wear or damage of thrust
washer.
Replace.
(3) Broken pinion mate shaft. Replace.
(4) Seized or damaged side bearing. Replace.
DI-95
DIFFERENTIALS
6. Gear Noise
NOTE:
Since noises from engine, muffler, trans-
mission, 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 coast-
ing, accelerating, cruising, and jacking-up
all four wheels. Perform these inspections
according to the condition of trouble.
When listening to noises, shift gears into
four wheel drive and fourth speed posi-
tion, trying to pick up only differential
noise.
(1) Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.
(2) Improper backlash of the hypoid gear. Readjust.
(3) Scored or chipped teeth of hypoid
gear.
Replace hypoid gear set.
(4) Seized hypoid gear. Replace hypoid gear set.
(5) Improper preload for front or rear
bearings.
Readjust.
(6) Seized, cut-away or chipped front or
rear bearing.
Replace.
(7) Seized, cut-away or chipped side
bearing.
Replace.
(8) Vibrating differential gear. Replace.
Symptom or trouble Possible cause Remedy
DI-96
DIFFERENTIALS
TC-2
General Description
TRANSFER CASE
A: NOTE
For general description, refer to the 4AT, 5AT,
5MT or 6MT section.
4AT model:
<Ref. to 4AT-2, General Description.>
5AT model:
<Ref. to 5AT-2, General Description.>
5MT model:
<Ref. to 5MT-2, General Description.>
6MT model:
<Ref. to 6MT-2, General Description.>
TC-3
TRANSFER CASE
2. Transfer Case and Extension
Case Assembly
A: NOTE
For removal, installation and inspection, refer to the
5MT section. <Ref. to 5MT-38, Transfer Case and
Extension Case Assembly.>
TC-4
Transfer Clutch
TRANSFER CASE
3. Transfer Clutch
A: NOTE
4AT or 5AT section.
4AT model:
<Ref. to 4AT-75, Transfer Clutch.>
5AT model:
<Ref. to 5AT-69, Transfer Clutch.>
TC-5
Extension Case
TRANSFER CASE
4. Extension Case
A: NOTE
4AT, 5AT or 6MT section.
4AT model:
<Ref. to 4AT-71, Extension Case.>
5AT model:
<Ref. to 5AT-67, Extension Case.>
6MT model:
<Ref. to 6MT-43, Extension Case.>
TC-6
Oil Seal
TRANSFER CASE
5. Oil Seal
A: NOTE
For replacement and inspection, refer to the 4AT,
5AT, 5MT or 6MT section.
4AT model:
<Ref. to 4AT-45, Extension Case Oil Seal.> <Ref.
to 4AT-46, Differential Side Retainer Oil Seal.>
5AT model:
<Ref. to 5AT-48, Extension Case Oil Seal.> <Ref.
to 5AT-49, Differential Side Retainer Oil Seal.>
5MT model:
<Ref. to 5MT-33, Oil Seal.> <Ref. to 5MT-34, Dif-
ferential Side Retainer Oil Seal.>
6MT model:
<Ref. to 6MT-28, Oil Seal.> <Ref. to 6MT-29, Dif-
ferential Side Retainer Oil Seal.>
TC-7
Transfer Drive Gear
TRANSFER CASE
6. Transfer Drive Gear
A: NOTE
5MT or 6MT section.
5MT model:
<Ref. to 5MT-42, Transfer Drive Gear.>
6MT model:
<Ref. to 6MT-53, Transfer Drive Gear.>
TC-8
TRANSFER CASE
7. Transfer Driven Gear
A: NOTE
5MT or 6MT section.
5MT model:
<Ref. to 5MT-44, Transfer Driven Gear.>
6MT model:
<Ref. to 6MT-55, Transfer Driven Gear.>
TC-9
TRANSFER CASE
8. Reduction Drive Gear
A: NOTE
4AT section. <Ref. to 4AT-85, Reduction Drive
Gear.>
TC-10
TRANSFER CASE
9. Center Differential Carrier
A: NOTE
4AT or 5AT section.
4AT model:
<Ref. to 4AT-87, Center Differential Carrier.>
5AT model:
<Ref. to 5AT-76, Center Differential Carrier.>
TC-11
TRANSFER CASE
A: NOTE
4AT or 5AT section.
4AT model:
<Ref. to 4AT-83, Reduction Driven Gear.>
5AT model:
<Ref. to 5AT-73, Reduction Driven Gear.>
TC-12
Center Differential
TRANSFER CASE
A: NOTE
5MT or 6MT section.
5MT model:
<Ref. to 5MT-46, Center Differential.>
6MT model:
<Ref. to 6MT-57, Center Differential.>
TC-13
TRANSFER CASE
12.Transfer Clutch Pressure
Test
A: NOTE
For inspection, refer to 4AT or 5AT section.
4AT model:
<Ref. to 4AT-35, Transfer Clutch Pressure Test.>
5AT model:
<Ref. to 5AT-36, Transfer Clutch Pressure Test.>
TC-14
TRANSFER CASE
DS-2
General Description
DRIVE SHAFT SYSTEM
A: SPECIFICATION
1. PROPELLER SHAFT
Model 5MT 6MT 4AT 5AT
Propeller shaft type EDJ
Propeller shaft length: L mm (in)
1,483
(58.39)
1,423
(56.02)
1,423
(56.02)
1,310
(51.57)
Front propeller shaft Joint-to-joint length: L
1
mm (in) 735 (28.9) 675 (26.6) 675 (26.6) 562 (22.1)
Rear propeller shaft Joint-to-Joint length: L
2
mm (in) 748 (29.4)
Outer diameter of tube: mm (in)
D
1
63.5 (2.50)
D
2
57.5 (2.26)
DS-00226
D1 D2
L
L1 L2
DS-3
General Description
DRIVE SHAFT SYSTEM
2. FRONT DRIVE SHAFT ASSEMBLY
3. REAR DRIVE SHAFT ASSEMBLY
Model Type of drive shaft Axle diameter D mm (in) Axle length L mm (in)
Turbo 5MT, 6MT EBJ + PTJ 26 (1.0) 332.5 (13.09)
Other than above EBJ + PTJ 26 (1.0) 349.6 (13.76)
(A) Axle diameter (B) Axle length
Model Type of drive shaft Axle diameter D mm (in) Axle length L mm (in)
2.5 i AT BJ + DOJ 22 (0.87) 382 (15.04)
6MT EBJ + DOJ 22 (0.87) 331.8 (13.06)
Other than above EBJ + DOJ 22 (0.87) 375.1 (14.77)
(A) Axle diameter (B) Axle length
DS-00227
(B)
(A)
DS-00228
(A)
(B)
DS-4
General Description
DRIVE SHAFT SYSTEM
B: COMPONENT
1. PROPELLER SHAFT
(1) Propeller shaft (4) Rear differential (T-type) Tightening torque:Nm (kgf-m, ft-lb)
(2) Bushing (5) Rear differential (VA2-type) T1: 31 (3.2, 23.1)
(3) Rear differential (VA1-type) T2: 52 (5.3, 38.3)
DS-00229
(2)
(2)
T2
(1)
(3)
T1
T1
(4)
(5)
T1
DS-5
General Description
DRIVE SHAFT SYSTEM
2. FRONT AXLE
(1) Circlip (7) Boot band (13) Front hub unit bearing
(2) Baffle plate (8) Boot (PTJ) (14) Axle nut
(3) Outer race (PTJ) (9) Boot (EBJ)
(4) Snap ring (10) EBJ shaft ASSY Tightening torque:Nm (kgf-m, ft-lb)
(5) Trunnion (11) Housing T1: 220 (22.4, 162)
(6) Snap ring (12) Hub bolt T2: 65 (6.6, 47.9)
(3)
(2)
(1)
(13)
(4)
(5)
(14)
(9)
(10)
(12)
(7)
(6)
(11)
T2
T1
(8)
DS-00232
DS-6
General Description
DRIVE SHAFT SYSTEM
3. REAR AXLE
(1) Baffle plate (DOJ) (8) Boot band (13) Hub bolt
(2) Outer race (DOJ) (9) Boot (DOJ) (14) Axle nut
(3) Snap ring (10) Boot (BJ)
(4) Inner race (11) BJ shaft ASSY (2.5 i AT model)
EBJ shaft ASSY (Except for 2.5 i
AT model)
(5) Ball T1: 65 (6.6, 47.9)
(6) Cage T2: 240 (24.5, 177)
(7) Snap ring (12) Rear hub unit bearing
DS-00233
(13)
(12)
T1
(5)
(4)
(6)
(3)
(2)
(1)
(11)
(10)
(9)
(8)
(8)
(8)
(7)
(14)
T2
DS-7
General Description
DRIVE SHAFT SYSTEM
C: CAUTION
forming any work.
Use SUBARU genuine grease etc. or equivalent. Do
not mix grease etc. of different grades or manufacturers.
points.
Apply grease onto sliding or revolving surfaces
Before installing snap rings, apply sufficient
amount of grease to avoid damage and deformation.
ing materials such as wood blocks, aluminum
plates, or waste cloth between the part and the
vise.
DS-8
General Description
DRIVE SHAFT SYSTEM
D: PREPARATION TOOL
1. SPECIAL TOOL
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.
Used together with the AXLE SHAFT PULLER
PLATE (28099PA110).
SIDE OIL SEAL
INSTALLER
seal.
927080000 HUB STAND Used for assembling hub bolt in hub.
ST-925091000
(A)
(B)
ST-926470000
ST18675AA000
ST-927080000
DS-9
General Description
DRIVE SHAFT SYSTEM
2. GENERAL TOOL
28099PA110 AXLE SHAFT
PULLER PLATE
Exchange with the plate of the AXLE SHAFT
PULLER (926470000) to use.
28099PA090 OIL SEAL
PROTECTOR
rear differential.
For protecting the oil seal.
28399SA010 OIL SEAL
PROTECTOR
Used for installing front drive shaft into front
differential.
For protecting the oil seal.
28399AG000 HUB STAND Used for extracting hub bolt.
DESCRIPTION REMARKS
Puller Used for removing the ball joint from knuckle arm.
Dial gauge Used for inspecting the propeller shaft run-out.
Extension cap Used for preventing leakage of gear oil or ATF.
Bar Used for extracting drive shaft.
ST28099PA110
ST28099PA090
ST28399SA010
ST28399AG000
DS-10
Propeller Shaft
DRIVE SHAFT SYSTEM
2. Propeller Shaft
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. The rubber boot may be damaged due to in-
terference with adjacent metal parts while bending
the EDJ during removal.
8) Make alignment marks on the flange yoke and
rear differential before removal.
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 bear-
ing to vehicle body.
12) Remove the propeller shaft from transmission.
CAUTION:
Be careful not to damage oil seals and fric-
tional surface of the sleeve yoke.
Cover the center exhaust pipe with a cloth to
keep off any ATF or oil spilled from transmis-
sion when removing propeller shaft.
NOTE:
Use a container to catch ATF or oil flowing from
propeller shaft.
(A) Heat shield cover
DS-00239
DS-00230
(A)
(A) Alignment mark
DS-00028
(A)
DS-00141
DS-00030
DS-11
Propeller Shaft
DRIVE SHAFT SYSTEM
13) Install an extension cap to the transmission.
NOTE:
If extension cap is not available, place vinyl bag
over opening and fasten with string to prevent gear
oil or ATF from leaking.
B: INSTALLATION
1) Insert the sleeve yoke into the transmission and
attach center bearing to body.
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
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)
4) Install the center exhaust pipe.
7) Connect the ground cable to the battery.
(A) Extension cap
(A) Alignment mark
DS-00031
(A)
DS-00141
DS-00028
(A)
DS-12
Propeller Shaft
DRIVE SHAFT SYSTEM
C: INSPECTION
NOTE:
Do not disassemble propeller shaft. Check the fol-
lowing and replace if necessary.
Tube surface for dents of cracks
Splines for deformation or abnormal wear
Unsmooth joint operation or abnormal noise
Center bearing for free play, noise or non-
smooth operation.
Oil seals for abnormal wear or damage
Damaged center bearing
Check the following points with propeller shaft in-
stalled in vehicle.
1. JOINTS AND CONNECTIONS
3) Check for any looseness of the yoke flange
mounting bolts which connect to the rear differen-
tial and center bearing bracket mounting bolts.
2. SPLINES AND BEARING
4) Turn the propeller shaft by hand to see if abnor-
mal free play exists at splines. Also move yokes to
see if abnormal free play exists at spiders and
bearings.
3. RUNOUT OF PROPELLER SHAFT
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:
Service limit 0.6 mm (0.024 in)
4. CENTER BEARING FREE PLAY
4) Move the propeller shaft near the center bearing
up, down, left, right by hand, to check for any ab-
normal free play of the bearings.
DS-00035
(A) Propeller shaft
(B) Dial gauge
DS-00036
(B)
(A)
DS-00037
DS-13
Front Axle
DRIVE SHAFT SYSTEM
3. Front Axle
A: REMOVAL
3) Lift the crimped section of axle nut.
4) Remove the axle nut using a socket wrench
while depressing the brake pedal.
CAUTION:
Remove the wheel before loosening the axle
nut. Failure to follow this rule may damage the
wheel bearings.
6) Remove the disc brake caliper from the housing,
and suspend it from strut using a wire.
7) Remove the disc rotor from the hub.
NOTE:
If it is difficult to remove the disc rotor from the hub,
drive the 8 mm bolt into the threaded end of rotor,
and then remove the rotor.
8) Remove the cotter pin and castle nut securing
the tie-rod end to the housing knuckle arm.
9) Using a puller, remove the tie-rod ball joint from
knuckle arm.
CAUTION:
When removing tie-rod, do not hit the tie-rod
end with hammer.
10) Remove the ABS wheel speed sensor assem-
bly and harness.
DS-00038
DS-00143
DS-00041
(A) Cotter pin
(B) Castle nut
(C) Tie-rod
DS-00042
(C)
(B)
(A)
DS-00043
DS-00249
DS-14
Front Axle
DRIVE SHAFT SYSTEM
11) Remove the bolts which secure the sensor har-
ness to the strut.
12) Remove the front arm ball joint from the housing.
13) Remove the PTJ from transmission.
14) Remove the front drive shaft assembly from the
hub. If it is hard to remove, use the ST.
ST1 926470000 AXLE SHAFT PULLER
ST2 28099PA110 AXLE SHAFT PULLER
PLATE
15) After scribing an alignment mark on camber ad-
justing bolt head, remove the bolts which connect
the housing and strut, and disconnect the housing
from strut.
B: INSTALLATION
1) Align the alignment mark on the camber adjust-
ing bolt head, and tighten the housing and strut us-
ing a new self-locking nut.
Tightening torque:
175 Nm (17.8 kgf-m, 129.1 ft-lb)
3) Install the front arm ball joint to the housing.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
4) Install the ABS sensor harness to the strut.
5) Install the ABS wheel speed sensor on the housing.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
6) Install the disc rotor to hub.
7) Install the disc brake caliper on the housing.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
8) Install the stabilizer link.
9) Connect the tie-rod end ball joint to the knuckle
arm with a castle nut.
Tightening torque:
27.0 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.
10) 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.
DS-00144
DS-00045
DS-00145
ST2
ST1
DS-00046
(A) Cotter pin
(B) Castle nut
(C) Tie-rod
DS-00042
(C)
(B)
(A)
DS-15
Front Axle
DRIVE SHAFT SYSTEM
11) While depressing the brake pedal, tighten a new
axle nut to the specified torque and lock it securely.
Tightening torque:
220 Nm (22.4 kgf-m, 162 ft-lb)
CAUTION:
Install the wheel after installation of axle nut.
Failure to follow this rule may damage the
wheel bearing.
Be sure to tighten the axle nut to specified
torque. Do not overtighten it as this may dam-
age the wheel bearing.
12) After tightening the axle nut, lock it securely.
13) Install the wheel and tighten the wheel nuts to
specified torque.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
C: DISASSEMBLY
1) Remove the four bolts from the housing, and re-
move the front hub unit bearing and disc cover.
CAUTION:
Do not get closer the tool which charged
magnetism to magnetic encoder.
Be careful not to damage the magnetic encoder.
2) Disassemble the front hub unit bearing. <Ref. to
DS-18, DISASSEMBLY, Front Hub Unit Bearing.>
DS-00048
(A) Housing
(1) Magnetic encoder
(2) Front hub unit bearing
DS-00231
(A)
(2)
DS-00250
(1)
DS-16
Front Axle
DRIVE SHAFT SYSTEM
D: ASSEMBLY
1) Assemble the front hub unit bearing. <Ref. to
DS-18, ASSEMBLY, Front Hub Unit Bearing.>
2) Place the disc cover between housing and front
hub unit, and tighten the four bolts.
Tightening torque:
65 Nm (6.6 kgf-m, 47.9 ft-lb)
CAUTION:
E: INSPECTION
1) Moving the front tire up and down by hand,
check there is no backlash in bearing, and check
the wheel rotates smoothly.
2) Inspect the lean of axis direction using a dial
gauge. Replace the bearing if the load range ex-
ceeds the limitation.
Service limit:
Maximum: 0.05 mm (0.0020 in)
(A) Housing
DS-00231
(A)
(2)
DS-00250
(1)
DS-00061
DS-00062
DS-17
Front Hub Unit Bearing
DRIVE SHAFT SYSTEM
4. Front Hub Unit Bearing
A: REMOVAL
CAUTION:
wheel bearings.
5) Remove the disc brake caliper from the housing,
and suspend it from strut using a wire.
NOTE:
drive the 8 mm bolt into the threaded end of rotor,
and then remove the rotor.
7) Remove the four bolts from the housing.
CAUTION:
8) Remove the front hub unit bearing. If it is hard to
remove, use the ST.
PLATE
DS-00038
DS-00041
(A) Housing
DS-00231
(A)
(2)
DS-00250
(1)
DS-00145
ST2
ST1
DS-18
Front Hub Unit Bearing
DRIVE SHAFT SYSTEM
B: INSTALLATION
1) Place the disc cover between housing and front
hub unit, and tighten the four bolts.
Tightening torque:
65 Nm (6.6 kgf-m, 47.9 ft-lb)
3) Tighten the axle nut temporarily.
5) Install the disc brake caliper on the housing.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
Tightening torque:
220 Nm (22.4 kgf-m, 162 ft-lb)
CAUTION:
wheel bearing.
specified torque.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
C: DISASSEMBLY
Using the ST and a hydraulic press, push out the
hub bolts.
ST 28399AG000 HUB STAND
CAUTION:
Be careful not to hammer the hub bolts. This
may deform the hub.
Do not reuse the hub bolt.
NOTE:
Since the hub unit bearing can not be disassem-
bled, only hub bolts can be removed.
D: ASSEMBLY
1) Attach the hub to the ST securely.
ST 927080000 HUB STAND
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.
E: INSPECTION
Refer to Front Axle for inspection procedures.
<Ref. to DS-16, INSPECTION, Front Axle.>
CAUTION:
If there is any fault in the bearing, replace hub
unit bearing.
(A) Housing
DS-00231
(A)
DS-00048
ST
DS-00252
(1)
DS-00253
ST
(1)
DS-19
Rear Hub Unit Bearing
DRIVE SHAFT SYSTEM
5. Rear Hub Unit Bearing
A: REMOVAL
2) Lift up the vehicle, then remove the rear wheels.
4) While applying the parking brake, remove the
axle nut using a socket wrench.
CAUTION:
wheel bearings.
6) Remove the rear ABS wheel speed sensor.
7) Remove the disc brake caliper from back plate,
and suspend it from the stabilizer using a wire.
NOTE:
Mark the mating surface of hub and disc rotor be-
fore removing the disc rotor to avoid confusing
when installing.
If it is difficult to remove the disc rotor from the
hub, drive the 8 mm bolt into the threaded end of ro-
tor, and then remove the rotor.
9) Remove the four bolts from rear arm.
DS-00038
DS-00147
DS-00148
DS-00149
DS-20
DRIVE SHAFT SYSTEM
10) Remove the hub unit bearing.
CAUTION:
NOTE:
If it is hard to remove, use the ST.
PLATE
B: INSTALLATION
1) Aligning the hub unit bearing to the mounting
hole of the back plate, install the hub unit assembly
and back plate. Tighten the axle nut temporarily.
CAUTION:
2) Tighten the four bolts.
Tightening torque:
65 Nm (6.6 kgf-m, 47.9 ft-lb)
3) Remove the axle nut.
4) Draw the rear drive shaft into specified position.
5) Tighten the new axle nut temporarily.
CAUTION:
Use a new axle nut (olive color).
(2) Rear hub unit bearing
DS-00251
(2)
(1)
DS-00150
DS-00122
ST2
ST1
DS-00251
(2)
(1)
DS-00149
DS-21
DRIVE SHAFT SYSTEM
7) Install the disc brake caliper on the back plate.
Tightening torque:
66 Nm (6.7 kgf-m, 48.7 ft-lb)
8) Install the rear ABS wheel speed sensor and
brake cable bracket.
9) Adjust the parking brake lever stroke by turning
the adjuster. <Ref. to PB-4, ADJUSTMENT, Park-
ing Brake Lever.>
10) While applying the parking brake and depress-
ing the brake pedal, tighten a new axle nut to the
specified torque and lock it securely.
Tightening torque:
240 Nm (24.5 kgf-m, 177 ft-lb)
CAUTION:
wheel bearing.
specified torque.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
C: DISASSEMBLY
Using the ST and a hydraulic press, push out the
hub bolts.
ST 28399AG000 HUB STAND
CAUTION:
Be careful not to hammer the hub bolts. This
may deform the hub.
Do not reuse the hub bolt.
NOTE:
Since the hub unit bearing can not be disassem-
bled, only hub bolts can be removed.
D: ASSEMBLY
1) Attach the hub to the ST securely.
ST 927080000 HUB STAND
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.
DS-00152
DS-00147
DS-00048
DS-00254
ST
(1)
DS-00255
ST
(1)
DS-22
DRIVE SHAFT SYSTEM
E: INSPECTION
1) Moving the rear tire up and down by hand, check
there is no backlash in bearing, and check the
wheel rotates smoothly.
2) Inspect the lean of axis direction using a dial
gauge. Replace the hub bearing if the play exceeds
the limit value.
Service limit:
Maximum: 0.05 mm (0.0020 in)
DS-00183
DS-00062
DS-23
Front Drive Shaft
DRIVE SHAFT SYSTEM
6. Front Drive Shaft
A: REMOVAL
3) Drain the transmission gear oil. (MT model)
4) Drain the differential gear oil. (AT model)
CAUTION:
wheel bearings.
7) Remove the stabilizer link from front arm.
8) Disconnect the front arm ball joint from the housing.
9) Remove the front drive shaft assembly. If it is
hard to remove, use ST1 and ST2.
PLATE
10) Using a bar, remove the front drive shaft from
transmission.
CAUTION:
Be careful not to allow the bar to damage holder
area.
B: INSTALLATION
1) Using the ST, replace the differential side retain-
er oil seal with a new seal.
SEAL INSTALLER
NOTE:
After pulling out the drive shaft, be sure to replace
with a new oil seal.
2) Insert the EBJ into hub splines.
3) Draw the drive shaft into specified position.
CAUTION:
Do not hammer drive shaft when installing it.
5) Using the ST, install the front drive shaft to
transmission.
6) Connect the front arm ball joint to the housing.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
DS-00038
FS-00106
DS-00145
ST2
ST1
ST
MT-00103
AT-00110
ST
DS-24
Front Drive Shaft
DRIVE SHAFT SYSTEM
7) Install the stabilizer link.
Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
CAUTION:
Be sure to use a new self-locking nut.
Tightening torque:
220 Nm (22.4 kgf-m, 162 ft-lb)
CAUTION:
wheel bearing.
Be sure to tighten axle nut to specified
9) After tightening axle nut, lock it securely.
10) Fill the transmission gear oil. (MT model)
11) Fill the differential gear oil. (AT model)
C: DISASSEMBLY
1) Place alignment marks on the shaft and outer
race.
2) Remove the PTJ boot band and boot.
CAUTION:
Be careful not to damage the boot.
3) Remove the snap ring from PTJ outer race.
4) Remove the PTJ outer race from shaft assembly.
5) Wipe off grease.
CAUTION:
The grease is a special type of grease. Do not
mix with other grease.
6) Place alignment marks on the roller kit and trunnion.
7) Remove the roller kit from trunnion.
CAUTION:
Be careful with the roller kit position.
8) Place alignment marks on the trunnion and
shaft.
DS-00106
DS-00107
DS-00108
DS-00109
DS-00110
DS-25
Front Drive Shaft
DRIVE SHAFT SYSTEM
9) Remove the snap ring and trunnion.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
protect the boot from scratches.
10) Remove the PTJ boot.
NOTE:
The BJ is a non-disassembly part, so the axle dis-
assembly stops here.
D: ASSEMBLY
NOTE:
Use specified grease.
PTJ side:
NKG302 (Part No. 28395AG02A)
1) Place the PTJ boot at the center of shaft.
2) Align alignment marks and install the trunnion on
the shaft.
3) Install the snap ring to shaft.
CAUTION:
Confirm that the snap ring is completely fitted
in shaft groove.
4) Fill 100 to 110 g (3.53 to 3.88 oz) of specified
grease into the interior of PTJ outer race.
5) Apply a thin coat of specified grease to the roller
kit and trunnion.
6) Align alignment marks on roller kit and trunnion
and install the roller kit.
CAUTION:
Be careful with the roller kit position.
7) Align the alignment marks of the shaft and outer
race, and install the outer race.
8) Install the snap ring in the groove on PTJ outer
race.
CAUTION:
Pull the shaft lightly and assure that the snap
ring is completely fitted in the groove.
9) 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.
10) Install the PTJ boot taking care not to twist it.
CAUTION:
The large end of PTJ boot and the boot
groove shall be cleaned completely so as to be
free from grease and other substances.
When installing PTJ boot, position outer race
of PTJ at center of its travel.
DS-00111
DS-00110
DS-00109
DS-00106
DS-26
Front Drive Shaft
DRIVE SHAFT SYSTEM
11) Put a new band through the clip and wind twice
in the band groove of the boot.
12) Pinch the end of band with pliers. Hold the clip
and tighten securely.
NOTE:
When tightening boot, use care so that the air with-
in the boot is appropriate.
13) Tighten the band using the ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten the band until it cannot be moved by hand.
14) Tap the clip with the punch provided at the end
of the ST.
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
15) Cut off the band with an allowance of about 10
mm (0.39 in) left from the clip and bend this allow-
ance over the clip.
CAUTION:
Make sure that the end of the band is in close
contact with clip.
16) Extend and retract the PTJ to provide equal
grease coating.
E: INSPECTION
Check the removed parts for damage, wear, corro-
sion etc. If faulty, repair or replace.
PTJ (pillow tripod joint)
Check for seizure, corrosion, damage, wear and
excessive play.
EBJ (high-efficiency compact ball fixed joint)
Check for seizure, corrosion, damage and exces-
sive play.
Shaft
Check for excessive bending, twisting, damage
and wear.
Boot
Check for wear, warping, breakage and scratches.
Grease
Check for discoloration and fluidity.
DS-00132
DS-00133
DS-27
Rear Drive Shaft
DRIVE SHAFT SYSTEM
7. Rear Drive Shaft
A: REMOVAL
4) While applying the parking brake, remove the
axle nut using a socket wrench.
CAUTION:
wheel bearings.
5) Remove the rear differential assembly.
T-type
<Ref. to DI-31, REMOVAL, Rear Differential (T-
type).>
VA-type
<Ref. to DI-60, REMOVAL, Rear Differential (VA-
type).>
6) Remove the axle nut and rear drive shaft. If it is
hard to remove, use ST1 and ST2.
PLATE
CAUTION:
Do not hammer drive shaft when removing.
Do not damage the oil seal and magnetic
encoder.
B: INSTALLATION
1) Insert the BJ or EBJ into the rear hub splines.
CAUTION:
2) Draw the rear drive shaft into specified position.
CAUTION:
Do not hammer drive shaft when installing it.
4) Install the rear differential assembly.
T-type
(T-type).>
VA-type
(VA-type).>
5) While applying the parking brake and depress-
ing the brake pedal, tighten a new axle nut to the
specified torque and lock it securely.
Tightening torque:
240 Nm (24.5 kgf-m, 177 ft-lb)
CAUTION:
wheel bearing.
DS-00038
DS-00122
ST2
ST1
DS-00251
(2)
(1)
DS-28
Rear Drive Shaft
DRIVE SHAFT SYSTEM
6) Lock the axle nut securely.
7) Install the wheel.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
C: DISASSEMBLY
1) Straighten the bent claw at the larger end of the
DOJ boot.
2) Loosen the band by means of screwdriver or pliers.
CAUTION:
Be careful not to damage the boot.
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 round circlip at the neck of
DOJ outer race with a screwdriver.
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 con-
stant velocity joints). Do not mix with other
greases.
NOTE:
Disassemble exercising care not to lose balls (6 pcs).
8) To remove the cage from inner race, turn the
cage by a half pitch to the track groove of inner race
and shift the cage.
9) Using pliers, remove the snap ring fixing the in-
ner race to the shaft.
10) Take out the DOJ inner race.
11) Take off the DOJ cage from shaft and remove
the DOJ boot.
CAUTION:
prevent boot from scratches.
12) Remove the BJ boot or EBJ boot in the same
procedure as the DOJ boot.
NOTE:
Further disassembly of axle is impossible because
the BJ and EBJ cannot be disassembled.
DS-00048
DS-00124
DS-00125
(A) Outer race
(B) Grease
DS-00126
(B)
(A)
DS-29
Rear Drive Shaft
DRIVE SHAFT SYSTEM
D: ASSEMBLY
NOTE:
Use specified grease.
BJ, EBJ side:
DOJ side:
1) Install the BJ or EBJ boot in specified position,
and fill it with 60 to 70 g (2.12 to 2.47 oz.) of speci-
fied grease.
2) Place the DOJ boot at the center of shaft.
CAUTION:
prevent boot from scratches.
3) Insert the DOJ cage onto shaft.
NOTE:
Insert the cage with the cutout portion facing the
shaft end, since the cage has an orientation.
4) Install the DOJ inner race on shaft and fix the
snap ring in place with pliers.
NOTE:
Confirm that the snap ring is completely fitted in the
shaft groove.
5) Install the cage to inner race fixed upon shaft.
NOTE:
Fit the cage with the protruding section aligned with
the track on the inner race, and turn by a half pitch.
6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified
grease into the inner side of the DOJ outer race.
7) Apply a thin coat of specified grease to the cage
pocket and six ball bearings.
8) Insert the six ball bearings into the cage pocket.
9) Align the outer race track and ball positions, and
place the shaft, inner race, cage and ball bearings
in the original positions, and then fix outer race in
place.
(A) Cage
(B) Cutout portion
DS-00395
(B)
(A)
DS-00128
(A) Inner race
(B) Cage
(A) Outer race
(B) Grease
(B)
(A)
DS-00129
DS-00126
(B)
(A)
DS-30
Rear Drive Shaft
DRIVE SHAFT SYSTEM
10) Install the snap ring in the groove on the DOJ
outer race.
NOTE:
Assure that the balls, cage and inner race are
completely fitted in the outer race of DOJ.
Use care not to place the matched position of
snap ring in the ball groove of outer race.
Pull the shaft lightly and assure that the circlip is
completely fitted in the groove.
11) 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.
12) Install the DOJ boot taking care not to twist it.
NOTE:
The inside of the larger end of DOJ boot and the
boot groove shall be cleaned so as to be free from
grease and other substances.
When installing the DOJ boot, position the outer
race of DOJ at center of the stroke.
13) Put a new band through the clip and wind twice
in the band groove of the boot.
14) Pinch the end of band with pliers. Hold the clip
and tighten securely.
NOTE:
When tightening boot, use care so that the air with-
in the boot is appropriate.
15) Tighten the band using the ST.
NOTE:
Tighten the band until it cannot be moved by hand.
16) Tap the clip with the punch provided at the end
of the ST.
NOTE:
Tap to an extent that the boot underneath is not
damaged.
17) Cut off the band with an allowance of about
10 mm (0.39 in) left from the clip and bend this al-
lowance over the clip.
NOTE:
Be careful so that the end of the band is in close
contact with clip.
18) Install the BJ boot or EBJ boot in the same pro-
cedure as a DOJ boot.
19) Extend and retract the DOJ repeatedly to pro-
vide an equal coating of grease.
E: INSPECTION
Check the removed parts for damage, wear, corro-
sion etc. Repair or replace if defective.
DOJ (Double Offset Joint)
excessive play.
EBJ (High-efficiency Compact Ball Fixed Joint)
excessive play.
Shaft
Check for excessive bending, twisting, damage
and wear.
BJ (Bell Joint)
Check for seizure, corrosion, damage and exces-
sive play.
Boot
Check for wear, warping, breakage and scratches.
Grease
Check for discoloration and fluidity.
DS-00125
DS-00132
DS-00133
DS-31
DRIVE SHAFT SYSTEM
A: INSPECTION
NOTE:
Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper
wheel alignment, etc.
Noise or vibration from propeller shaft Center bearing Check the center bearing. <Ref. to DS-12, CEN-
TER BEARING FREE PLAY, INSPECTION, Pro-
peller Shaft.>
Runout of propeller shaft Check for deflection of the propeller shaft. <Ref.
to DS-12, RUNOUT OF PROPELLER SHAFT,
INSPECTION, Propeller Shaft.>
Loose or gap at connections Check the joints and connectors. <Ref. to DS-12,
JOINTS AND CONNECTIONS, INSPECTION,
Propeller Shaft.>
Check the spline and bearing. <Ref. to DS-12,
SPLINES AND BEARING, INSPECTION, Pro-
peller Shaft.>
Abnormal wheel vibration Wheel is out of balance. Check the wheel balance. <Ref. to WT-9,
ADJUSTMENT, Wheel Balancing.>
Front wheel alignment Check the front wheel alignment. <Ref. to FS-8,
INSPECTION, Wheel Alignment.>
Rear wheel alignment Check the rear wheel alignment. <Ref. to RS-7,
Front strut Check the front strut. <Ref. to FS-25, INSPEC-
TION, Front Strut.>
Rear shock absorber Check the rear shock absorber. <Ref. to RS-16,
INSPECTION, Rear Shock Absorber.>
Front drive shaft Check the front drive shaft. <Ref. to DS-26,
INSPECTION, Front Drive Shaft.>
Rear drive shaft Check the rear drive shaft. <Ref. to DS-30,
INSPECTION, Rear Drive Shaft.>
Front hub unit bearing Check the front hub unit bearing. <Ref. to DS-18,
INSPECTION, Front Hub Unit Bearing.>
Rear hub unit bearing Check the rear hub unit bearing. <Ref. to DS-22,
INSPECTION, Rear Hub Unit Bearing.>
Noise from the underbody Wheel is out of balance. Check the wheel balance. <Ref. to WT-9,
ADJUSTMENT, Wheel Balancing.>
Front wheel alignment Check the front wheel alignment. <Ref. to FS-8,
Rear wheel alignment Check the rear wheel alignment. <Ref. to RS-7,
Front strut Check the front strut. <Ref. to FS-25, INSPEC-
TION, Front Strut.>
Rear shock absorber Check the rear shock absorber. <Ref. to RS-16,
INSPECTION, Rear Shock Absorber.>
DS-32
DRIVE SHAFT SYSTEM
ABS-2
General Description
ABS
A: SPECIFICATION
Item Specification or identification
ABS wheel speed sensor
ABS wheel speed sensor gap
(for reference)
Front 0.77 1.43 mm (0.030 0.056 in)
Rear 0.64 1.56 mm (0.025 0.061 in)
Identifications of harness
(marks, color)
Front
RH K1 (White)
LH K2 (Yellow)
Rear
RH K5 (White)
LH K6 (Yellow)
G sensor G sensor voltage 2.30.2 V
ABSCM&H/U identification
AT (Except for OUTBACK) J9
MT (Except for OUTBACK) JA
AT (OUTBACK) JB
MT (OUTBACK) JE
ABS-3
General Description
ABS
B: COMPONENT
1. ABS WHEEL SPEED SENSOR
(1) G sensor (4) Rear ABS wheel speed sensor LH Tightening torque:Nm (kgf-m, ft-lb)
(2) Front ABS wheel speed sensor LH (5) Hub unit bearing T1: 7.5 (0.76, 5.5)
(3) Front housing (6) Magnetic encoder T2: 33 (3.3, 24)
T1
ABS00380
T2
T1
(1)
(5)
(4)
(3)
(2)
T2
T1
(6)
T2
ABS-4
General Description
ABS
2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
C: CAUTION
forming any work.
the battery.
points.
(1) ABS control module and hydraulic
control unit (ABSCM&H/U)
(6) Primary inlet (11) Bracket
(7) Secondary inlet
(2) Front outlet RH (8) Damper Tightening torque:Nm (kgf-m, ft-lb)
(3) Rear outlet LH (9) Spacer T1: 7.5 (0.76, 5.5)
(4) Rear outlet RH (10) Damper T2: 33 (3.3, 24)
(5) Front outlet LH
(1)
(8)
(11)
(7)
(6)
(5)
(4)
(3)
(10)
(2)
T1
T2
T2
(9)
T2
ABS00938
ABS-5
General Description
ABS
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
MONITOR III KIT
TOOL NAME REMARKS
Pressure gauge Used for measuring oil pressure.
TORX
bit E5 Used for replacing the ABSCM.

ST1B021XU0
ABS-6
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) Use compressed air to remove water and dust
around the ABSCM&H/U.
NOTE:
If the terminals become dirty, it may cause improp-
er contact.
3) Lift the lock lever and disconnect the ABSCM&H/
U connector.
CAUTION:
Do not pull on the harness when disconnecting
the connector.
4) Remove the harness clip.
5) Disconnect the brake pipes from the ABSCM&H/U.
6) 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.
7) 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.
8) Remove the ABSCM&H/U bracket.
B: INSTALLATION
1) Install the ABSCM&H/U bracket.
Tightening torque:
33 Nm (3.3 kgf-m, 24 ft-lb)
2) Align the damper groove of the ABSCM&H/U to
the bracket side claw, and install the ABSCM&H/U
with new nuts (Part No. 023506000).
NOTE:
Check the identification marks of the ABSCM&H/U.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
3) Connect the brake pipes to their correct AB-
SCM&H/U positions.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
4) Using a harness clip, secure the ABSCM&H/U
harness to the bracket.
5) Connect the connector to the ABSCM&H/U.
NOTE:
Be sure to remove all foreign matter from inside
the connector before connecting.
Make sure the ABSCM&H/U connector is se-
curely locked.
6) Bleed air from the brake system.
ABS00382
ABS00383
ABS00383
ABS-7
ABS
C: INSPECTION
1) Check the condition of connection and settle-
ment of connector.
2) Check the mark used for ABSCM&H/U identification.
Refer to SPECIFICATION for the identification
mark. <Ref. to ABS-2, SPECIFICATION, General
Description.>
1. CHECKING THE HYDRAULIC UNIT ABS
OPERATION BY PRESSURE GAUGE
1) Lift up the vehicle, and remove the wheels.
2) Remove the air bleeder screws from FL and FR
caliper bodies.
3) Connect two pressure gauges to FL and FR cal-
iper bodies.
CAUTION:
Use a pressure gauge used exclusively for
brake fluid measurement.
Do not use the pressure gauge used for the
measurement of transmission oil. Doing so will
cause the piston seal to expand and deform.
NOTE:
Wrap sealing tape around the pressure gauge.
4) Bleed air from the pressure gauges and the FL
and FR caliper bodies.
5) Perform ABS sequence control.
<Ref. to ABS-10, ABS Sequence Control.>
6) When the hydraulic unit begins to work, first the
FL side performs decompression, hold and com-
pression, and then the FR side performs decom-
pression, hold and compression.
7) Read values indicated on the pressure gauge and
check if the fluctuation of the values between decom-
pression and compression meets the standard val-
ues. Depress the brake pedal and check that the kick-
back is normal, and tightness is normal.
8) Disconnect the pressure gauges from FL and FR
caliper bodies.
9) Install the air bleeder screws of FL and FR cali-
per bodies.
10) Remove the air bleeder screws from RL and
RR caliper bodies.
11) Connect two pressure gauges to RL and RR
caliper bodies.
13) Bleed air from RL and RR caliper bodies, and
pressure gauge.
RR side performs decompression, hold and com-
pression, and then the RL side performs decom-
pression, hold and compression.
16) Read values indicated on the pressure gauge
and check if the fluctuation of the values between
decompression and compression meets specifica-
tion. Depress the brake pedal and check that the
kick-back is normal, and tightness is normal.
17) Disconnect the pressure gauge from the RL
and RR caliper bodies.
18) Install the air bleeder screws of RL and RR cal-
iper bodies.
(1) Identification mark
ABS00384
(1)
ABS00134
Initial value
3,500 kPa
(36 kgf/cm
2
, 511 psi)
3,500 kPa
(36 kgf/cm
2
, 511 psi)
When
depressurized
500 kPa
(5 kgf/cm
2
, 73 psi)
or less
500 kPa
(5 kgf/cm
2
, 73 psi)
or less
When
pressurized
3,500 kPa
(36 kgf/cm
2
, 511 psi)
or more
3,500 kPa
(36 kgf/cm
2
, 511 psi)
or more
ABS-8
ABS
OPERATION WITH THE BRAKE TESTER
1) Install the spare fuse to the FWD connector lo-
cated in the main fuse box for models without AT
VTD.
2) Since the MT model and AT VTD model cannot
cut off the AWD circuit, set the wheels other than
the measured one on free rollers.
3) Prepare for ABS sequence control.
4) Set the front wheels or rear wheels on the brake
tester and set the gear to neutral.
5) Operate the brake tester.
7) When the hydraulic unit begins to work, check
the following work sequence.
(1) The FL wheel performs decompression,
hold and compression in sequence, and subse-
quently the FR wheel repeats the cycle.
(2) The RR wheel performs decompression,
hold and compression in sequence, and subse-
quently the RL wheel repeats the cycle.
8) Read values indicated on the brake tester and
check if the fluctuation of the values between de-
compression and compression meets specifica-
tion.
9) After the inspection, depress the brake pedal
and check that it is not abnormally hard, and tight-
ness is normal.
D: REPLACEMENT
CAUTION:
Because the seal of the ABSCM cannot be re-
placed, 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 re-
placement. If a problem is found such as not
being able to torque the screw to specifications
even before 5 replacement operations are per-
formed, 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 bracket. <Ref. to
ABS-6, REMOVAL, ABS Control Module and Hy-
draulic Control Unit (ABSCM&H/U).>
2) To prevent entry of foreign objects and brake flu-
id leakage, plug the oil pressure port of the AB-
SCM&H/U using a screw plug, etc.
(1) Main fuse box
(2) FWD connector
(1) Brake tester
ABS00392
(1)
(2)
ABS00136
(1)
ABS00137
(1)
Initial value
1,000 N
(102 kgf, 225 lb)
1,000 N
(102 kgf, 225 lb)
When depressurized
500 N
(51 kgf, 112 lb)
or less
500 N
(51 kgf, 112 lb)
or less
When pressurized
1,000 N
(102 kgf, 225 lb)
or more
1,000 N
(102 kgf, 225 lb)
or more
ABS-9
ABS
3) Set the pump motor section of the removed AB-
SCM&H/U face down on a vise.
NOTE:
4) Using TORX
bit E5, remove the four screws of

ABSCM.
NOTE:
These screws cannot be reused.
5) Slowly pull out the ABSCM upward from the H/U.
NOTE:
To prevent damaging of coil section, remove the
ABSCM straight up from H/U without twisting.
6) Make sure there is no dirt or damage on the seal-
ing surface of the H/U.
CAUTION:
Do not clean the ABSCM and 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)
10) Check that there is no foreign matter in mating
surface between the ABSCM and H/U.
11) Using a TORX
bit E5, tighten the screws in the

order of (1) through (4) again.
Tightening torque:
3 Nm (0.3 kgf-m, 2.2 ft-lb)
12) Check that there is no gap in the mating sur-
face between ABSCM and H/U.
13) Install the ABSCM&H/U to the vehicle.
(1) Aluminum plate, etc.
(2) Vise
ABS00430
(1)
(2)
ABS00431
ABS00432
(4) (2)
(1) (3)
ABS-10
ABS Sequence Control
ABS
3. ABS Sequence Control
A: OPERATION
1) While the ABS sequence control is being per-
formed, 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 the
1. ABS SEQUENCE CONTROL
WITH SUBARU SELECT MONITOR
NOTE:
In the event of any trouble, the ABS sequence con-
trol will not operate.
1) Connect the Subaru Select Monitor to 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 select-
ed, the ABS sequence control will start.
6) Execute the following operations when the mes-
sage Press the brake pedal so that the brake ped-
al force is between 100 and 150 kgf is displayed.
(1) [When the brake tester is used, press brake
pedal pad with a force of 1,000 N (102 kgf, 225
lb). ]
(2) When using a pressure gauge, press the
brake pedal so that the pressure gauge indi-
cates 3,500 kPa (36 kg/cm
2
, 511 psi).
7) OKwill 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
ABS00943
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(24)
(25)
(28)
(27)
(26)
V max < 4 km/h (2.5 MPH)
OFF
(16) (17)
OFF
ON
OFF ON
OFF ON
(21)
(18)
OFF
ON
OFF ON
OFF ON
OFF ON
OFF ON
OFF ON
OFF ON
OFF ON
ON
(15) (19) (18) (19)
V max < 10 km/h (6 MPH)
(16)
(17) (17)
(16) (16)
(21)
(18)
(22) (23)
(20)
ABS-12
ABS
NOTE:
The control 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 re-
turned 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 ABS
sequence control and the stop light switch is be-
comes OFF.
3) After completion of ABS sequence control.
4) When a malfunction is detected.
(1) All wheel speed (11) RR compression valve (20) 0.6 sec.
(2) Ignition key (12) RL decompression valve (21) 0.4 sec.
(3) ABS warning light (13) RL compression valve (22) Point A
(4) Stop light switch (14) Pump motor (23) Reset
(5) Valve relay (15) 1.5 sec. (24) Master cylinder pressure
(6) FL decompression valve (16) Light OFF (25) FL wheel cylinder pressure
(7) FL compression valve (17) Light ON (26) FR wheel cylinder pressure
(8) FR decompression valve (18) 1.0 sec. (27) RR wheel cylinder pressure
(9) FR compression valve (19) 1.4 sec. (28) RL wheel cylinder pressure
(10) RR decompression valve
ABS-13
Front ABS Wheel Speed Sensor
ABS
4. Front ABS Wheel Speed
Sensor
A: REMOVAL
2) Disconnect the ABS wheel speed sensor con-
nector located next to the front strut mounting
house in the engine compartment.
3) Remove the sensor harness bracket.
4) Remove the bolts which secure the sensor har-
ness to the front strut.
5) Remove the front ABS wheel speed sensor from
housing.
CAUTION:
Be careful not to damage the sensor.
Do not apply excessive force to the sensor
harness.
B: INSTALLATION
Tightening torque:
Sensor:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
Bracket:
33 Nm (3.3 kgf-m, 24 ft-lb)
CAUTION:
NOTE:
Check the identification (mark) on the harness to
make sure there is no warpage. (RH: K1 (White),
LH: K2 (Yellow))
Check if the harness is not pulled and does not
come in contact with the suspension or body during
steering wheel effort.
C: INSPECTION
1. CHECK WITH SUBARU SELECT
MONITOR
link connector.
2) Select {Current Data Display & Save}. Check if
the speed indicated on the display changes in the
same manner as the speedometer reading during
acceleration/deceleration when the steering wheel
is in the straight-ahead position.
3) If the speed indicated on the display does not
change, check the ABS wheel speed sensor. <Ref.
to ABS-14, ABS WHEEL SPEED SENSOR, IN-
SPECTION, Front ABS Wheel Speed Sensor.>
(1) To the front ABS wheel speed sensor connector
(2) Sensor harness bracket
ABS00386
(1)
(2)
ABS00387
ABS-14
ABS
1) Check the tip of the ABS wheel speed sensor for
foreign particles or damage. If necessary, clean the
tip or replace the ABS wheel speed sensor.
2) Connect a 12 V power supply to No. 2 terminal of
sensor connector as shown in the figure, then at-
tach resistance to the No. 1 terminal. Rotate the
wheel at about 2.75 km/h (2 MPH), and measure
the voltage using an oscilloscope.
Standard value of output voltage:
0.7 1.4 V
NOTE:
Check the ABS wheel speed sensor cable for dis-
continuity. If necessary, replace with a new part.
(1) Oscilloscope
(2) ABS wheel speed sensor
ABS00388
(2)
(1)
100
1.4 V
0.7 V
12 V
2
1
1 2
ABS-15
Rear ABS Wheel Speed Sensor
ABS
5. Rear ABS Wheel Speed Sensor
A: REMOVAL
wheel speed sensor.
3) Remove the sensor harness bracket from the
rear arm.
4) Remove the rear ABS wheel speed sensor from
the rear arm.
CAUTION:
Do not apply excessive force to the sensor
harness.
B: INSTALLATION
CAUTION:
Tightening torque:
Sensor:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
Bracket:
33 Nm (3.3 kgf-m, 24 ft-lb)
NOTE:
Check the identification (mark) on the harness to
make sure there is no warpage. (RH: K5 (White),
LH: K6 (Yellow))
C: INSPECTION
<Ref. to ABS-14, ABS WHEEL SPEED SENSOR,
INSPECTION, Front ABS Wheel Speed Sensor.>
ABS00389
ABS00166
ABS00167
ABS00168
ABS00390
ABS-16
Front Magnetic Encoder
ABS
6. Front Magnetic Encoder
A: REMOVAL
Refer to Front Hub Bearing for removal, because
the front magnetic encoder is integrated with front
hub bearing.
<Ref. to DS-17, REMOVAL, Front Hub Unit Bearing.>
B: INSTALLATION
Refer to Front Hub Bearing for installation, be-
cause the front magnetic encoder is integrated with
front hub bearing.
<Ref. to DS-18, INSTALLATION, Front Hub Unit
Bearing.>
C: INSPECTION
Visually check the magnetic encoder for any damage.
If necessary, replace with a new hub unit bearing.
NOTE:
Because the magnetic encoder is integrated with
front hub unit bearing assembly, replace the hub
unit bearing with a new part if there is any defect
found on the magnetic encoder.
ABS-17
Rear Magnetic Encoder
ABS
7. Rear Magnetic Encoder
A: REMOVAL
Refer to Rear Hub Unit Bearing for removal, be-
cause the rear magnetic encoder is integrated with
rear hub unit bearing.
<Ref. to DS-19, REMOVAL, Rear Hub Unit Bearing.>
B: INSTALLATION
Refer to Rear Hub Unit Bearing for installation,
because the rear magnetic encoder is integrated
with rear hub unit bearing.
<Ref. to DS-20, INSTALLATION, Rear Hub Unit
Bearing.>
C: INSPECTION
Visually check the magnetic encoder parts for any
damage. If necessary, replace with a new hub unit
bearing.
NOTE:
Because the magnetic encoder is integrated with
rear hub unit bearing assembly, replace the hub
unit bearing with a new part if there is any defect
found on the magnetic encoder.
ABS-18
G Sensor
ABS
8. G Sensor
A: REMOVAL
<Ref. to EI-54, REMOVAL, Console Box.>
3) Disconnect the connector from 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.
B: INSTALLATION
CAUTION:
Do not drop or bump the G sensor.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
ABS00463
Step Check Yes No
1 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 value.
Is the value 1.2 1.2 m/s
2
when the vehicle is in horizontal
position?
connector between
the G sensor and
ABSCM&H/U. Or
replace G sensor.
2 CHECK G SENSOR.
2) Remove the G sensor from vehicle. (Do not
disconnect the connector.)
3) Read the Subaru Select Monitor display.
2
when G sensor is inclined for-
ward to 90?
connector between
the G sensor and
ABSCM&H/U. Or
replace G sensor.
3 CHECK G SENSOR.
Read the Subaru Select Monitor display.
2
when G sensor is inclined back-
ward 90?
G sensor is normal. Repair the harness
connector between
the G sensor and
ABSCM&H/U. Or
replace G sensor.
ABS(diag)-2
ABS (DIAGNOSTICS)
A: PROCEDURE
CAUTION:
Remove foreign matter (dust, water, oil etc.) from the ABSCM&H/U connector during removal and in-
stallation.
NOTE:
To check harness for open 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.>
Step Check Yes No
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.>
Are components which might
affect the ABS problem operat-
ing correctly?
each component.
2 CHECK INDICATION OF DTC ON SCREEN.
3) Turn the ignition switch to ON and start up
NOTE:
lect Monitor cannot be executed normally, check
the communication circuit. <Ref. to ABS(diag)-
17, COMMUNICATION FOR INITIALIZING IM-
POSSIBLE, INSPECTION, Subaru Select Moni-
tor.>
4) Read the DTC. <Ref. to ABS(diag)-22,
(DTC).>
5) Record all DTCs and freeze frame data.
Is DTC displayed? Go to step 4. Go to step 3.
1) Perform the inspection using General Diag-
nostic Table. <Ref. to ABS(diag)-67, General
Diagnostic Table.>
ABS(diag)-16, CLEAR MEMORY MODE,
ABS(diag)-23, Inspection Mode.>
READ DIAGNOSTIC TROUBLE CODE (DTC),
Check the DTC is not displayed.
Does the ABS warning light go
off after turning the ignition
switch to ON?
Finish the diagno-
sis.
Check using ABS
Diagnostic Proce-
dure. <Ref. to
ABS(diag)-20,
WITHOUT DTC,
INSPECTION,
Subaru Select
Monitor.>
ABS(diag)-3
ABS (DIAGNOSTICS)
(DTC). <Ref. to ABS(diag)-33, LIST, List of
ABS(diag)-23, Inspection Mode.>
READ DIAGNOSTIC TROUBLE CODE (DTC),
Is DTC displayed? Repeat step 1 to 4
until DTC does not
appear.
Finish the diagno-
sis.
Step Check Yes No
ABS(diag)-4
ABS (DIAGNOSTICS)
A: CHECK
Check the following items regarding condition of the vehicle.
1. STATE OF ABS WARNING LIGHT
ABS warning light
illuminates.
Always
Sometimes
Only once
Does not come on
When and for how long does it illuminate?
Ignition key position LOCK
ACC
ON (before starting engine)
START
ON (after starting engine, engine is running)
ON (after starting engine, engine is at a standstill)
Timing Immediately after turning the ignition ON.
Immediately after turning the ignition to START.
While accelerating km/h
MPH
While driving at a constant speed km/h MPH
While decelerating km/h
MPH
When turning to the right Steering angle: deg
Steering time: Sec.
When turning to the left Steering angle: deg
Steering time: Sec.
When other electrical parts are operating
Parts name:
Operating condition:
ABS(diag)-5
ABS (DIAGNOSTICS)
2. STATE OF BRAKE WARNING LIGHT
Brake warning light
illuminates.
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 illuminate?
ACC
START
Timing Immediately after turning the ignition ON.
Immediately after turning the ignition to START.
MPH
MPH
Steering time: Sec.
Steering time: Sec.
Parts name:
ABS(diag)-6
ABS (DIAGNOSTICS)
3. SYMPTOMS
ABS operating condi-
tion
Does not operate.
Operates only when applying the brakes suddenly. Vehicle speed: km/h
MPH
Procedures for stepping on the brake pedal:
a) Operating time: Sec.
b) Operating noise: Occurs. / Does not occur.
What kind of noise? Knocking
Gong gong
Thump
Buzz
Gong gong buzz
Others:
c) Reaction force of brake pedal
Sticks
Weak pedal resistance
Strong pedal resistance
Others:
Condition of vehicle a) Directional stability cannot be obtained or the steering does not respond when applying brakes:
Yes / No
When: When turning to the right
When turning to the left
When spinning out
Others:
b) Directional stability cannot be obtained or the steering does not respond when accelerating:
Yes / No
When: When turning to the right
When turning to the left
When spinning out
Others:
c) Poor brake performance: Yes / No
What kind: Braking distance is long.
Brakes lock or drag.
Pedal stroke is long.
Pedal sticks.
Others:
d) Poor acceleration: Yes / No
What kind: Fails to accelerate.
Engine stalls.
Others:
e) Occurrence of vibration: Yes / No
Where
What kind:
Where
What kind:
g) Other troubles occurred: Yes/ No
What kind:
ABS(diag)-7
ABS (DIAGNOSTICS)
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
Others:
d) Road surface Dry
Wet
Covered with fresh snow
Covered with hardened snow
Frozen slope
Others:
Condition a) Brakes Deceleration: G
Intermittent / Temporary
b) Accelerator Acceleration: G
Intermittent / Temporary
c) Vehicle speed km/h MPH
Advancing
While accelerating
While decelerating
At low speed
When turning
Others:
d) Tire inflation pressure Front RH tire: kPa
Front LH tire: kPa
Rear RH tire: kPa
Rear LH tire: kPa
e) Degree of wear Front RH tire:
Front LH tire:
Rear RH tire:
Rear LH tire:
f) Genuine parts are used: 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: Yes / No
Contents:
l) Others:
ABS(diag)-8
General Description
ABS (DIAGNOSTICS)
A: CAUTION
AIRBAG
ABS wheel speed sensor and ABSCM&H/U.
CAUTION:
All airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
wiring harness when servicing the ABS wheel
speed sensor and ABSCM&H/U.
B: INSPECTION
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 tightening torque of ground (GB-7) bolt
of ABS.
Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)
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-8,
CHECKING THE HYDRAULIC UNIT ABS OPERA-
TION WITH THE BRAKE TESTER, INSPECTION,
ABS Control Module and Hydraulic Control Unit
(ABSCM&H/U).>
When not using the brake tester <Ref. to ABS-7,
CHECKING THE HYDRAULIC UNIT ABS OPERA-
TION 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-15, INSPECTION, Front Brake
Pad.> <Ref. to BR-16, INSPECTION, Front Disc
Rotor.>
Rear <Ref. to BR-22, INSPECTION, Rear Brake
Pad.> <Ref. to BR-24, INSPECTION, Rear Disc
Rotor.>
7. TIRE
Check the tire specifications, tire wear and air pres-
sure. <Ref. to WT-2, SPECIFICATION, General
Description.>
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
MONITOR III KIT
TOOL NAME REMARKS
ST1B021XU0
ABS(diag)-9
ABS (DIAGNOSTICS)
A: LOCATION
(4) ABS warning light (9) G sensor
(5) Brake and EBD warning light (10) Transmission control module
(TCM) (AT model)
(2) Two-way connector (6) Caliper body
(For Subaru Select Monitor)
(7) Magnetic encoder seal (11) Stop light switch
(8) ABS wheel speed sensor (12) Master cylinder
ABS00591
(1)
(12)
(2)
(10)
(4)
(5)
(11)
(8) (7) (6)
(9)
(3)
(8)
(7)
(6)
ABS(diag)-10
ABS (DIAGNOSTICS)
ABS00405
(1)
ABS00598
(5)
(4)
ABS00600
(3)
ABS00408
(8)
(7)
(7)
FRONT
(8)
(7)
(7)
ABS00407
REAR
(9)
ABS00599
ABS(diag)-11
ABS (DIAGNOSTICS)
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.
control unit (ABSCM&H/U) con-
nector

ABS00409
B301
7 8 9 10 11 6 5 4 1
15 14 13 12
2 3
22 23 24 25 26 21 20 19 16 17 18
(1)
ABS(diag)-12
ABS (DIAGNOSTICS)
*1: Measure the I/O signal voltage after removing the connector from the ABSCM&H/U terminal.
Description
Terminal No.
(+) ()
Input/Output signal
(Wheel speed sensor)
Front LH wheel
Power supply 16 15 4.5 16.5 V
Signal 1 5.9 16.8 mA: Rectangle waveform
Front RH wheel
Rear LH wheel
Rear RH wheel
CAN communication line (+) 26 2.5 1.5 V pulse signal
CAN communication line () 11 3.5 2.5 V pulse signal
Valve relay power supply *1 14 15 10 15 V
Motor relay power supply *1 13 15 10 15 V
G sensor
Ground 10
Output 21 10 2.1 2.5 V when the vehicle is on level surface
Stop light switch *1 20 15
1.5 V or less when the stop light is OFF;
otherwise, 10 15 V when the stop light is ON.
ABS warning light 22 15
After turning the ignition switch to ON,
10 15 V during 1.5 seconds and 1.5 V
or less after 1.5 seconds passed.
Brake warning light (EBD warning light) 8 15
After turning the ignition switch to ON,
10 15 V during 1.5 seconds and 1.5 V
or less after 1.5 seconds passed.
Subaru Select Monitor 7 15
1.5 V or less when no data is received.
0 12 V pulse (in communication)
Power supply *1 18 15 10 15 V when the ignition switch is ON.
Grounding line 15
Vehicle speed output signal 23 15 0 5 V pulse
ABS(diag)-13
ABS (DIAGNOSTICS)
B: WIRING DIAGRAM
(1) Battery (11) Front outlet solenoid valve RH (21) Brake warning light
(2) Ignition switch (12) Rear inlet solenoid valve LH (22) Parking brake switch
(13) Rear outlet solenoid valve LH (23) Brake fluid level switch
(14) Rear inlet solenoid valve RH (24) Stop light switch
(4) ABS control module (15) Rear outlet solenoid valve RH (25) Stop light
(5) Valve relay (16) Body integrated unit (26) G sensor
(6) Motor relay (17) Engine control module (ECM) (27) Front ABS wheel speed sensor LH
(7) Motor (18) Transmission control module
(TCM)
(28) Front ABS wheel speed sensor RH
(8) Front inlet solenoid valve LH (29) Rear ABS wheel speed sensor LH
(9) Front outlet solenoid valve LH (19) Data link connector (30) Rear ABS wheel speed sensor RH
(10) Front inlet solenoid valve RH (20) ABS warning light
ABS00592
(3)
(7)
(8)
M
(9)
(10)
(19)
(20)
(2)
(4)
(5)
(6)
(1)
(21)
(22)
(24)
(25)
(26)
(27)
(11)
(12)
(13)
(14)
(15)
(28)
(29)
(30)
(23)
(16)
(17)
(18)
ABS(diag)-14
ABS (DIAGNOSTICS)
A: OPERATION
(DTC)
ABS(diag)-8, SPECIAL TOOL, PREPARATION
2) Prepare the personal computer in which the
Subaru Select Monitor has been installed.
3) Connect the USB cable to the SDI (Subaru Diag-
nostic Interface) and the USB port of the personal
computer (port for Subaru Select Monitor).
NOTE:
The port for Subaru Select Monitor is the USB port
used for installing the Subaru Select Monitor.
the lower portion of the instrument panel
(on the drivers side).
CAUTION:
ru Select Monitor.
start up the PC application help for Subaru Select
Monitor.
8) Select {Each System Check} in Main Menu.
screen, select the {Brake Control}.
10) Click on the [OK] after the {ABS} is displayed.
11) On the Brake Control Diagnosis display
screen, select the {Diagnostic Trouble Code}.
12) Record the DTC and data.
NOTE:
agnostic Trouble Code (DTC). <Ref. to ABS(diag)-
Up to 3 DTCs are displayed in the order of detec-
tion.
If a particular DTC is not stored in memory prop-
erly 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 Se-
lect Monitor display screen. This shows it may be
an unreliable reading.
13) If communication is not possible between the
ABS and the Subaru Select Monitor, check the
communication circuit. <Ref. to ABS(diag)-17,
COMMUNICATION FOR INITIALIZING IMPOSSI-
BLE, INSPECTION, Subaru Select Monitor.>
14) When DTC is not displayed, check the meter
circuit and CAN communication circuit. <Ref. to
ABS(diag)-20, WITHOUT DTC, INSPECTION,
EN-05692
ABS00465
(1)
Display Contents to be monitored
Current
The current DTC is displayed on Subaru
Select Monitor display screen.
Old
The latest DTC in previous troubles is
displayed on Subaru Select Monitor dis-
play screen.
Older
The second latest DTC in previous trou-
bles is displayed on Subaru Select Moni-
tor display screen.
Third previous
The third latest DTC in previous prob-
lems is displayed on Subaru Select Mon-
itor display screen.
ABS(diag)-15
ABS (DIAGNOSTICS)
2) On the System Selection Menu display screen, select the {Brake Control}.
4) Select {Current Data Display & Save} in Brake Control Diagnosis display screen.
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.
NOTE:
FR Wheel Speed Wheel speed detected by front ABS wheel speed sensor RH is displayed. km/h or MPH
FL Wheel Speed Wheel speed detected by front ABS wheel speed sensor LH is displayed. km/h or MPH
RR Wheel Speed Wheel speed detected by rear ABS wheel speed sensor RH is displayed. km/h or MPH
RL Wheel Speed Wheel speed detected by rear ABS wheel speed sensor LH is displayed. km/h or MPH
BLS Signal Brake ON/OFF is displayed. ON or OFF
G Sensor Vehicle acceleration detected by analog G sensor is displayed. m/s (m/s
2
)
Valve Relay Signal Valve relay operation signal is displayed. ON or OFF
ABS Warning Light ON operation of the ABS warning light is displayed. ON or OFF
EBD Warning Light ON operation of the EBD warning light is displayed. ON or OFF
Motor Relay Monitor Motor relay monitor voltage is displayed. V
IG Power Supply Voltage Voltage supplied to ABSCM&H/U is displayed. V
ABS Control Flag ABS control condition is displayed. ON or OFF
ABS OK B Signal ABS system normal/abnormal is displayed. OK or NG
ABS(diag)-16
ABS (DIAGNOSTICS)
screen, select the {Brake Control}.
4) On the Brake Control Diagnosis display
screen, select the {Clear Memory}.
screen, press YES button.
switch to OFF.
NOTE:
5. FREEZE FRAME DATA
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 pow-
er 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 Contents to be monitored Index No.
ABS
sequence
control
Operate the valve and
pump motor continuously
to perform the ABS
sequence control.
<Ref. to ABS-10,
ABS Sequence
Control.>
FR Wheel Speed
Wheel speed detected by front ABS
wheel speed sensor RH is displayed in
km/h or MPH.
FL Wheel Speed
wheel speed sensor LH is displayed in
km/h or MPH.
RR Wheel Speed
Wheel speed detected by rear ABS
wheel speed sensor RH is displayed in
km/h or MPH.
RL Wheel Speed
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
Motor relay condition is displayed.
BLS Signal Brake ON/OFF is displayed.
Vehicle Speed
Vehicle speed calculated by ABS control
module is displayed.
ABS Control Flag ABS control condition is displayed.
Power Supply
Failure
Whether abnormal voltage occurred or
not is displayed during malfunction.
ABS(diag)-17
ABS (DIAGNOSTICS)
B: INSPECTION
TROUBLE SYMPTOM:
Communication is impossible between ABS and Subaru Select Monitor.
WIRING DIAGRAM:
ABS00905
B301 B40
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
3
3B40
B301
E
E
16
7
7
1
5
1
8
ABSCM & H/U
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
N
o
.
1
3
IGNITION
SWITCH
BATTERY
DATA LINK
CONNECTOR
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
ABS(diag)-18
ABS (DIAGNOSTICS)
Step Check Yes No
switch to ON, and
select ABS mode
using Subaru
Select Monitor.
2 CHECK BATTERY.
2) Measure the battery voltage.
the battery.
3 CHECK BATTERY TERMINAL. Is there poor contact at the bat-
tery terminal?
Repair or tighten
the battery termi-
nal.
Go to step 4.
COMMUNICATION.
Are the system name and
model year displayed on Sub-
aru Select Monitor?
COMMUNICATION.
2) Disconnect the ABSCM&H/U connectors.
4) Check whether communication to other sys-
tems can be executed normally.
aru Select Monitor?
Replace the
ABSCM&H/U.
<Ref. to ABS-6,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 6.
CONNECTOR.
2) Disconnect the ABSCM&H/U, ECM and
TCM.
more?
and connector
between each con-
trol module and
data link connec-
tor.
7 CHECK OUTPUT VOLTAGE OF ABSCM&H/U.
2) Measure the voltage between data link con-
and connector
between each con-
trol module and
data link connec-
tor.
ABSCM&H/U AND DATA LINK CONNECTOR.
Measure the resistance between ABSCM&H/U
connector and data link connector.
(B301) No. 7 (B40) No. 7:
Is the resistance less than 0.5
?
Go to step 9. Repair harness
and connector
between
ABSCM&H/U and
data link connec-
tor.
9 CHECK INSTALLATION OF ABSCM&H/U
CONNECTOR.
Is the ABSCM&H/U connector
inserted into ABSCM&H/U until
the clamp locks onto it?
Go to step 10. Insert ABSCM&H/
U connector into
ABSCM&H/U.
10 CHECK THE POWER SUPPLY CIRCUIT.
between ABSCM&H/U connector and chassis
ground.
of harness
between
ABSCM&H/U and
battery.
ABS(diag)-19
ABS (DIAGNOSTICS)
ABSCM&H/U AND CHASSIS GROUND.
between ABSCM&H/U connector and chassis
ground.
Is the resistance less than 0.5 ? Go to step 12. Repair the open
circuit of the har-
ness between
ABSCM&H/U and
connector, and
poor contact.
12 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in the con-
trol module power supply,
ground circuit and data link con-
nector?
Repair the connec-
tor.
Replace the
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Step Check Yes No
ABS(diag)-20
ABS (DIAGNOSTICS)
2. WITHOUT DTC
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:
MAIN SBF
S
B
F
-
6
No.5
N
o
.
3
3
A: i10
B: i11
E
E
B301
1
8
1
5
2
2
ABSCM & H/U
A
7
8
i3
B38
A
3
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
i10
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
A:
B301 B38
BATTERY
COMBINATION
METER
IGNITION
SWITCH
A
B
S

W
A
R
N
I
N
G

L
I
G
H
T
B
R
A
K
E

W
A
R
N
I
N
G
L
I
G
H
T
1
*
2
0
9
1
*
: NORMAL METER : A5
i11 B:
2 1 3 4 5 6
14 13 12 11 10 9 8 7
ABS00924
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
: B5 : METER WITH MID
ABS(diag)-21
ABS (DIAGNOSTICS)
Step Check Yes No
1 CHECK SUBARU SELECT MONITOR DATA.
1) Select {Current Data Display & Save} in the
2) Read the condition of ABS warning light.
Is ON indicated? Replace the
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 2.
Measure the resistance between ABSCM con-
nector and combination meter connector.
Normal meter model
(i10) No. 5 (B301) No. 22:
Meter model with MID
(i11) No. 5 (B301) No. 22:
Is the resistance less than 0.5 ? Go to step 3. Repair harness
and connector
between
ABSCM&H/U and
combination meter.
3 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in ABSCM
connector and combination
meter connector?
Repair the connec-
tor.
Check the combi-
nation meter.
ABS(diag)-22
ABS (DIAGNOSTICS)
Code (DTC)
A: OPERATION
For details about reading of DTCs, refer to Subaru
Select Monitor. <Ref. to ABS(diag)-14, Subaru Se-
lect Monitor.>
ABS(diag)-23
Inspection Mode
ABS (DIAGNOSTICS)
8. Inspection Mode
A: PROCEDURE
as much as possible.
Drive the vehicle at a speed of 40 km/h (25 MPH) or
more for at least one minute.
ABS(diag)-24
Clear Memory Mode
ABS (DIAGNOSTICS)
A: OPERATION
Subaru Select Monitor. <Ref. to ABS(diag)-14,
ABS(diag)-25
ABS Warning Light / Brake Warning Light Illumination Pattern
ABS (DIAGNOSTICS)
10.ABS Warning Light / Brake Warning Light Illumination Pattern
A: INSPECTION
(1) Ignition switch (5) ABS warning light (9) Brake warning light
(EBD warning light)
(2) OFF (6) Light OFF
(3) ON (7) Light ON (10) Parking brake
(4) Engine start (8) 1.5 sec. (11) Released
ABS00442
(2)
(1)
(3)
(3)
(4)
(6)
(5)
(6)
(7)
(8)
(9)
(10)
(6) (6)
(11)
(7)
ABS(diag)-26
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)-27, ABS WARNING LIGHT DOES NOT COME ON, ABS Warning Light / Brake Warning Light Il-
lumination Pattern.>
3) When ABS warning light does not go off, check the combination meter circuit. <Ref. to ABS(diag)-29, 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)-31, 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 1.5 seconds from ABS warning light
illumination, the ABS function operates normally when the warning light goes off while driving at approxi-
mately 12 km/h (7 MPH). However, the ABS system does not work while the ABS warning light is illuminated.
ABS(diag)-27
ABS (DIAGNOSTICS)
B: ABS WARNING LIGHT DOES NOT COME ON
Defective harness
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), ABS warning light does not come on.
WIRING DIAGRAM:
MAIN SBF
S
B
F
-
6
No.5
N
o
.
3
3
A: i10
B: i11
E
E
B301
1
8
1
5
2
2
ABSCM & H/U
A
7
8
i3
B38
A
3
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
i10
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
A:
B301 B38
BATTERY
COMBINATION
METER
IGNITION
SWITCH
A
B
S

W
A
R
N
I
N
G

L
I
G
H
T
B
R
A
K
E

W
A
R
N
I
N
G
L
I
G
H
T
1
*
2
0
9
1
*
: NORMAL METER : A5
i11 B:
2 1 3 4 5 6
14 13 12 11 10 9 8 7
ABS00924
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
ABS(diag)-28
ABS (DIAGNOSTICS)
Step Check Yes No
1 CHECK ILLUMINATION OF OTHER LIGHTS.
Turn the ignition switch to ON. (engine OFF)
Do other warning lights illumi-
nate?
Go to step 2. Check the combi-
nation meter.
2 READ DTC.
Read the DTC. <Ref. to ABS(diag)-22, Read
nosis according to
DTC.
Go to step 3.
1) Turn the ignition OFF.
2) Disconnect the connector (B301) from the
ABSCM&H/U.
3) Disconnect the connector (i10) from combi-
nation meter.
4) Measure the resistance between ABSCM
more?
Go to step 4. Repair harness
and connector
between
ABSCM&H/U and
combination meter.
4 CHECK ABSCM.
1) Connect the connector (B301) to the
ABSCM&H/U.
2) Turn the ignition to ON.
3) Measure the resistance between the combi-
nation meter connector and chassis ground
soon after the ignition switch is turned to ON
(within 1.5 seconds).
Normal meter model
more?
Check the combi-
nation meter.
Replace the
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS(diag)-29
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:
MAIN SBF
S
B
F
-
6
No.5
N
o
.
3
3
A: i10
B: i11
E
E
B301
1
8
1
5
2
2
ABSCM & H/U
A
7
8
i3
B38
A
3
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
i10
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
A:
B301 B38
BATTERY
COMBINATION
METER
IGNITION
SWITCH
A
B
S

W
A
R
N
I
N
G

L
I
G
H
T
B
R
A
K
E

W
A
R
N
I
N
G
L
I
G
H
T
1
*
2
0
9
1
*
: NORMAL METER : A5
i11 B:
2 1 3 4 5 6
14 13 12 11 10 9 8 7
ABS00924
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
ABS(diag)-30
ABS (DIAGNOSTICS)
Step Check Yes No
1 READ DTC.
nosis according to
DTC.
Go to step 2.
1) Turn the ignition OFF.
ABSCM&H/U.
nation meter.
4) Measure the resistance between ABSCM
connector and combination meter connector.
Normal meter model
(B301) No. 22 (i10) No. 5:
(B301) No. 22 (i11) No. 5:
and connector
between
ABSCM&H/U and
combination meter.
Check for poor contact in all connectors.
Is there poor contact? Repair the connec-
tor.
Go to step 4.
4 CHECK ABSCM.
1) Connect the connector (B301) to the
ABSCM&H/U.
3) Measure the resistance between combina-
tion meter connector and chassis ground.
Normal meter model
nation meter.
Replace the
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS(diag)-31
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.
WIRING DIAGRAM:
B301 B16
1
2
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
i10
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
A:
B:
E
MAIN SBF
S
B
F
-
6
E
No.5
8
B301
B36
B16
i1
B38
i3
B404
i10 A:
i11 B:
ABSCM & H/U
A
3
A
7
2
0
1
6
1
5
1
2
1
*
2
*
: NORMAL METER : B10 2
*
B38
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
i1
5 6 7 8
2 1
9
4 3
10
24
22
23 25 27 26 28
11 12 13 14 15 16
17 18 19 20 21
ABS00994
: NORMAL METER : A8 1
*
1 2 3 4 5 6
7 8 9 10 11 12 13 14
i11
BATTERY
IGNITION
SWITCH
COMBINATION
METER
P
A
R
K
I
N
G

B
R
A
K
E

F
L
U
I
D

L
E
V
E
L

W
A
R
N
I
N
G

L
I
G
H
T
BRAKE FLUID
LEVEL SWITCH
PARKING
SWITCH
METER WITH MID : A4
METER WITH MID : A8
ABS(diag)-32
ABS (DIAGNOSTICS)
Step Check Yes No
1 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.
Is the connector firmly
inserted?
Go to step 2. Insert the
ABSCM&H/U con-
nector until the
clamp locks com-
pletely.
2 READ DTC.
nosis according to
DTC.
Go to step 3.
3 CHECK BRAKE FLUID AMOUNT.
Check the amount of brake fluid in the reservoir
tank of the master cylinder.
Is the amount of brake fluid
between the lines of MAX and
MIN?
Go to step 4. Replenish brake
fluid to the speci-
fied value.
4 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:
Is the resistance 1 M or more? Go to step 5. Replace the mas-
ter cylinder.
5 CHECK PARKING BRAKE SWITCH.
1) Disconnect the connector (B404) from park-
ing brake switch.
3) Measure the resistance between parking
brake switch terminal and chassis ground.
Is the resistance 1 M or more? Go to step 6. Replace the park-
ing brake switch.
1) Disconnect the connector (i10) and (i11)
from the combination meter.
Normal meter model
Is the resistance 1 M or more? Go to step 7. Repair the harness
connector between
combination meter
and parking brake
switch.
7 CHECK HARNESS.
ABSCM&H/U.
nation meter.
3) Measure the resistance between the
ABSCM&H/U connector and combination
meter connector.
(B301) No. 8 (i10) No. 7:
between the
ABSCM&H/U and
the combination
meter.
tor.
Go to step 9.
9 CHECK ABSCM.
1) Connect the connector to the ABSCM&H/U.
nation meter.
Replace the
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS(diag)-33
ABS (DIAGNOSTICS)
A: LIST
DTC Content of diagnosis Display Reference target
C0101
ABS wheel speed
sensor malfunction
(Broken wire, short)
Rear ABS wheel
speed sensor RH
Rear Right ABS Sen-
sor Circuit Open or
Shorted Battery
<Ref. to ABS(diag)-36, DTC C0101 ABS
WHEEL SPEED SENSOR MALFUNCTION
RR SENSOR (BROKEN WIRE, INPUT
VOLTAGE TOO HIGH), Diagnostic Proce-
C0102
Rear ABS wheel
speed sensor LH
Rear Left ABS Sensor
Circuit Open or
Shorted Battery
RL SENSOR (BROKEN WIRE, INPUT
C0103
Front ABS wheel
speed sensor RH
Front Right ABS Sen-
sor Circuit Open or
Shorted Battery
FR SENSOR (BROKEN WIRE, INPUT
C0104
Front ABS wheel
speed sensor LH
Front Left ABS Sensor
Circuit Open or
Shorted Battery
FL SENSOR (BROKEN WIRE, INPUT
C0105
ABS wheel speed
sensor malfunction
(ABS wheel speed
sensor abnormal
signal)
Abnormal signal of
rear ABS wheel speed
sensor RH
Rear Right ABS Sen-
sor Signal
<Ref. to ABS(diag)-39, DTC C0105 REAR
ABS WHEEL SPEED SENSOR RH MAL-
FUNCTION (ABS WHEEL SPEED SEN-
SOR ABNORMAL SIGNAL), Diagnostic
Procedure with Diagnostic Trouble Code
(DTC).>
C0106
Abnormal signal of
rear ABS wheel speed
sensor LH
Signal
ABS WHEEL SPEED SENSOR LH MAL-
(DTC).>
C0107
Abnormal signal of
front ABS wheel speed
sensor RH
Front Right ABS Sen-
sor Signal
<Ref. to ABS(diag)-39, DTC C0107 FRONT
ABS WHEEL SPEED SENSOR RH MAL-
(DTC).>
C0108
Abnormal signal of
front ABS wheel speed
sensor LH
Signal
ABS WHEEL SPEED SENSOR LH MAL-
(DTC).>
C0109 Power voltage malfunction
Power Supply Voltage
Failure
<Ref. to ABS(diag)-52, DTC C0109 POWER
VOLTAGE MALFUNCTION, Diagnostic Pro-
cedure with Diagnostic Trouble Code
(DTC).>
C0110 ABS control module malfunction ECM
CONTROL MODULE MALFUNCTION,
Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
ABS(diag)-34
ABS (DIAGNOSTICS)
C0111 Motor/motor relay on failure Motor and Motor Relay
<Ref. to ABS(diag)-57, DTC C0111
MOTOR/MOTOR RELAY MALFUNCTION,
ble Code (DTC).>
C0114 Defective valve relay Valve Relay
<Ref. to ABS(diag)-55, DTC C0114 VALVE
RELAY MALFUNCTION, Diagnostic Proce-
C0115
ABS wheel speed sen-
sor malfunction (ABS
wheel speed sensor
abnormal signal)
Abnormal ABS wheel
speed sensor on any
one of four sensors
Any One of Four ABS
Sensors Signal
WHEEL SPEED SENSOR SIGNAL MAL-
FUNCTION IN ONE OF FOUR WHEELS,
ble Code (DTC).>
C0116 Stop light switch circuit malfunction Brake Light Switch
<Ref. to ABS(diag)-59, DTC C0116 FAULTY
STOP LIGHT SWITCH, Diagnostic Proce-
C0118 Fauity G sensor output voltage G Sensor Failure
<Ref. to ABS(diag)-61, DTC C0118 G SEN-
SOR OUTPUT VOLTAGE MALFUNCTION,
ble Code (DTC).>
C0119 Abnormal G sensor output signal G Sensor Signal
<Ref. to ABS(diag)-64, DTC C0119 G SEN-
SOR OUTPUT VOLTAGE MALFUNCTION,
ble Code (DTC).>
C0120
Inlet valve malfunction
in hydraulic unit
Front inlet valve LH
FL Hold Valve mal-
function
INLET SOLENOID VALVE LH MALFUNC-
TION IN ABS CONTROL MODULE AND
HYDRAULIC CONTROL UNIT (ABSCM&H/
U), Diagnostic Procedure with Diagnostic
C0121
Outlet valve malfunc-
tion in hydraulic unit
Front outlet valve LH
FL Pressure Reducing
Valve malfunction
OUTLET SOLENOID VALVE LH MALFUNC-
C0122
in hydraulic unit
Front inlet valve RH
FR Hold Valve mal-
function
INLET SOLENOID VALVE RH MALFUNC-
C0123
Front outlet valve RH
FR Pressure Reducing
Valve malfunction
OUTLET SOLENOID VALVE RH MAL-
FUNCTION IN ABS CONTROL MODULE
AND HYDRAULIC CONTROL UNIT
(ABSCM&H/U), Diagnostic Procedure with
C0124
in hydraulic unit
Rear inlet valve LH
RL Hold Valve mal-
function
INLET SOLENOID VALVE LH MALFUNC-
ABS(diag)-35
ABS (DIAGNOSTICS)
C0125
Rear outlet valve LH
RL Pressure Reduc-
ing Valve malfunction
OUTLET SOLENOID VALVE LH MALFUNC-
C0126
in hydraulic unit
Rear inlet valve RH
RR Hold Valve mal-
function
INLET SOLENOID VALVE RH MALFUNC-
C0127
Rear outlet valve RH
RR Pressure Reduc-
ing Valve malfunction
OUTLET SOLENOID VALVE RH MAL-
FUNCTION IN ABS CONTROL MODULE
AND HYDRAULIC CONTROL UNIT
(ABSCM&H/U), Diagnostic Procedure with
C0140 Defective CAN communication
Improper CAN com-
munication
<Ref. to ABS(diag)-54, DTC C0140 CAN
COMMUNICATION MALFUNCTION, Diag-
nostic Procedure with Diagnostic Trouble
Code (DTC).>
ABS(diag)-36
ABS (DIAGNOSTICS)
A: DTC C0101 ABS WHEEL SPEED SENSOR MALFUNCTION RR SENSOR
(BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
NOTE:
Refer to DTC C0104 for diagnostic procedure. <Ref. to ABS(diag)-37, DTC C0104 ABS WHEEL SPEED
SENSOR MALFUNCTION FL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH), Diagnostic Pro-
B: DTC C0102 ABS WHEEL SPEED SENSOR MALFUNCTION RL SENSOR
NOTE:
C: DTC C0103 ABS WHEEL SPEED SENSOR MALFUNCTION FR SENSOR
NOTE:
ABS(diag)-37
ABS (DIAGNOSTICS)
D: DTC C0104 ABS WHEEL SPEED SENSOR MALFUNCTION FL SENSOR
Defective ABS wheel speed sensor (broken wire, input voltage too high)
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:
4 3 1
1
6
1
7
2
1
5
B98
R72
R2
E
12
1
5
1
4
6 5
R73
12
B6 B15
R73
R72
1 2
1 2 2 1
6 5
B301
21
B15
B6
B301 B98
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
ABSCM & H/U
ABS00995
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
FRONT ABS
WHEEL SPEED
SENSOR LH
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
ABS(diag)-38
ABS (DIAGNOSTICS)
Step Check Yes No
Check if there is poor contact between
ABSCM&H/U and ABS wheel speed sensor.
tor.
Go to step 2.
ABSCM&H/U AND ABS WHEEL SPEED
SENSOR.
ABSCM&H/U.
2) Disconnect the connector from the ABS
wheel speed sensor.
3) Measure the resistance between
ABSCM&H/U connector and ABS wheel speed
sensor connector.
DTC C0101
(B301) No. 3 (R72) No. 1:
(B301) No. 4 (R72) No. 2:
DTC C0102
(B301) No. 2 (R73) No. 1:
(B301) No. 17 (R73) No. 2:
DTC C0103
(B301) No. 5 (B6) No. 2:
(B301) No. 6 (B6) No. 1:
DTC C0104
(B301) No. 16 (B15) No. 2:
(B301) No. 1 (B15) No. 1:
connector between
ABSCM&H/U and
ABS wheel speed
sensor.
Measure the resistance between the
ABSCM&H/U connector and chassis ground.
DTC C0101
DTC C0102
DTC C0103
DTC C0104
connector between
ABSCM&H/U and
ABS wheel speed
sensor.
4 CHECK ABS WHEEL SPEED SENSOR
1) Connect ABSCM&H/U connector.
3) Measure the voltage between ABS wheel
speed sensor connector and chassis ground.
DTC C0101
DTC C0102
DTC C0103
DTC C0104
ABS(diag)-39
ABS (DIAGNOSTICS)
E: DTC C0105 REAR ABS WHEEL SPEED SENSOR RH MALFUNCTION
(ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL)
NOTE:
Refer to DTC C0108 for diagnostic procedure. <Ref. to ABS(diag)-40, DTC C0108 FRONT ABS WHEEL
SPEED SENSOR LH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL), Diagnostic
F: DTC C0106 REAR ABS WHEEL SPEED SENSOR LH MALFUNCTION
NOTE:
G: DTC C0107 FRONT ABS WHEEL SPEED SENSOR RH MALFUNCTION
NOTE:
5 CHECK THE ABSCM&H/U POWER SUPPLY
CIRCUIT.
4) Measure the voltage between ABSCM&H/U
(B301) No. 18 (+) (B301) No. 15 ():
Is the voltage 10 15 V? Go to step 6. Check the genera-
tor, battery and
ABSCM&H/U
power supply cir-
cuit.
SIGNAL.
1) Install the ABS wheel speed sensor.
2) Prepare an oscilloscope.
3) Check the ABS wheel speed sensor. <Ref.
to ABS-14, ABS WHEEL SPEED SENSOR,
INSPECTION, Front ABS Wheel Speed Sen-
sor.>
Is the pattern the same wave-
form as shown in the figure?
Go to step 7. Replace the ABS
wheel speed sen-
sor.
7 CHECK ABSCM&H/U.
2) Erase the memory.
4) Read the DTC.
Is the same DTC displayed? Replace the
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 8.
8 CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Perform the diag-
nosis according to
DTC.
It results from a
temporary noise
interference.
Step Check Yes No
ABS(diag)-40
ABS (DIAGNOSTICS)
H: DTC C0108 FRONT ABS WHEEL SPEED SENSOR LH MALFUNCTION
Defective ABS wheel speed sensor signal (noise, abnormal signal, etc.)
TROUBLE SYMPTOM:
WIRING DIAGRAM:
4 3 1
1
6
1
7
2
1
5
B98
R72
R2
E
12
1
5
1
4
6 5
R73
12
B6 B15
R73
R72
1 2
1 2 2 1
6 5
B301
21
B15
B6
B301 B98
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
ABSCM & H/U
ABS00995
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
FRONT ABS
WHEEL SPEED
SENSOR LH
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
ABS(diag)-41
ABS (DIAGNOSTICS)
Step Check Yes No
1 CHECK OUTPUT OF ABS WHEEL SPEED
SENSOR USING SUBARU SELECT
MONITOR.
2) Read the defective ABS wheel speed sen-
sor output.
Does the speed indicated on
the display change in response
to the speedometer reading
during acceleration/decelera-
tion when the steering wheel is
in the straight-ahead position?
tors between ABSCM&H/U and
ABS wheel speed sensor?
Repair the connec-
tor.
Go to step 3.
3 CHECK CAUSE OF SIGNAL NOISE.
Make sure the radio wave devices and elec-
tronic components are installed correctly.
Are the radio wave devices and
electronic components
installed correctly?
Go to step 4. Install the radio
wave devices and
electric compo-
nents properly.
Check if the noise sources (such as an
antenna) are installed near the sensor harness.
Are noise sources installed? Install the noise
sources apart from
sensor harness.
Go to step 5.
5 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 6.
nosis according to
DTC.
It results from a
temporary noise
interference.
7 CHECK INSTALLATION OF ABS WHEEL
SPEED SENSOR.
Is the ABS wheel speed sensor
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?
Go to step 8. Tighten the ABS
wheel speed sen-
sor installation
bolts.
SIGNAL.
sor.>
Does the oscilloscope indicate
the waveform pattern like
shown in the figure when the
tire is slowly turned? Does the
oscilloscope indication repeat
tire is slowly turned in equal
speed for one rotation or more?
OR MAGNETIC ENCODER.
Are there foreign matter, break-
age or damage at the tip of ABS
wheel speed sensor or mag-
netic encoder?
Remove dirt thor-
oughly. Also
replace the ABS
wheel speed sen-
sor or magnetic
encoder as a unit
with hub unit bear-
ing if it is broken or
damaged.
Go to step 10.
wave devices and
electric compo-
nents properly.
Is the noise sources installed? Go to step 12. Install the noise
sources apart from
sensor harness.
ABS(diag)-42
ABS (DIAGNOSTICS)
12 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 13.
nosis according to
DTC.
It results from a
temporary noise
interference.
NOTE:
Though the ABS
warning light re-
mains on at this
time, it is normal.
Drive the vehicle at
12 km/h (7 MPH)
or more in order to
turn ABS warning
light off. Be sure to
drive the vehicle
and check that the
warning light goes
off.
Step Check Yes No
ABS(diag)-43
ABS (DIAGNOSTICS)
I: DTC C0115 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 illuminates as well as the ABS warning light.
WIRING DIAGRAM:
4 3 1
1
6
1
7
2
1
5
B98
R72
R2
E
12
1
5
1
4
6 5
R73
12
B6 B15
R73
R72
1 2
1 2 2 1
6 5
B301
21
B15
B6
B301 B98
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
ABSCM & H/U
ABS00995
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
FRONT ABS
WHEEL SPEED
SENSOR LH
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
ABS(diag)-44
ABS (DIAGNOSTICS)
Step Check Yes No
1 WHETHER A WHEEL TURNED FREELY
OR NOT.
Check if the wheels have been turned freely for
one minute or more, such as when the vehicle is
jacked-up, under full-lock cornering or when the
wheels are not in contact with road surface.
Did the wheels turn freely? ABS is normal.
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 jacked-
up, or when steer-
ing wheel is contin-
uously turned all
the way.
Go to step 2.
2 CHECK TIRE SPECIFICATIONS.
Are the tire specifications cor-
rect?
3 CHECK WEAR OF TIRE. Is the tire worn excessively? Replace the tire. Go to step 4.
4 CHECK TIRE INFLATION PRESSURE. Is the tire pressure correct? Go to step 5. Adjust the tire
pressure.
SPEED SENSOR.
Are the ABS wheel speed sen-
sor installation bolts tightened
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?
(For four wheels)
wheel speed sen-
sor installation
bolts.
SIGNAL.
sor.>
OR MAGNETIC ENCODER.
netic encoder?
Remove dirt thor-
oughly. Also
replace the ABS
wheel speed sen-
sor or magnetic
encoder as a unit
with hub unit bear-
damaged.
Go to step 8.
8 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 9.
ABS(diag)-45
ABS (DIAGNOSTICS)
J: DTC C0120 FRONT INLET SOLENOID VALVE LH MALFUNCTION IN ABS
CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE:
Refer to DTC C0126 for diagnostic procedure. <Ref. to ABS(diag)-46, DTC C0126 REAR INLET SOLENOID
VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/
U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
K: DTC C0122 FRONT INLET SOLENOID VALVE RH MALFUNCTION IN ABS
NOTE:
L: DTC C0124 REAR INLET SOLENOID VALVE LH MALFUNCTION IN ABS
NOTE:
nosis according to
DTC.
It results from a
temporary noise
interference.
NOTE:
Though the ABS
warning light re-
mains on at this
time, it is normal.
12 km/h (7 MPH)
or more in order to
turn ABS warning
drive the vehicle
and check that the
warning light goes
off.
Step Check Yes No
ABS(diag)-46
ABS (DIAGNOSTICS)
M: DTC C0126 REAR INLET SOLENOID VALVE RH MALFUNCTION IN ABS
Defective inlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
NOTE:
WIRING DIAGRAM:
ABS00805
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
3
3
B301
E
E
1
5
1
8
ABSCM & H/U
BATTERY
GENERATOR
IGNITION
SWITCH
B301
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
ABS(diag)-47
ABS (DIAGNOSTICS)
N: DTC C0121 FRONT OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS
NOTE:
Refer to DTC C0127 for diagnostic procedure. <Ref. to ABS(diag)-48, DTC C0127 REAR OUTLET SOLE-
NOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (AB-
SCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
O: DTC C0123 FRONT OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS
NOTE:
P: DTC C0125 REAR OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS
NOTE:
Step Check Yes No
1 CHECK INPUT VOLTAGE OF ABSCM&H/U.
Is the voltage 10 15 V? Go to step 2. Repair the
ABSCM&H/U
power circuit.
2 CHECK THE ABSCM&H/U GROUND
CIRCUIT.
Is the resistance less than 0.5 ? Go to step 3. Repair the
ABSCM&H/U
ground harness.
tor between generator, battery
and ABSCM&H/U?
Repair the connec-
tor.
Go to step 4.
4 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM&H/U.
<Ref. to ABS-6,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 5.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
ABS(diag)-48
ABS (DIAGNOSTICS)
Q: DTC C0127 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS
Defective outlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
NOTE:
WIRING DIAGRAM:
ABS00805
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
3
3
B301
E
E
1
5
1
8
ABSCM & H/U
BATTERY
GENERATOR
IGNITION
SWITCH
B301
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
ABS(diag)-49
ABS (DIAGNOSTICS)
Step Check Yes No
ABSCM&H/U
power circuit.
2 CHECK THE ABSCM&H/U GROUND CIR-
CUIT.
ABSCM&H/U
ground harness.
and ABSCM&H/U?
Repair the connec-
tor.
Go to step 4.
4 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM&H/U.
<Ref. to ABS-6,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 5.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
ABS(diag)-50
ABS (DIAGNOSTICS)
R: DTC C0110 ABS CONTROL MODULE MALFUNCTION
Defective ABSCM&H/U
TROUBLE SYMPTOM:
NOTE:
WIRING DIAGRAM:
ABS00415
E
ABSCM & H/U B301
1
5
B301
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
ABS(diag)-51
ABS (DIAGNOSTICS)
Step Check Yes No
1 CHECK THE ABSCM&H/U GROUND CIRCUIT.
ABSCM&H/U and chassis ground.
ABSCM&H/U
ground harness.
2 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact of the con-
nector between the battery, igni-
tion switch and ABSCM&H/U?
Repair the connec-
tor.
Go to step 3.
3 CHECK CAUSE OF SIGNAL NOISE. Is the car telephone or the radio
properly installed?
Go to step 4. Properly install the
car telephone or
the wireless trans-
mitter.
4 CHECK CAUSE OF SIGNAL NOISE. Is there a noise source (such as
an antenna) installed near the
sensor harness?
Install the noise
source apart from
the sensor har-
ness.
Go to step 5.
5 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 6.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
ABS(diag)-52
ABS (DIAGNOSTICS)
S: DTC C0109 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:
ABS00805
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
3
3
B301
E
E
1
5
1
8
ABSCM & H/U
BATTERY
GENERATOR
IGNITION
SWITCH
B301
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
ABS(diag)-53
ABS (DIAGNOSTICS)
Step Check Yes No
1 CHECK GENERATOR.
2) Run the engine at idle after warming up.
3) Measure the voltage between generator ter-
minal B and chassis ground.
Terminals
Generator B terminal (+) Chassis
ground ():
Is the voltage 10 15 V? Go to step 2. Repair the genera-
tor.
2 CHECK BATTERY TERMINAL.
Are the positive and negative
battery terminals tightened
securely?
Go to step 3. Tighten the termi-
nal.
3) Operate devices such as headlights, air
conditioner, defogger, etc. which produce an
electrical load.
ABSCM&H/U
power circuit.
4 CHECK THE ABSCM&H/U GROUNDCIRCUIT.
ABSCM&H/U
ground harness.
and ABSCM&H/U?
Repair the connec-
tor.
Go to step 6.
6 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 7.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
ABS(diag)-54
ABS (DIAGNOSTICS)
T: DTC C0140 CAN COMMUNICATION MALFUNCTION
Defective CAN communication
TROUBLE SYMPTOM:
Possibly the vehicle speed cannot output on CAN.
Step Check Yes No
1 CHECK LAN SYSTEM.
Perform the diagnosis for LAN system. <Ref. to
LAN(diag)-24, OPERATION, Read Diagnostic
Is there any fault in LAN sys-
tem?
Repair it according
to DTC of LAN sys-
tem.
Replace the
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS(diag)-55
ABS (DIAGNOSTICS)
U: DTC C0114 VALVE RELAY MALFUNCTION
Defective valve relay
TROUBLE SYMPTOM:
EBD does not operate depending on the trouble contents.
NOTE:
Brake warning light illuminates as well as ABS warning light when EBD does not operate.
WIRING DIAGRAM:
B301
B301
E
1
4
1
5
ABSCM & H/U
1
8
M
F
L

I
N
L
E
T
MAIN SBF
S
B
F
-
6
N
o
.
1
N
o
.
3
3
E
F
R

I
N
L
E
T
R
L

I
N
L
E
T
R
R

I
N
L
E
T
F
L

O
U
T
L
E
T
F
R

O
U
T
L
E
T
R
L

O
U
T
L
E
T
R
R

O
U
T
L
E
T
4 5 6 7 8 9
16 17 18 19 20
2 3 1
21 22 23 24 25 26
10 11
13 14 12 15
ABS00996
BATTERY
IGNITION
SWITCH
M
O
T
O
R

R
E
L
A
Y
VALVE RELAY
S
O
L
E
N
O
I
D

V
A
L
V
E
P
U
M
P

M
O
T
O
R
ABS(diag)-56
ABS (DIAGNOSTICS)
Step Check Yes No
Is the voltage 10 15 V? Go to step 2. Repair the harness
connector between
battery and
ABSCM&H/U.
ABSCM&H/U
ground harness.
3 CHECK VALVE RELAY IN ABSCM&H/U.
ABSCM&H/U terminals.
Terminals
No. 14 No. 15:
Is the resistance 1 M or more? Go to step 4. Replace the
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
and ABSCM&H/U?
Repair the connec-
tor.
Go to step 5.
5 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 6.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
ABS(diag)-57
ABS (DIAGNOSTICS)
V: DTC C0111 MOTOR/MOTOR RELAY MALFUNCTION
Defective motor
Defective motor relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B301
E E
1
3
1
5
1
2
ABSCM & H/U
1
8
M
MAIN SBF
S
B
F
-
6
N
o
.
3
3
E
SBF-1
F
L

I
N
L
E
T
F
R

I
N
L
E
T
R
L

I
N
L
E
T
R
R

I
N
L
E
T
F
L

O
U
T
L
E
T
F
R

O
U
T
L
E
T
R
L

O
U
T
L
E
T
R
R

O
U
T
L
E
T
B301
4 5 6 7 8 9
16 17 18 19 20
2 3 1
21 22 23 24 25 26
10 11
13 14 12 15
ABS00997
P
U
M
P

M
O
T
O
R
BATTERY
IGNITION
SWITCH
M
O
T
O
R

R
E
L
A
Y
VALVE RELAY
S
O
L
E
N
O
I
D

V
A
L
V
E
ABS(diag)-58
ABS (DIAGNOSTICS)
Step Check Yes No
connector between
battery and
ABSCM&H/U.
2 CHECK INSTALLATION OF MOTOR
GROUND.
Is the motor ground terminal
33 Nm (3.3 kgf-m, 24.3 ft-lb)?
Go to step 3. Tighten the motor
ground terminal
installation bolt.
3 CHECK GROUND CIRCUIT OF MOTOR.
ABSCM&H/U
ground harness.
connector between
battery, ignition
switch and
ABSCM&H/U.
ABSCM&H/U
ground harness.
and ABSCM&H/U?
Repair the connec-
tor.
Go to step 7.
7 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM&H/U.
<Ref. to ABS-6,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 8.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
NOTE:
Though the ABS
warning light re-
mains on at this
time, it is normal.
12 km/h (7 MPH)
or more in order to
turn ABS warning
drive the vehicle
and check that the
warning light goes
off.
ABS(diag)-59
ABS (DIAGNOSTICS)
W: DTC C0116 FAULTY STOP LIGHT SWITCH
Defective stop light switch
WIRING DIAGRAM:
M
A
I
N

S
B
F
S
B
F
-
2
N
o
.
8
7
.
5
A
B301
2
3
E
2
0
ABSCM & H/U
B65
9
5
B159
3
4
B225
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
9
4
7 6
2 1
5
3
8
B159 B301 B65
1 2
3 4
B225
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
ABS00998
BATTERY
STOP LIGHT
SWITCH
FUSE
(RELAY BLOCK)
ABS(diag)-60
ABS (DIAGNOSTICS)
Step Check Yes No
1 CHECK OUTPUT OF STOP LIGHT SWITCH
2) Release the brake pedal.
3) Read the stop light switch signal in Subaru
Select Monitor.
Is OFF displayed on the
screen?
2) Read the stop light switch output in Subaru
Select Monitor.
Is ON displayed on the
screen?
3 CHECK IF STOP LIGHTS COME ON.
Depress the brake pedal.
Does the stop light illuminate? Go to step 4. Repair the stop
light circuit.
4 CHECK FUSE.
Check the fuse (B225).
Is the fuse OK? Go to step 5. Replace the fuse.
5 CHECK OPEN CIRCUIT IN HARNESS.
between stop light
switch and
ABSCM&H/U con-
nector.
6 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in the con-
nector between stop light
switch and ABSCM&H/U?
Repair the connec-
tor.
Go to step 7.
7 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 8.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
ABS(diag)-61
ABS (DIAGNOSTICS)
X: DTC C0118 G SENSOR OUTPUT VOLTAGE MALFUNCTION
Defective G sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
ABS00808
ABSCM & H/U B301
B301
1
0
2
4
2
1
1
5
B292
ABS G SENSOR
E
3 2 1
B292
1 2 3 1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
ABS(diag)-62
ABS (DIAGNOSTICS)
Step Check Yes No
1 CHECK OUTPUT OF G SENSOR USING
2) Read the G sensor output on Subaru Select
Monitor.
Is the reading indicated on dis-
play 1.2 1.2 m/s when the
G sensor is horizontal?
G sensor?
Repair the connec-
tor.
Go to step 3.
3 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 4.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
5 CHECK INPUT VOLTAGE OF G SENSOR.
3) Remove the G sensor from vehicle.
5) Measure the voltage between G sensor
(B292) No. 1 (+) No. 3 ():
connector between
the G sensor and
ABSCM&H/U.
6 CHECK OPEN CIRCUIT IN G SENSOR OUTPUT
HARNESS AND GROUND HARNESS.
ABSCM&H/U connector terminals.
(B301) No. 21 No. 10:
3.6 3.8 k?
connector between
the G sensor and
ABSCM&H/U.
7 CHECK GROUND SHORT IN G SENSOR
OUTPUT HARNESS.
1) Disconnect the connector from G sensor.
between the G
sensor and
ABSCM&H/U.
8 CHECK G SENSOR.
1) Connect the connector to G sensor.
(B292) No. 2 (+) No. 3 ():
G sensor is in horizontal posi-
tion?
Go to step 9. Replace G sensor.
<Ref. to ABS-18, G
Sensor.>
ABS(diag)-63
ABS (DIAGNOSTICS)
9 CHECK G SENSOR.
Measure the voltage between G sensor con-
nector terminals.
(B292) No. 2 (+) No. 3 ():
the G sensor is inclined forward
to 90?
<Ref. to ABS-18, G
Sensor.>
10 CHECK G SENSOR.
nector terminals.
(B292) No. 2 (+) No. 3 ():
G sensor is inclined back 90?
<Ref. to ABS-18, G
Sensor.>
G sensor?
Repair the connec-
tor.
Go to step 12.
12 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 13.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
Step Check Yes No
ABS(diag)-64
ABS (DIAGNOSTICS)
Y: DTC C0119 G SENSOR OUTPUT VOLTAGE MALFUNCTION
Defective G sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
ABS00808
ABSCM & H/U B301
B301
1
0
2
4
2
1
1
5
B292
ABS G SENSOR
E
3 2 1
B292
1 2 3 1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
ABS(diag)-65
ABS (DIAGNOSTICS)
Step Check Yes No
OR NOT.
Have the wheels spun free of
load when the vehicle is lifted
up, or during driving on a rough
road?
ABS is normal.
Erase the memory.
Go to step 2.
Is the reading indicated on dis-
play 1.2 1.2 m/s when the
G sensor is horizontal?
Is the value indicated on the
screen 8.1 11.2 m/s when
G sensor is inclined forward to
90?
<Ref. to ABS-18, G
Sensor.>
Read the Subaru Select Monitor display.
Is the value indicated on the
screen 8.1 11.2 m/s when
G sensor is inclined backward
to 90?
<Ref. to ABS-18, G
Sensor.>
G sensor?
Repair the connec-
tor.
Go to step 6.
6 CHECK ABSCM&H/U.
4) Read the DTC.
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 7.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
8 CHECK OPEN CIRCUIT IN G SENSOR OUTPUT
HARNESS AND GROUND HARNESS.
ABSCU&H/U connector terminals.
(B301) No. 21 No. 10:
3.6 and 3.8 k?
connector between
the G sensor and
ABSCM&H/U.
connector between
the G sensor and
ABSCM&H/U.
ABS(diag)-66
ABS (DIAGNOSTICS)
10 CHECK G SENSOR.
3) Connect the connector to G sensor.
(B292) No. 2 (+) No. 3 ():
G sensor is in horizontal posi-
tion?
<Ref. to ABS-18, G
Sensor.>
11 CHECK G SENSOR.
nector terminals.
(B292) No. 2 (+) No. 3 ():
the G sensor is inclined forward
to 90?
<Ref. to ABS-18, G
Sensor.>
12 CHECK G SENSOR.
nector terminals.
(B292) No. 2 (+) No. 3 ():
G sensor is inclined back 90?
<Ref. to ABS-18, G
Sensor.>
13 CHECK ABSCM&H/U.
5) Read the DTC.
ABSCM only. <Ref.
to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Go to step 14.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-33, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
Step Check Yes No
ABS(diag)-67
ABS (DIAGNOSTICS)
A: INSPECTION
Vehicle instability during braking
Vehicle is pulled to either right
or left side.
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)
Vehicle spins.
Brake (pad)
Poor brake performance
Long braking/stopping distance
Brake (pad)
Air in brake line
Wheel locks.
ABSCM&H/U (solenoid valve, motor)
Brake drag
Master cylinder
Brake (caliper and piston)
Parking brake
Axle & wheels
Brake pedal play
Long brake pedal stroke
Air in brake line
Brake pedal play
Vehicle vertical pitching
Suspension play or fatigue (reduced damping)
Road surface (uneven)
Unstable or uneven braking
Brake (caliper, piston and pad)
Vibration and/or noise
(while driving on slippery roads)
Excessive pedal vibration
Noise from the ABSCM&H/U
ABSCM&H/U (mount bushing)
Brake line
Noise from front of vehicle
ABSCM&H/U (mount bushing)
Master cylinder
Brake (caliper, piston, pad and rotor)
Brake line
Brake booster and check valve
Suspension play or fatigue
Noise from rear of vehicle
Brake (caliper, piston, pad and rotor)
Parking brake
Brake line
ABS(diag)-68
ABS (DIAGNOSTICS)
VDC-2
General Description
VEHICLE DYNAMICS CONTROL (VDC)
A: SPECIFICATION
Item Specification or identification
ABS wheel speed sensor gap (for reference)
Front 0.77 1.43 mm (0.030 0.056 in)
Rear 0.64 1.56 mm (0.025 0.061 in)
Identifications of harness (marks, color)
Front
RH K1 (White)
LH K2 (Yellow)
Rear
RH K5 (White)
LH K6 (Yellow)
VDCCM&H/U Identification
AT(2.5GT SED, OBK 2.5XT, OBK 3.0R) T3
AT (other than above) T7
MT T4
VDC-3
General Description
B: COMPONENT
(1) Front ABS wheel speed sensor (4) Hub unit bearing Tightening torque:Nm (kgf-m, ft-lb)
(2) Front housing (5) Magnetic encoder T1: 7.5 (0.76, 5.5)
(3) Rear ABS wheel speed sensor T2: 33 (3.4, 24)
VDC00194
T1
T2
T1
(3)
(2)
(1)
T2
(4)
(5)
T2
VDC-4
General Description
2. YAW RATE & LATERAL G SENSOR
3. STEERING ANGLE SENSOR
(1) Yaw rate & lateral G sensor (2) Bracket Tightening torque:Nm (kgf-m, ft-lb)
T: 7.5 (0.76, 5.5)
VDC00447
(1)
(2)
T
T
(1) Steering angle sensor
VDC00196
(1)
VDC-5
General Description
4. VDC CONTROL MODULE & HYDRAULIC CONTROL UNIT (VDCCM&H/U)
C: CAUTION
forming any work.
the battery.
points.
(1) VDC control module & hydraulic
control unit (VDCCM&H/U)
(5) Front LH outlet (10) Damper
(6) Primary inlet
(2) Front RH outlet (7) Secondary inlet Tightening torque:Nm (kgf-m, ft-lb)
(3) Rear LH outlet (8) Damper T1: 7.5 (0.76, 5.5)
(4) Rear RH outlet (9) Spacer T2: 33 (3.4, 24)
VDC00480
(1)
(8)
(7)
(6)
(5)
(4)
(3)
(10)
(2)
T1
T2
(11)
(9)
T2
T2
VDC-6
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
MONITOR III KIT
TOOL NAME REMARKS
Pressure gauge Used for measuring oil pressure.
ST1B021XU0
VDC-7
VDC Control Module and Hydraulic Control Unit (VDCCM&H/U)
2. VDC Control Module and
Hydraulic Control Unit
(VDCCM&H/U)
A: REMOVAL
2) Use compressed air to remove moisture and
dust around the VDCCM&H/U.
NOTE:
If the terminals become dirty, it may cause improp-
er contact.
3) Lift the lock lever and Disconnect the VDC-
CM&H/U connector.
CAUTION:
Do not pull on the harness when disconnecting
the connector.
4) Disconnect the brake pipes from the VDCCM&H/
U.
5) 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.
6) Remove the nuts and remove the VDCCM&H/U.
CAUTION:
Do not drop or bump the VDCCM&H/U.
Do not turn the VDCCM&H/U upside down or
place it sideways during storage.
Be careful not to let foreign matter enter the
VDCCM&H/U.
Be careful that no water enters the connec-
tors.
7) Remove the VDCCM&H/U bracket.
B: INSTALLATION
1) Install the VDCCM&H/U bracket.
Tightening torque:
33 Nm (3.4 kgf-m, 24 ft-lb)
2) Install the VDCCM&H/U with a new nut (Part No.
023506000) by aligning the damper groove of the
VDCCM&H/U to the bracket side claw.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
VDC00449
VDC00450
VDC00450
VDC-8
3) Connect the brake pipes to their correct VDC-
CM&H/U positions.
Tightening torque:
T1: 15 Nm (1.5 kgf-m, 11.1 ft-lb)
T2: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
4) Connect the VDCCM&H/U connector.
NOTE:
Be sure to remove all foreign matter from inside
the connector before connecting.
Make sure the VDCCM&H/U connector is se-
curely locked.
6) Check the parameter to confirm that the applied
models and grades of the relevant vehicle are in-
cluded. <Ref. to VDC(diag)-17, PARAMETER
CHECK, OPERATION, Subaru Select Monitor.>
7) If the applied model and grade of the target ve-
hicle are not included on the {Parameter Check}
display screen, perform parameter selection and
registration. <Ref. to VDC(diag)-17, PARAMETER
SELECTION, OPERATION, Subaru Select Moni-
tor.>
NOTE:
When the VDCCM&H/U is replaced with a new
part, be sure to perform the selection and registra-
tion operation.
For the selection and registration of parameter,
the Subaru Select Monitor is required.
When no data is registered, ABS/EBD/VDC
warning light illuminates and the DTC Parameter
selection failure is detected.
C: INSPECTION
1) Check the condition of connection and settle-
ment of connector.
2) Check the mark used for VDCCM&H/U identifi-
cation.
Refer to SPECIFICATION for the identification
mark. <Ref. to VDC-2, SPECIFICATION, General
Description.>
OPERATION BY PRESSURE GAUGE
<Ref. to ABS-7, CHECKING THE HYDRAULIC
UNIT ABS OPERATION BY PRESSURE GAUGE,
INSPECTION, ABS Control Module and Hydraulic
Control Unit (ABSCM&H/U).>
OPERATION WITH THE BRAKE TESTER
<Ref. to ABS-8, CHECKING THE HYDRAULIC
UNIT ABS OPERATION WITH THE BRAKE
TESTER, INSPECTION, ABS Control Module and
Hydraulic Control Unit (ABSCM&H/U).>
VDC00451
T1
T2
(1) Identification mark
VDC00452
(1)
VDC-9
3. CHECKING THE HYDRAULIC UNIT VDC
OPERATION USING A PRESSURE GAUGE
1) Lift up the vehicle, and remove the wheels.
2) Remove the air bleeder screws from FL and FR
caliper bodies.
3) Connect two pressure gauges to FL and FR cal-
iper bodies.
CAUTION:
Use a pressure gauge used exclusively for
brake fluid measurement.
Do not use a pressure gauge used for the
measuring transmission oil pressure, as the
piston seal may expand and deform.
NOTE:
Wrap sealing tape around the pressure gauge.
4) Bleed air from the pressure gauge.
5) Perform VDC sequence control.
<Ref. to VDC-13, VDC Sequence Control.>
FL side performs compression, hold, and decom-
pression, and then the FR side performs compres-
sion, hold, and decompression.
7) Read values indicated on the pressure gauge
and check if the fluctuation of the values between
decompression and compression meets specifica-
tion. Depress the brake pedal and check that it is
not abnormally hard, and tightness is normal.
8) Disconnect the pressure gauges from FL and FR
caliper bodies.
9) Install the air bleeder screws of FL and FR cali-
per bodies.
10) Remove the air bleeder screws from RL and
RR caliper bodies.
11) Connect two pressure gauges to RL and RR
caliper bodies.
12) Bleed air from RL and RR caliper bodies, and
pressure gauge.
RR side performs compression, hold, and decom-
pression, and then the RL side performs compres-
sion, hold, and decompression.
15) Read the values indicated on the pressure
gauges and check if it is within specification. De-
press the brake pedal and check that it is not abnor-
mally hard, and tightness is normal.
16) Disconnect the pressure gauge from the RL
and RR caliper bodies.
17) Install the air bleeder screws of RL and RR cal-
iper bodies.
18) Bleed air from the brake line.
4. CHECK HYDRAULIC UNIT VDC OPERA-
TION WITH BRAKE TESTER
1) Set wheels other than the one to measure free
rollers.
2) Prepare to operate the VDC sequence control.
3) Set the front wheels or rear wheels on the brake
tester and set the select lever position to the N
range.
4) Operate the brake tester.
When
pressurized
3,000 kPa
(31 kgf/cm
2
, 441 psi)
or more
3,000 kPa
(31 kgf/cm
2
, 441 psi)
or more
When
depressurized
500 kPa
(5 kgf/cm
2
, 73 psi)
or less
500 kPa
(5 kgf/cm
2
, 73 psi)
or less
ABS00134
(1) Brake tester
ABS00136
(1)
ABS00137
(1)
VDC-10
6) When the hydraulic unit begins to work, check
the following work sequence.
(1) The FL wheel performs compression, hold
and decompression in sequence, and subse-
quently the FR wheel repeats the cycle.
(2) The RR wheel performs compression, hold
and decompression in sequence, and subse-
quently the RL wheel repeats the cycle.
7) Read values indicated on the brake tester and
check if the fluctuation of the values between de-
compression and compression meets specifica-
tion.
8) After the inspection, depress the brake pedal
and check that it is not abnormally hard, and tight-
ness is normal.
D: REPLACEMENT
CAUTION:
Because the pressure sensor built into the H/U
is easily damaged by static electricity, start the
operation after performing static electricity mea-
sures.
Be careful not to touch the sensors in the H/U
to prevent damage.
Because the seal of the VDCCM cannot be re-
placed, 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 re-
placement. If a problem is found such as not
being able to torque the screw to specifications
even before 5 replacement operations are per-
formed, replace the H/U body.
When installing the VDCCM, always use new
screws.
When the sealing surface of the VDCCM or H/U
is dirty or damaged and it cannot be cleaned or
repaired, replace with a new part.
1) Remove the VDCCM&H/U. <Ref. to VDC-7, RE-
MOVAL, VDC Control Module and Hydraulic Con-
trol Unit (VDCCM&H/U).>
2) To prevent entry of foreign objects and brake flu-
id leakage, plug the oil pressure port of the VDC-
CM&H/U using a screw plug, etc.
3) Set the pump motor section of the removed VD-
CCM&H/U face down on a vise.
NOTE:
4) Using TORX
bit E5, remove the four screws of

VDCCM.
NOTE:
These screws cannot be reused.
5) Slowly pull out the VDCCM upward from the H/
U.
NOTE:
To prevent damaging of coil section, remove the
VDCCM straight up from H/U without twisting.
6) Make sure there is no dirt or damage on the seal-
ing surface of the H/U.
CAUTION:
Do not clean the VDCCM&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 VDCCM to align with
the H/U valve.
8) To prevent deformation of the VDCCM housing
cover, hold the corner of VDCCM and install it to
the H/U without tilting.
When
pressurized
2,000 N
(203 kgf, 447 lb)
or more
2,000 N
(203 kgf, 447 lb)
or more
When
depressurized
500 N
(51 kgf, 112 lb)
or less
500 N
(51 kgf, 112 lb)
or less
(1) Aluminum plate, etc.
(2) Vise
ABS00430
(1)
(2)
ABS00431
VDC-11
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)
10) Check that there is no foreign matter in mating
surface between the VDCCM&H/U.
11) Using a TORX
bit E5, tighten the screws in the

order of (1) through (4) again.
Tightening torque:
3 Nm (0.3 kgf-m, 2.2 ft-lb)
12) Check that there is no gap in the mating sur-
face between VDCCM&H/U.
13) Install the VDCCM&H/U to the vehicle.
15) Perform the selection and registration opera-
tion of parameter. <Ref. to VDC(diag)-17, PARAM-
ETER SELECTION, OPERATION, Subaru Select
Monitor.>
NOTE:
After replacing the VDCCM, be sure to perform
the selection and registration operation of parame-
ter.
For the selection and registration of parameter,
the Subaru Select Monitor is required.
When no data is registered, ABS/EBD/VDC
warning light illuminates and the DTC Parameter
selection failure is detected.
16) Check the parameter to confirm that the ap-
plied models and grades of the relevant vehicle are
included. <Ref. to VDC(diag)-17, PARAMETER
CHECK, OPERATION, Subaru Select Monitor.>
17) If the applied models and grades of the relevant
vehicle are not included, perform the selection and
registration operation of parameter with the {Con-
firm Parameter} screen again. <Ref. to VDC(diag)-
17, PARAMETER SELECTION, OPERATION,
18) Execute Clear Memory after parameter selec-
tion and registration operations because the DTC
for Parameter selection failure is memorized.
E: ADJUSTMENT
When the following replacement, removal and in-
stallation are performed, be sure to perform the
centering of the steering angle sensor and zero
point setting of yaw rate & lateral G sensor.
VDCCM&H/U
Steering angle sensor
Yaw rate & lateral G sensor
Steering wheel parts (Including airbag)
Suspension parts
Wheel alignment adjustment
1) Park the vehicle straight on a level surface. (En-
gine operation in the P or N range)
2) Check that steering wheel is positioned at the
center. (When the center position is not correct, ad-
just the wheel alignment.)
3) Set the Subaru Select Monitor to the vehicle, and
select {Set up mode for Neutral of Steering Angle
Sensor & Lateral G Sensor 0 point} in the Function
check sequence screen. (Follow the steps on the
display.)
4) On the Brake Control System display screen,
select {Current Data Display & Save}, and check
that the steering angle sensor shows 0 deg.
5) When the 0 deg is not displayed, repeat the
above steps and check that the 0 deg is dis-
played.
6) Drive the vehicle for 10 minutes, and check that
the ABS and VDC warning light is not illuminated.
7) Check that there is no unnecessary VDC opera-
tion or steering control loss. If there is a problem,
repeat the steps above.
ABS00432
(4) (2)
(1) (3)
VDC-12
3. ABS Sequence Control
A: OPERATION
<Ref. to ABS-10, OPERATION, ABS Sequence
Control.>
<Ref. to ABS-10, ABS SEQUENCE CONTROL
WITH SUBARU SELECT MONITOR, OPERATION,
ABS Sequence Control.>
2. CONDITIONS FOR
ABS SEQUENCE CONTROL
<Ref. to ABS-11, CONDITIONS FOR ABS SEQUENCE
CONTROL, OPERATION, ABS Sequence Control.>
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION
OF ABS SEQUENCE CONTROL
<Ref. to ABS-12, CONDITIONS FOR COMPLE-
TION OF ABS SEQUENCE CONTROL, SPECIFI-
CATION, ABS Sequence Control.>
VDC-13
VDC Sequence Control
4. VDC Sequence Control
A: OPERATION
1) While the VDC sequence control is performed,
the operation of the hydraulic unit can be checked
using the brake tester or pressure gauge after the
hydraulic unit solenoid valve is operated.
2) VDC sequence control can be started by Subaru
Select Monitor.
1. VDC SEQUENCE CONTROL
NOTE:
In the event of any trouble, sequence control will
not operate.
1) Connect the Subaru Select Monitor to data link
connector under the drivers side instrument panel
lower cover.
4) Set the Subaru Select Monitor to Brake Control
mode.
5) When the VDC Inspection Mode is selected
from the Function check sequence menu, the
VDC sequence control will start.
6) OK will be displayed. Select the OK.
7) Operation points will be displayed on Subaru Se-
lect Monitor.
VDC-14
2. CONDITIONS FOR VDC SEQUENCE CONTROL
(20)
ON
ON
(23) (23) (23)
(4)
(5)
(19)
(32)
(3)
(2)
(1)
(22) (22) (22) (22)
V max < 4 km/h (2.5 MPH)
V max < 10 km/h (6 MPH)
OFF
OFF
OFF
OFF
OFF
ON
VDC
(21)
(27) (28)
(25) (26) (24)
(29) (30) (31) (25)
(24)
(8)
(7)
(9)
(10)
OFF
(11)
OFF
(12)
OFF
(14)
OFF
(15)
OFF
(16)
OFF
(13)
OFF
(18)
OFF
(17)
(6)
(33)
(35)
(34)
(36)
VDC00275
(29) (30) (31) (25)
VDC-15
NOTE:
The control 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 re-
turned 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 pressed during se-
quence control and the stop light switch is set to
ON.
3) After completion of VDC sequence control.
4) When a malfunction is detected.
(1) All wheel speed (13) FR decompression valve (25) 1 second
(2) Ignition key (14) FR compression valve (26) 1.6 seconds
(3) ABS warning light (15) RR decompression valve (27) Point A
(4) VDC warning light (16) RR compression valve (28) Reset
(5) Stop light switch (17) RL decompression valve (29) 0.8 seconds
(6) Valve relay (18) RL compression valve (30) 1.2 seconds
(7) VDC switching valve 1 FL (19) Pump motor (31) 0.4 seconds
(8) VDC switching valve 1 FR (20) 1.5 seconds (32) Master cylinder pressure
(9) VDC switching valve 2 FL (21) Approx. 3 seconds (33) FR wheel cylinder pressure
(10) VDC switching valve 2 FR (22) Light OFF (34) FL wheel cylinder pressure
(11) FL decompression valve (23) Light ON (35) RL wheel cylinder pressure
(12) FL compression valve (24) 3.4 seconds (36) RR wheel cylinder pressure
VDC-16
Yaw Rate and Lateral G Sensor
5. Yaw Rate and
Lateral G Sensor
A: REMOVAL
<Ref. to EI-54, Console Box.>
3) Disconnect the connector from yaw rate & lateral
G sensor.
4) Remove the yaw rate & lateral G sensor.
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
CAUTION:
After completion of installation, set the follow-
ing two positions.
Positioning to the center of steering angle
sensor
Positioning the yaw rate & lateral G sensors
to zero.
The above procedure is required VDCCM&H/U
to identify the vehicle position afterward. For
the setting procedures of the 2 steps above, re-
fer to VDC Control Module and Hydraulic Con-
trol Unit (VDCCM&H/U). <Ref. to VDC-11,
ADJUSTMENT, VDC Control Module and Hy-
draulic Control Unit (VDCCM&H/U).>
C: INSPECTION
1. YAW RATE & LATERAL G SENSOR
VDC00453
Step Check Yes No
1 CHECK YAW RATE & LATERAL G SENSOR.
2) Connect the Subaru Select Monitor connec-
tor to the data link connector.
4) Set the Subaru Select Monitor connector to
the {Brake Control} mode.
5) Select {Current Data Display & Save}.
6) Read the output of the yaw rate & lateral
G sensor.
Are the indicated values when
the vehicle is placed horizon-
tally, Lateral G sensor:
1.5 1.5 m/s, Yaw rate sen-
sor:4 4 deg/s?
connector between
yaw rate & lateral
G sensor and
VDCCM&H/U. Or
replace the yaw
rate & lateral
G sensor.
2) Remove the yaw rate & lateral G sensors
from vehicle. (Do not disconnect the connector.)
3) Read the display of Subaru Select Monitor.
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.
when the yaw rate & lateral
G sensor is inclined 90 to the
right?
connector between
yaw rate & lateral
G sensor and
VDCCM&H/U. Or
replace the yaw
rate & lateral
G sensor.
Read the display of Subaru Select Monitor.
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.
when the yaw rate & lateral
G sensor is inclined 90 to the
left?
Yaw rate & lateral
G sensors are nor-
mal.
Repair the harness
connector between
yaw rate & lateral
G sensor and
VDCCM&H/U. Or
replace the yaw
rate & lateral
G sensor.
VDC-17
Steering Angle Sensor
6. Steering Angle Sensor
A: REPLACEMENT
CAUTION:
Do not perform the removal except when the
replacement.
When replacing three times or more, replace
the combination switch as assembly to protect
the threads.
1) Set the steering wheel in a straight-ahead posi-
tion.
3) Remove the airbag module.
<Ref. to AB-14, REMOVAL, Drivers Airbag Mod-
ule.>
WARNING:
Always refer to Airbag System when perform-
ing the airbag module repair service.
<Ref. to AB-4, CAUTION, General Description.>
4) Remove the steering wheel.
<Ref. to PS-14, REMOVAL, Steering Wheel.>
5) Remove the screws and remove the steering
column lower cover.
6) Remove the two screws securing the steering
column upper cover.
7) Disconnect the connector of paddle shift assem-
bly. (Model with paddle shift)
8) Remove the paddle shift assembly. (Model with
paddle shift)
9) Disconnect the connector of roll connector and
steering angle sensor.
10) Remove the screws which secure the roll con-
nector to steering column.
11) Remove the vinyl tape binding the harness,
and remove the steering angle sensor from roll
connector.
CS-00728
CS-00729
VDC00207
VDC00208
VDC-18
12) Turn the protrusion portion of new steering an-
gle sensor to match the alignment mark of inspec-
tion hole.
CAUTION:
Be careful not to allow foreign matter to enter
into inspection hole.
13) Align the center of roll connector.
<Ref. to AB-24, INSTALLATION, Roll Connector.>
14) Apply a thin coat of grease that is supplied with
the new part, to the 4 protruding sections of the
steering angle sensor.
15) Align the position of the protrusion and install
roll connector to steering angle sensor.
Tightening torque:
0.5 Nm (0.05 kgf-m, 0.36 ft-lb)
16) Install the roll connector to combination switch
and bind the harness with vinyl tape as originally
bound.
17) Install the paddle shift. (Model with paddle shift)
18) Install the steering wheel.
<Ref. to PS-14, INSTALLATION, Steering Wheel.>
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
19) Install the airbag module to the steering wheel.
<Ref. to AB-14, INSTALLATION, Drivers Airbag
Module.>
WARNING:
forming the service operation.
<Ref. to AB-4, CAUTION, General Description.>
20) Connect the ground cable to the battery.
CAUTION:
After completion of installation, adjust the fol-
lowing two positions.
Positioning to the center of steering angle
sensor
Positioning the yaw rate & lateral G sensors
to zero.
The above procedure is required for the VDC-
CM to identify vehicle position afterward. For
the setting procedures of the 2 steps above, re-
fer to VDC Control Module and Hydraulic Con-
trol Unit (VDCCM&H/U). <Ref. to VDC-11,
ADJUSTMENT, VDC Control Module and Hy-
draulic Control Unit (VDCCM&H/U).>
(1) Protrusion portion
(2) Inspection hole
(3) Alignment mark
(1) Apply grease.
VDC00209
(1)
(2)
(3)
ABS00435
(1)
VDC00208
VDC00207
VDC-19
7. 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 inspec-
tion procedures.
<Ref. to ABS-13, Front ABS Wheel Speed Sen-
sor.>
VDC-20
Rear ABS Wheel Speed Sensor
8. 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 inspec-
tion procedures.
<Ref. to ABS-15, Rear ABS Wheel Speed Sen-
sor.>
VDC-21
Front Magnetic Encoder
9. Front Magnetic Encoder
A: NOTE
Vehicles equipped with VDC have the same mag-
netic encoder as installed on vehicles equipped
with ABS. Refer to Front Magnetic Encoder for re-
moval, installation and inspection procedures.
<Ref. to ABS-16, Front Magnetic Encoder.>
VDC-22
Rear Magnetic Encoder
10.Rear Magnetic Encoder
A: NOTE
Vehicles equipped with VDC have the same mag-
netic encoder as installed on vehicles equipped
with ABS. Refer to Rear Magnetic Encoder for re-
moval, installation and inspection procedures.
<Ref. to ABS-17, Rear Magnetic Encoder.>
VDC-23
VDC OFF Switch
11.VDC OFF Switch
A: REMOVAL
1) Remove the instrument panel lower cover.
2) Remove the screws, and then remove the VDC
OFF switch.
B: INSTALLATION
C: INSPECTION
Measure the resistance between the VDC OFF
switch terminals.
If NG, replace the VDC OFF switch.
Switch position Terminal No. Standard
OFF 5 15 1 M or more
ON 5 15 Less than 1
VDC00240
7 6 5 4 3 2 1
15 14 13 12 11 10 9 8
VDC-24
VDC OFF Switch
VDC(diag)-2
VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS)
A: PROCEDURE
CAUTION:
Remove foreign matter (dust, water, oil etc.) from the VDCCM&H/U connector during removal and in-
stallation.
NOTE:
To check the harness for broken wires or short circuits, shake problem spot or connector.
Refer to Check List for Interview. <Ref. to VDC(diag)-4, Check List for Interview.>
Step Check Yes No
VDC(diag)-4, Check List for Interview.>
2) Before performing diagnostics, check the
component which might affect VDC problems.
<Ref. to VDC(diag)-8, INSPECTION, General
Description.>
Is the component that might
influence the VDC problem nor-
mal?
each component.
2 CHECK INDICATION OF DTC.
4) Read the DTC using the Subaru Select
Monitor. <Ref. to VDC(diag)-21, OPERATION,
Read Diagnostic Trouble Code (DTC).>
NOTE:
lect Monitor cannot be executed normally,
check the communication circuit. <Ref. to
VDC(diag)-18, COMMUNICATION FOR INI-
TIALIZING IMPOSSIBLE, INSPECTION, Sub-
5) Record all DTCs and freeze frame data.
Select Monitor?
1) Perform the inspection by referring to Gen-
eral Diagnostic Table. <Ref. to VDC(diag)-100,
INSPECTION, General Diagnostic Table.>
VDC(diag)-23, OPERATION, Clear Memory
Mode.>
VDC(diag)-22, PROCEDURE, Inspection
Mode.>
4) Read the DTC. <Ref. to VDC(diag)-21,
(DTC).>
5) Check the DTC is not displayed.
Do the VDC warning light and
ABS warning light go off after
starting the engine?
Finish the diagno-
sis.
Check the combi-
nation meter cir-
cuit. <Ref. to
VDC(diag)-29,
ABS WARNING
LIGHT DOES NOT
GO OFF, Warning
Light Illumination
Pattern.> <Ref. to
VDC(diag)-31,
VDC WARNING
LIGHT AND VDC
OFF INDICATOR
LIGHT DO NOT
GO OFF, Warning
Light Illumination
Pattern.>
VDC(diag)-3
(DTC).
NOTE:
For the DTC list, refer to List of Diagnostic
Trouble Code (DTC). <Ref. to VDC(diag)-34,
LIST, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-23, OPERATION, Clear Memory
Mode.>
Mode.>
5) Read the DTC. <Ref. to VDC(diag)-21,
(DTC).>
Is DTC displayed? Repeat step 4 until
DTC is not shown.
Finish the diagno-
sis.
Step Check Yes No
VDC(diag)-4
A: CHECK
Check the following item about the vehicles state.
1. STATE OF ABS WARNING LIGHT
ABS warning light
illuminates.
Always
Sometimes
Only once
Does not come on
When/How long does it illuminate?
ACC
START
Timing Immediately after turning the ignition switch to ON
Immediately after turning the ignition switch to START
MPH
MPH
Steering time: Sec.
Steering time: Sec.
Part name:
VDC(diag)-5
2. STATE OF VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT
3. STATE OF VDC INDICATOR LIGHT
VDC warning light
and VDC OFF indi-
cator light illuminate.
Always
Sometimes
Only once
Does not come on
ACC
START
MPH
MPH
Steering time: Sec.
Steering time: Sec.
Part name:
VDC operation indi-
cator light illuminate.
Always
Sometimes
Only once
Does not come on
ACC
START
MPH
MPH
Steering time: Sec.
Steering time: Sec.
Part name:
VDC(diag)-6
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)-7
Condition a) Brakes Deceleration: G
Continuous / Intermittent
b) Accelerator Acceleration: G
Continuous / Intermittent
c) Vehicle speed km/h MPH
Advancing
While accelerating
While decelerating
At low speed
When turning
Others:
d) Tire inflation pressure Front RH tire: kPa
Front LH tire: kPa
Rear RH tire: kPa
Rear LH tire: kPa
e) Degree of wear Front RH tire:
Front LH tire:
Rear RH tire:
Rear LH tire:
f) Steering wheel Sharp turning
Gentle turning
Straight forward motion
Gentle return
Sharp return
g) Tire/Wheel size Specified size
Except specification ( )
h) Tire variation Summer tire
Studless tire (Brand: )
i) Tire chain is attached: Yes / No
j) T-type tire is used: Yes / No
k) Condition of suspension alignment:
l) Loading state:
m) Repair parts are used: Yes / No
Contents:
n) Others:
VDC(diag)-8
General Description
A: CAUTION
AIRBAG
ABS wheel speed sensor and VDCCM&H/U.
CAUTION:
All airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
wiring harness when servicing the ABS wheel
speed sensor and VDCCM&H/U.
B: INSPECTION
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 torque of ground (GB-4) bolt
of VDC.
Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)
3. BRAKE FLUID
1) Check the brake fluid level.
2) Check the brake fluid for leaks.
4. HYDRAULIC UNIT
Check the hydraulic unit.
With brake tester <Ref. to VDC-8, CHECKING
THE HYDRAULIC UNIT ABS OPERATION WITH
THE BRAKE TESTER, INSPECTION, VDC Con-
trol Module and Hydraulic Control Unit (VDC-
CM&H/U).>
Without brake tester <Ref. to VDC-8, CHECK-
ING THE HYDRAULIC UNIT ABS OPERATION
BY PRESSURE GAUGE, INSPECTION, VDC
Control Module and Hydraulic Control Unit (VDC-
CM&H/U).>
5. BRAKE DRAG
Check for brake drag.
6. BRAKE PAD AND ROTOR
Check the brake pad and rotor.
Front <Ref. to BR-15, INSPECTION, Front Brake
Pad.> <Ref. to BR-16, INSPECTION, Front Disc
Rotor.>
Rear <Ref. to BR-22, INSPECTION, Rear Brake
Pad.> <Ref. to BR-24, INSPECTION, Rear Disc
Rotor.>
7. TIRE
Check the tire specifications, tire wear and air pres-
sure. <Ref. to WT-2, SPECIFICATION, General
Description.>
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
MONITOR III KIT
TOOL NAME REMARKS
ST1B021XU0
VDC(diag)-9
A: LOCATION
(1) VDC control module and hydraulic
(5) ABS warning light (10) Magnetic encoder
(6) VDC indicator light (11) ABS wheel speed sensor
(2) Connector (7) VDC warning light
and VDC OFF indicator light
(12) Yaw rate & lateral G sensor
(3) Transmission control module (TCM) (13) Data link connector
(4) Brake warning light
(EBD warning light)
(8) Steering angle sensor (14) Engine control module (ECM)
(9) VDC OFF switch (15) Stop light switch
VDC00469
(4)
(5)
(6)
(7)
(8)
(1)
(2)
(3)
(15)
(14)
(12)
(13)
(11) (10)
(11)
(10)
(9)
VDC(diag)-10
VDC00455
(1)
VDC00251
(6) (7) (5)
(4)
(8)
VDC00235 VDC00234
(11)
(10)
(10)
VDC00456
(12)
VDC00242
(13)
VDC(diag)-11
NOTE:
Terminal numbers in VDCCM&H/U connector are shown in the figure.
When the connector is removed from VDCCM&H/U, the ABS warning light, VDC warning light and VDC
OFF indicator light illuminate.
VDC00457
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC(diag)-12
Content
Terminal No.
(+) ()
Input/Output signal
Power supply 28 25 10 15 V when the ignition switch is ON.
Front LH wheel
Power
supply
26 25 4.5 16.5 V
Front RH wheel
Power
supply
5 25 4.5 16.5 V
Rear LH wheel
Power
supply
2 25 4.5 16.5 V
Rear RH wheel
Power
supply
3 25 4.5 16.5 V
CAN communication line (+) 35 2.5 1.5 V pulse signal
CAN communication line () 10 3.5 2.5 V pulse signal
Valve relay power supply 24 25 10 15 V when the ignition switch is ON.
Motor relay power supply 23 22 10 15 V when the ignition switch is ON.
ABS warning light 32 25
After turning the ignition switch to ON, 10 15 V during
1.5 seconds, and 1.5 V or less after 1.5 seconds passed.
Brake warning light (EBD warning light) 8 25
After turning the ignition switch to ON, 10 15 V during
1.5 seconds, and 1.5 V or less after 1.5 seconds passed.
Stop light switch 30 25
1.5 V or less when the stop light is OFF; otherwise,
10 15 V when the stop light is ON.
Subaru Select Monitor 7 25 0 12 V pulse (in communication)
Vehicle speed output signal 33 0 12 V pulse
Ground 25
VDC(diag)-13
B: WIRING DIAGRAM
(1) Battery (14) Rear inlet solenoid valve RH (27) Parking brake switch
(2) Ignition switch (15) Rear outlet solenoid valve RH (28) Brake fluid level switch
(3) VDC control module and hydraulic
(16) Primary cut solenoid valve (29) Stop light switch
(17) Primary suction solenoid valve (30) Stop light
(4) VDC control module (18) Secondary cut solenoid valve (31) Body integrated unit
(5) Valve relay (19) Secondary suction solenoid valve (32) Engine control module (ECM)
(6) Motor relay (20) Data link connector (33) Transmission control module (TCM)
(7) Motor (21) VDC OFF switch (34) Steering angle sensor
(8) Front inlet solenoid valve LH (22) Combination meter (35) Yaw rate & lateral G sensor
(9) Front outlet solenoid valve LH (23) VDC indicator light (36) Pressure sensor
(10) Front inlet solenoid valve RH (24) VDC warning light and VDC OFF
indicator light
(37) Front ABS wheel speed sensor LH
(11) Front outlet solenoid valve RH (38) Front ABS wheel speed sensor RH
(12) Rear inlet solenoid valve LH (25) ABS warning light (39) Rear ABS wheel speed sensor LH
(13) Rear outlet solenoid valve LH (26) Brake warning light (40) Rear ABS wheel speed sensor RH
(3)
(7)
(6)
(5)
(11)
M
(12)
(13)
(20)
(2)
(24)
(23)
(22)
(4)
(28)
(1)
(29)
(30)
(37)
(14)
(8)
(9)
(10)
(15)
(16)
(17)
(18)
(21)
(33)
(32)
(31)
(34)
(35)
(38)
(39)
(40)
(27)
(26)
(25)
(19)
(36)
VDC00458
VDC(diag)-14
A: OPERATION
(DTC)
VDC(diag)-8, SPECIAL TOOL, PREPARATION
2) Prepare PC with Subaru Select Monitor installed.
NOTE:
Monitor.
5) Connect the SDI to the data link connector locat-
ed in the lower portion of the instrument panel (on
the drivers side).
CAUTION:
Do not connect scan tools other than the Subaru
Select Monitor.
6) Start the PC.
Monitor.
9) On the System Selection Menu, select {Brake
Control}.
10) Click the [OK] button after the {VDC} is displayed.
11) On the Brake Control Diagnosis screen, se-
lect {DTC Display}.
12) Record the DTC and data.
NOTE:
help on PC application for Subaru Select Monitor.
agnostic Trouble Code (DTC). <Ref. to VDC(di-
Up to 3 DTCs are displayed in the order of detec-
tion.
If a particular DTC is not stored in memory prop-
erly at the occurrence of problem (due to a drop in
VDCCM&H/U power supply etc.), the DTC suffixed
with a question mark ? is displayed on Subaru Se-
lect Monitor display screen. This shows it may be
an unreliable reading.
13) If VDC and Subaru Select Monitor cannot com-
municate, check the communication circuit. <Ref.
to VDC(diag)-18, COMMUNICATION FOR INI-
TIALIZING IMPOSSIBLE, INSPECTION, Subaru
Select Monitor.>
EN-05692
ABS00465
(1)
Current
The current DTC is displayed on Subaru
Select Monitor display screen.
Previous
The latest DTC in previous troubles is
displayed on Subaru Select Monitor dis-
play screen.
Second previous
The second latest DTC in previous trou-
bles is displayed on Subaru Select Moni-
tor display screen.
Third previous
The third latest DTC in previous prob-
lems is displayed on Subaru Select Mon-
itor display screen.
VDC(diag)-15
1) On the Main Menu display, select {Each System Check}.
2) On the System Selection Menu, select {Brake Control}.
4) On the Brake Control Diagnosis screen, select {Current Data Display & Save}.
5) On the Data Display Menu, select the data display method.
6) Using the scroll key, scroll the display screen up or down until necessary data is shown.
NOTE:
For details concerning the operation procedure, refer to the help on PC application for Subaru Select Monitor.
2) On the System Selection Menu, select {Brake Control}.
4) On the Brake Control Diagnosis, select {Clear Memory}.
5) When the Clear Memory? is shown on the screen, click the [YES] button.
6) When Done and Turn ignition switch to OFF are shown on the display screen, turn the ignition switch
to OFF.
NOTE:
For detailed operation procedure, refer to the help on PC application for Subaru Select Monitor.
FR Wheel Speed Wheel speed detected by front ABS wheel speed sensor RH is displayed. km/h or MPH
FL Wheel Speed Wheel speed detected by front ABS wheel speed sensor LH is displayed. km/h or MPH
RR Wheel Speed Wheel speed detected by rear ABS wheel speed sensor RH is displayed. km/h or MPH
RL Wheel Speed Wheel speed detected by rear ABS wheel speed sensor LH is displayed. km/h or MPH
Steering Angle Sensor Steering angle detected by steering angle sensor is displayed. deg
Yaw Rate Sensor Vehicle angular speed detected by yaw rate sensor is displayed. deg/s
Pressure Sensor Brake fluid pressure detected by pressure sensor is displayed. bar
Lateral G Sensor Vehicle lateral acceleration detected by lateral G sensor is displayed. m/s (m/s
2
)
IG power supply voltage Voltage supplied to VDCCM&H/U is displayed. V
E/G Control Prohibited Flag Engine control command signal is displayed. 1 or 0
ABS Control Flag ABS operation condition is displayed. ON or OFF
EBD Control Flag EBD operation condition is displayed. ON or OFF
TCS Control Flag TCS operation condition is displayed. ON or OFF
VDC Control Flag VDC operation condition is displayed. ON or OFF
VDC OFF Light ON/OFF condition of VDC OFF indicator light is displayed. ON or OFF
EBD Warning Light ON operation of the EBD warning light is displayed. ON or OFF
ABS Warning Light ON operation of the ABS warning light is displayed. ON or OFF
VDC Warning Light ON operation of the VDC warning light is displayed. ON or OFF
Valve Relay Signal Valve relay operation signal is displayed. ON or OFF
Motor Relay Signal Motor relay operation signal is displayed. ON or OFF
Motor Relay Monitor Voltage applied to the motor relay is displayed. V
OFF Switch Signal Operation condition of VDC OFF switch is displayed. ON or OFF
Brake Switch Brake ON/OFF is displayed. ON or OFF
VDC(diag)-16
4. FUNCTION CHECK
5. FREEZE FRAME DATA
NOTE:
Data stored at the time of trouble occurrence is
Each time a trouble occurs, the latest information
is stored in the freeze frame data in memory.
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 ? ap-
pears on the Subaru Select Monitor display. This
shows it may be an unreliable reading.
Display Contents of display Index No.
ABS sequence control
Operate the valve and pump motor continuously
to perform the ABS sequence control.
VDC confirmation mode
Operate the valve and pump motor continuously
to perform the VDC sequence control.
Set up mode for Neutral of
& Lateral G Sensor 0 Point is
not normal
Set the steering angle sensor neutral position
and the lateral G sensor 0 point.
<Ref. to VDC-17, Steering Angle Sensor.>
Steering angle
sensor
Steering angle detected by steering
angle sensor is displayed.
Yaw rate sensor
Vehicle angular speed detected by
yaw rate sensor is displayed.
Lateral G Sensor
Vehicle lateral acceleration detected
by lateral G sensor is displayed.
Pressure Sensor
Brake fluid pressure detected
by pressure sensor is displayed.
Vehicle Speed
Vehicle speed calculated by VDC
control module is displayed.
FR Wheel Speed
wheel speed sensor RH is displayed
in km/h or MPH.
FL Wheel Speed
wheel speed sensor LH is displayed
in km/h or MPH.
RR Wheel Speed
wheel speed sensor RH is displayed
in km/h or MPH.
RL Wheel Speed
wheel speed sensor LH is displayed
in km/h or MPH.
Acceleration
opening angle signal
Acceleration opening is displayed.
Engine Speed
Engine speed on malfunction
occurrence is displayed.
Gear position
Gear position on malfunction
occurrence is displayed.
IG power supply
voltage
Voltage supplied to VDC control
module is displayed.
Absolute angle
recognition flag
Whether the absolute angle of the
steering angle sensor was
determined is displayed.
EAM signal
Engine control command signal is
displayed.
VDC Control Flag VDC control condition is displayed.
EBD Control Flag EBD control condition is displayed.
TCS Control Flag TCS control condition is displayed.
ABS Control Flag ABS control condition is displayed.
VDC OFF light
ON/OFF condition of the VDC
operated by the driver is displayed.
Brake Switch Brake ON/OFF is displayed.
VDC(diag)-17
6. PARAMETER SELECTION
CAUTION:
Subaru Select Monitor is required for param-
eter selection.
This function can be used for the replace-
ment VDCCM&H/U and VDCCM.
NOTE:
When a VDCCM is replaced with a replacement,
use this function to select and register parameters
to the VDCCM.
For confirmation of applied models, refer to the
Model number plate attached to the vehicles.
<Ref. to ID-2, IDENTIFICATION, Identification.>
If a wrong applied model is written, it can be re-
written.
When no data is registered, ABS/EBD/VDC warn-
ing light illuminates and the DTC Parameter selec-
tion failure is detected.
2) On the Main Menu display, select {Each System
Check}.
Control}.
5) On the Brake Control Diagnosis, select {Pa-
rameter Selection}.
6) Check the applied model indicated in the Model
number plate. <Ref. to ID-2, IDENTIFICATION,
Identification.>
7) Enter the applied model of 7-digit alphanumeric
characters and press the [Enter] key.
8) When the confirmation screen indicating the ve-
hicle information appears, check that the correct
applied model and grade are displayed and click
the [OK] button.
NOTE:
When the displayed applied model and grade are
different from those of the vehicle, perform registra-
tion operations again after clicking the [OK] button.
9) Execute Clear Memory after parameter selec-
tion and registration operations because the DTC
for Parameter selection failure is memorized.
7. PARAMETER CHECK
NOTE:
The parameter data registered in the VDCCM is
2) On the Main Menu display, select {Each System
Check}.
Control}.
5) On the Brake Control Diagnosis, select {Pa-
rameter Check}.
6) On the {Parameter Check} display screen, check
that the applied model and grade of the target vehi-
cle are included, and click the [OK] button.
7) If the applied model and grade of the target ve-
hicle are not included on the {Parameter Check}
display screen, perform parameter selection and
registration. <Ref. to VDC(diag)-17, PARAMETER
SELECTION, OPERATION, Subaru Select Moni-
tor.>
VDC(diag)-18
B: INSPECTION
TROUBLE SYMPTOM:
Communication is impossible between VDC and Subaru Select Monitor.
WIRING DIAGRAM:
7
2
8
M
A
I
N

S
B
F
S
B
F
-
6
F
/
B
N
o
.
3
3
M
/
B
N
o
.
1
3
B310 VDCCM & H/U
E
2
5
B40
7
16
E
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00498
B40
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
BATTERY
IGNITION
SWITCH
DATA LINK
CONNECTOR
VDC(diag)-19
Step Check Yes No
switch to ON, and
select VDC mode
using Subaru
Select Monitor.
2 CHECK BATTERY.
2) Measure the battery voltage.
the battery.
3 CHECK BATTERY TERMINAL. Is there poor contact at the bat-
tery terminal?
Repair or tighten
the battery termi-
nal.
Go to step 4.
COMMUNICATION.
aru Select Monitor?
COMMUNICATION.
2) Disconnect the VDCCM&H/U connector.
4) Check whether communication to other
systems can be executed normally.
aru Select Monitor?
Replace the
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 6.
CONNECTOR.
2) Disconnect the VDCCM&H/U, ECM and
TCM.
and connector
between each con-
trol module and
data link connec-
tor.
7 CHECK OUTPUT SIGNAL FOR VDCCM&H/U.
2) Measure the voltage between data link
and connector
between each con-
trol module and
data link connec-
tor.
8 CHECK THE HARNESS CONNECTOR
BETWEEN VDCCM&H/U AND DATA LINK
CONNECTOR.
Measure the resistance between VDCCM&H/U
connector and data link connector.
(B310) No. 7 (B40) No. 7:
and connector
between
VDCCM&H/U and
data link connec-
tor.
9 CHECK INSTALLATION OF VDCCM&H/U
CONNECTOR.
Is the VDCCM&H/U connector
inserted into VDCCM&H/U until
the clamp locks onto it?
Go to step 10. Insert VDCCM&H/
U connector into
VDCCM&H/U.
10 CHECK POWER SUPPLY CIRCUIT.
between VDCCM&H/U connector and chassis
ground.
in harness
between
VDCCM&H/U and
battery.
VDC(diag)-20
11 CHECK THE HARNESS CONNECTOR
BETWEEN VDCCM&H/U AND CHASSIS
GROUND.
2) Disconnect the connector from the
VDCCM&H/U.
VDCCM&H/U connector and chassis ground.
Is the resistance less than 0.5 ? Go to step 12. Repair the open
circuit of
VDCCM&H/U
ground harness
and poor contact of
connector.
12 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in control
module power supply, ground
circuit and data link connector?
Repair the connec-
tor.
Replace the
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Step Check Yes No
VDC(diag)-21
Code (DTC)
A: OPERATION
For details concerning DTC reading procedure, re-
fer to Subaru Select Monitor. <Ref. to VDC(diag)-
14, Subaru Select Monitor.>
VDC(diag)-22
Inspection Mode
8. Inspection Mode
A: PROCEDURE
as much as possible.
Drive the vehicle at least ten minutes.
NOTE:
Make sure the vehicle is not dragged to one side
under usual driving condition.
VDC(diag)-23
Clear Memory Mode
A: OPERATION
Subaru Select Monitor. <Ref. to VDC(diag)-14,
VDC(diag)-24
Warning Light Illumination Pattern
10.Warning Light Illumination Pattern
A: INSPECTION
(1) Ignition switch (8) 2 sec. (12) Brake warning light
(EBD warning light)
(2) OFF (9) VDC indicator light
(3) ON (10) VDC warning light and VDC OFF
indicator light
(13) Parking brake
(4) Engine start (14) Released
(5) ABS warning light (11) Several seconds (depending on
engine coolant temperature)
(6) Light OFF
(7) Light ON
VDC00214
(2)
(6) (6)
(7)
(6) (6)
(7)
(8)
(6) (6)
(7)
(11)
(3) (3)
(4)
(1)
(5)
(9)
(10)
(6)
(7)
(12)
(14)
(13)
VDC(diag)-25
1) When warning lights or indicator lights do not il-
luminate in accordance with this illumination pat-
tern, there must be an electrical malfunction.
2) When warning lights or indicator lights remain
constantly OFF, check the combination meter cir-
cuit or CAN communication circuit. <Ref. to VDC(di-
ag)-26, VDC WARNING LIGHT, VDC OFF
INDICATOR LIGHT AND VDC INDICATOR LIGHT
DO NOT COME ON, Warning Light Illumination
Pattern.>
3) When ABS warning light does not go off, check
the combination meter circuit. <Ref. to VDC(diag)-
29, ABS WARNING LIGHT DOES NOT GO OFF,
Warning Light Illumination Pattern.>
4) When the VDC indicator light, VDC warning light
and VDC OFF indicator light do not go off, check
the combination meter circuit or CAN communica-
tion circuit. <Ref. to VDC(diag)-30, VDC INDICA-
TOR LIGHT DOES NOT GO OFF, Warning Light
Illumination Pattern.>
NOTE:
Even though the ABS warning light does not go off
after 2 seconds from ABS warning light illumination,
the ABS system operates normally when the warn-
ing 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.
It may take several minutes before VDC warning
light and VDC OFF indicator light goes off if the ve-
hicle is parked under low temperature for a speci-
fied time. This is not defective because it is resulted
from low engine coolant temperature.
With the vehicle jack-up/lift-up or set on free roll-
ers, when the wheels lock or spin after starting the
engine, ABS warning light, VDC warning light and
VDC OFF indicator light may illuminate because
VDCCM&H/U detects the abnormal conditions from
ABS wheel speed sensors. In this case, this is not a
malfunction. Perform the Clear Memory Mode.
VDC(diag)-26
B: VDC WARNING LIGHT, VDC OFF INDICATOR LIGHT AND VDC INDICATOR
LIGHT DO NOT COME ON
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), VDC indicator light, VDC warning light and VDC OFF
indicator light do not come on.
NOTE:
When pressing the VDC OFF switch for 10 seconds or more, the VDC OFF indicator light goes off and cannot
operate any more. When turning the ignition switch from OFF to ON, the OFF operation enabled status is re-
stored.
Step Check Yes No
1 CHECK OTHER INDICATOR LIGHT.
Does other indicator light illumi-
nate soon after ON.
diagnosis of com-
bination meter.
2 CHECK VDCCM.
When the engine does not start, display the cur-
rent data of VDCCM using Subaru Select Mon-
itor.
Is VDC warning light output
set to ON?
VDCCM only.
3 CHECK LAN SYSTEM.
tem?
Perform the diag-
nosis according to
DTC for LAN sys-
tem.
Go to step 4.
Check the combination meter.
Is combination meter OK? Replace the
VDCCM only.
Repair the combi-
nation meter
assembly.
VDC(diag)-27
C: ABS WARNING LIGHT DOES NOT COME ON
Defective harness
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), ABS warning light does not come on.
WIRING DIAGRAM:
MAIN SBF
S
B
F
-
6
No.5
N
o
.
3
3
A: i10
B: i11
E
E
B310
2
8
2
5
3
2
VDCCM & H/U
A
7
8
i3
B38
A
3
i10
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
A:
*
*
i11 B:
2 1 3 4 5 6
14 13 12 11 10 9 8 7
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00499
2
0
9
B38
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
BATTERY
IGNITION
SWITCH
COMBINATION
METER
B
R
A
K
E
W
A
R
N
I
N
G

L
I
G
H
T
A
B
S
W
A
R
N
I
N
G

L
I
G
H
T
: NORMAL METER : A5
METER WITH MID : B5
VDC(diag)-28
Step Check Yes No
1 CHECK OTHER LIGHTS TURN ON.
Turn the ignition switch to ON. (engine OFF)
Do other warning lights illumi-
nate?
Go to step 2. Check the combi-
nation meter.
2 READ DTC.
Read the DTC. <Ref. to VDC(diag)-21, Read
nosis according to
DTC.
Go to step 3.
3 CHECK GROUND SHORT CIRCUIT OF
HARNESS.
VDCCM&H/U.
3) Disconnect the connector (i10) or (i11) from
the combination meter.
connector between
VDCCM&H/U and
combination meter.
4 CHECK VDCCM.
1) Connect the connector (B310) to
VDCCM&H/U.
3) Measure the resistance between the combi-
nation meter connector and chassis ground
soon after the ignition switch is turned to ON
(within 2 seconds).
Normal meter model
Is the resistance 1 M or more? Check the combi-
nation meter.
Replace the
VDCCM only.
VDC(diag)-29
D: ABS WARNING LIGHT DOES NOT GO OFF
TROUBLE SYMPTOM:
When starting the engine, the ABS warning light is kept ON.
WIRING DIAGRAM:
MAIN SBF
S
B
F
-
6
No.5
N
o
.
3
3
A: i10
B: i11
E
E
B310
2
8
2
5
3
2
VDCCM & H/U
A
7
8
i3
B38
A
3
i10
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
A:
*
*
i11 B:
2 1 3 4 5 6
14 13 12 11 10 9 8 7
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00499
2
0
9
B38
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
BATTERY
IGNITION
SWITCH
COMBINATION
METER
B
R
A
K
E
W
A
R
N
I
N
G

L
I
G
H
T
A
B
S
W
A
R
N
I
N
G

L
I
G
H
T
: NORMAL METER : A5
METER WITH MID : B5
VDC(diag)-30
E: VDC INDICATOR LIGHT DOES NOT GO OFF
TROUBLE SYMPTOM:
When starting the engine, VDC indicator light is kept ON.
Step Check Yes No
1 READ DTC.
nosis according to
DTC.
Go to step 2.
VDCCM&H/U.
3) Disconnect the connector (i10) or (i11) from
the combination meter.
VDCCM&H/U connector and combination
meter connector.
Normal meter model
(B310) No. 32 (i10) No. 5:
(B310) No. 32 (i11) No. 5:
connector between
VDCCM&H/U and
combination meter.
tor.
Go to step 4.
4 CHECK VDCCM.
VDCCM&H/U.
Normal meter model
nation meter.
Replace the
VDCCM only.
Step Check Yes No
1 READ DTC.
nosis according to
DTC.
Go to step 2.
2 CHECK LAN SYSTEM.
tem?
Perform the diag-
nosis according to
DTC for LAN sys-
tem.
Go to step 3.
VDCCM only.
Repair the combi-
nation meter.
VDC(diag)-31
F: VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT DO NOT GO OFF
Defective engine
VDC OFF switch is shorted.
TROUBLE SYMPTOM:
When starting the engine, VDC OFF indicator light is kept ON.
NOTE:
When pressing the VDC OFF switch for 10 seconds or more, the VDC OFF indicator light goes off and cannot
operate any more. When turning the ignition switch from OFF to ON, the OFF operation enabled status is re-
stored.
Step Check Yes No
1 READ DTC.
nosis according to
DTC.
Go to step 2.
2 CHECK ENGINE. Does the malfunction indicator
light illuminate?
Repair the engine. Go to step 3.
3 CHECK ENGINE COOLANT TEMPERATURE.
Warm up the engine and check if VDC warning
light and VDC OFF indicator light illumination
condition changes.
When the engine coolant tem-
perature is too low, VDC warning
light and VDC OFF indicator light
illuminate. Do the lights go off
when the engine is warmed-up?
Normal operation Go to step 4.
4 CHECK VDC OFF SWITCH.
Remove and check VDC OFF switch.
Is the VDC OFF switch normal? Go to step 5. Replace the VDC
OFF switch.
5 CHECK LAN SYSTEM.
tem?
Perform the diag-
nosis according to
DTC for LAN sys-
tem.
Go to step 6.
VDCCM only.
Repair the combi-
nation meter.
VDC(diag)-32
G: 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.
WIRING DIAGRAM:
B301 B16
1
2
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
13 12 15 14
i10
2 1 3 4 6 7 8 9 10
22 21 20 19 18 17 16 15 14 13 12 11
5
A:
B:
E
MAIN SBF
S
B
F
-
6
E
No.5
8
B301
B36
B16
i1
B38
i3
B404
i10 A:
i11 B:
VDCCM & H/U
A
3
A
7
2
0
1
6
1
5
1
2
1
*
2
*
2
*
B38
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
i1
5 6 7 8
2 1
9
4 3
10
24
22
23 25 27 26 28
11 12 13 14 15 16
17 18 19 20 21
VDC00500
1
*
1 2 3 4 5 6
7 8 9 10 11 12 13 14
i11
BATTERY
IGNITION
SWITCH
P
A
R
K
I
N
G

B
R
A
K
E

F
L
U
I
D

L
E
V
E
L

W
A
R
N
I
N
G

L
I
G
H
T
COMBINATION
METER
PARKING
SWITCH
BRAKE FLUID
LEVEL SWITCH
: NORMAL METER : A8
METER WITH MID : A4
: NORMAL METER : B10
METER WITH MID : A8
VDC(diag)-33
Step Check Yes No
1 CHECK INSTALLATION OF VDCCM&H/U
CONNECTOR.
2) Check that the VDCCM&H/U connector is
inserted until it is locked by clamp.
Is the connector firmly
inserted?
Go to step 2. Insert the
VDCCM&H/U con-
nector until it is
locked by clamp.
2 READ DTC.
nosis according to
DTC.
Go to step 3.
3 CHECK BRAKE FLUID AMOUNT.
Check the amount of brake fluid in the reservoir
tank of master cylinder.
Is the amount of brake fluid
between the lines of MAX and
MIN?
Go to step 4. Replenish brake
fluid to the speci-
fied value.
4 CHECK BRAKE FLUID LEVEL SWITCH.
2) Disconnect the level switch connector (B16)
from master cylinder.
3) Measure the resistance of master cylinder
terminals.
Terminals
No. 1 No. 2:
Is the resistance 1 M or more? Go to step 5. Replace the mas-
ter cylinder.
5 CHECK PARKING BRAKE SWITCH.
1) Disconnect the connector (B404) from park-
ing brake switch.
3) Measure the resistance between parking
brake switch terminal and chassis ground.
Is the resistance 1 M or more? Go to step 6. Replace the park-
ing brake switch.
1) Disconnect the connectors (i10 and i11)
from the combination meter.
Normal meter model
connector between
combination meter
brake fluid level
switch and parking
brake switch.
7 CHECK HARNESS CONNECTOR.
VDCCM&H/U.
nation meter.
VDCCM&H/U connector and combination
meter connector.
(B310) No. 8 (i10) No. 7:
connector between
VDCCM&H/U and
combination meter.
tor.
Go to step 9.
9 CHECK VDCCM.
VDCCM&H/U.
2) Turn the ignition to ON.
nation meter.
Replace the
VDCCM only.
VDC(diag)-34
A: LIST
DTC
Detailed
code
Display Content of diagnosis Reference target
C0021 07B0H
Front Right ABS Sensor
Circuit Open or Shorted
Battery
Open/high input of front
sor RH
<Ref. to VDC(diag)-39, DTC C0021 FRONT
RIGHT ABS SENSOR CIRCUIT OPEN OR
SHORT, Diagnostic Procedure with Diagnostic
C0022
072FH
0736H
0737H
0738H
073AH
073CH
Front Right ABS Sensor
Signal
Front ABS wheel speed
sensor RH signal mal-
function
<Ref. to VDC(diag)-42, DTC C0022 FRONT
RIGHT ABS SENSOR SIGNAL, Diagnostic Pro-
C0023 06B0H
Battery
Open/high input of front
sor LH
<Ref. to VDC(diag)-39, DTC C0023 FRONT LEFT
ABS SENSOR CIRCUIT OPEN OR SHORT,
Code (DTC).>
C0024
062FH
0636H
0637H
0638H
063AH
063CH
Signal
Front ABS wheel speed
sensor LH signal mal-
function
<Ref. to VDC(diag)-42, DTC C0024 FRONT LEFT
ABS SENSOR SIGNAL, Diagnostic Procedure
C0025 09B0H
Rear Right ABS Sensor
Battery
Open/high input of rear
sor RH
<Ref. to VDC(diag)-39, DTC C0025 REAR RIGHT
Code (DTC).>
C0026
092FH
0936H
0937H
0938H
093AH
093CH
Rear Right ABS Sensor
Signal
Rear ABS wheel speed
sensor RH signal mal-
function
<Ref. to VDC(diag)-42, DTC C0026 REAR RIGHT
C0027 08B0H
Battery
Open/high input of rear
sor LH
<Ref. to VDC(diag)-40, DTC C0027 REAR LEFT
Code (DTC).>
C0028
082FH
0836H
0837H
0838H
083AH
083CH
Signal
Rear ABS wheel speed
sensor LH signal mal-
function
<Ref. to VDC(diag)-43, DTC C0028 REAR LEFT
C0029
0A11H
0A21H
0A42H
0A46H
0A50H
Any One of Four ABS
Sensors Signal
sor signal malfunction
in one of four wheels
<Ref. to VDC(diag)-46, DTC C0029 ANY OF
WHEEL SENSORS SIGNAL, Diagnostic Proce-
C0031
0DB8H
0DC0H
FR hold valve malfunc-
tion
Front inlet solenoid
valve RH malfunction in
VDCCM&H/U
<Ref. to VDC(diag)-48, DTC C0031 FR HOLD
VALVE MALFUNCTION, Diagnostic Procedure
C0032
0EB8H
0EC0H
FR pressure reducing
valve malfunction
Front outlet solenoid
VDCCM&H/U
<Ref. to VDC(diag)-48, DTC C0032 FR PRES-
SURE REDUCING VALVE MALFUNCTION,
Code (DTC).>
VDC(diag)-35
C0033
0BB8H
0BC0H
FL hold valve
malfunction
Front inlet solenoid
valve LH malfunction in
VDCCM&H/U
<Ref. to VDC(diag)-48, DTC C0033 FL HOLD
C0034
0CB8H
0CC0H
FL pressure reducing
valve malfunction
Front outlet solenoid
VDCCM&H/U
<Ref. to VDC(diag)-48, DTC C0034 FL PRES-
Code (DTC).>
C0035
11B8H
11C0H
RR hold valve
malfunction
Rear inlet solenoid
VDCCM&H/U
<Ref. to VDC(diag)-48, DTC C0035 RR HOLD
C0036
12B8H
12C0H
RR pressure reducing
valve malfunction
Rear outlet solenoid
VDCCM&H/U
<Ref. to VDC(diag)-48, DTC C0036 RR PRES-
Code (DTC).>
C0037
0FB8H
0FC0H
RL hold valve
malfunction
Rear inlet solenoid
VDCCM&H/U
<Ref. to VDC(diag)-49, DTC C0037 RL HOLD
C0038
10B8H
10C0H
RL pressure reducing
valve malfunction
Rear outlet solenoid
VDCCM&H/U
<Ref. to VDC(diag)-49, DTC C0038 RL PRES-
Code (DTC).>
C0039
0FB5H
11B5H
1AB5H
Any one of four solenoid
valves
Solenoid valve malfunc-
tion in one of four
wheels
<Ref. to VDC(diag)-49, DTC C0039 ANY ONE OF
FOUR SOLENOID VALVES, Diagnostic Proce-
C0041
ECM
VDC control module
malfunction
<Ref. to VDC(diag)-52, DTC C0041 ECM, Diag-
(DTC).>
1620H
1630H
16C0H
Parameter selection
error
VDC control module
parameter selection fail-
ure
<Ref. to VDC(diag)-54, DTC C0041 PARAMETER
SELECTION ERROR, Diagnostic Procedure with
C0042
0316H
031CH
0322H
0324H
Power Supply Voltage
Failure
Power voltage malfunc-
tion
<Ref. to VDC(diag)-55, DTC C0042 POWER
SUPPLY VOLTAGE FAILURE, Diagnostic Proce-
C0044 2921H
TCM communication
circuit
CAN communication
failure of transmission
control module
<Ref. to VDC(diag)-57, DTC C0044 TCM COM-
MUNICATION CIRCUIT, Diagnostic Procedure
C0045
2922H
2932H
Incorrect VDC Control
Module specifications
Different VDC control
module specification
<Ref. to VDC(diag)-58, DTC C0045 INCORRECT
VDC CONTROL MODULE SPECIFICATIONS,
Code (DTC).>
2923H TCM malfunction
AT control module mal-
function
<Ref. to VDC(diag)-59, DTC C0045 TCM MAL-
FUNCTION, Diagnostic Procedure with Diagnos-
DTC
Detailed
code
VDC(diag)-36
C0047
150EH
1512H
1513H
1514H
1518H
1519H
151AH
151BH
151DH
151EH
151FH
1520H
1531H
1540H
15C0H
Improper CAN Commu-
nication
Improper CAN commu-
nication
<Ref. to VDC(diag)-60, DTC C0047 CAN COM-
MUNICATION, Diagnostic Procedure with Diag-
C0051
021FH
0220H
0221H
0280H
0281H
02B0H
02B1H
02C0H
Valve Relay Valve Relay
<Ref. to VDC(diag)-62, DTC C0051 VALVE
RELAY, Diagnostic Procedure with Diagnostic
C0052
0580H Motor and Motor Relay
Motor/motor relay OFF
malfunction
<Ref. to VDC(diag)-64, DTC C0052 MOTOR AND
MOTOR RELAY OFF FAILURE, Diagnostic Pro-
05A0H
Motor and motor relay
ON failure
Motor/motor relay ON
malfunction
<Ref. to VDC(diag)-66, DTC C0052 MOTOR AND
MOTOR RELAY ON FAILURE, Diagnostic Proce-
0560H Motor malfunction Motor
<Ref. to VDC(diag)-67, DTC C0052 MOTOR
MALFUNCTION, Diagnostic Procedure with Diag-
C0054
04B0H Brake Light Switch BLS open circuit
<Ref. to VDC(diag)-68, DTC C0054 BLS CIR-
CUIT OPEN, Diagnostic Procedure with Diagnos-
043CH BLS ON Malfunction BLS ON malfunction
<Ref. to VDC(diag)-70, DTC C0054 BLS ON
04C1H BLS OFF Malfunction BLS OFF malfunction
<Ref. to VDC(diag)-72, DTC C0054 BLS OFF
C0057
2931H
ECM communication
circuit
CAN communication
failure of engine control
module
<Ref. to VDC(diag)-74, DTC C0057 ECM COM-
MUNICATION CIRCUIT, Diagnostic Procedure
2933H ECM control system
Coordinate control
prohibition of engine
control module
<Ref. to VDC(diag)-75, DTC C0057 ECM CON-
TROL SYSTEM, Diagnostic Procedure with Diag-
C0061
19B8H
19C0H
VDC switching valve 1 (S)
Secondary cut valve
malfunction in
VDCCM&H/U
<Ref. to VDC(diag)-49, DTC C0061 NORMAL
OPENING VALVE 1 MALFUNCTION, Diagnostic
C0062
1AB8H
1AC0H
VDC switching valve 1 (P)
Primary cut valve mal-
function in VDCCM&H/U
OPENING VALVE 2 MALFUNCTION, Diagnostic
C0063
1BB8H
1BC0H
VDC switching valve 2 (S)
Secondary suction
valve malfunction in
VDCCM&H/U
CLOSING VALVE 1 MALFUNCTION, Diagnostic
DTC
Detailed
code
VDC(diag)-37
C0064
1CB8H
1CC0H
VDC switching valve 2 (P)
Primary suction valve
malfunction in
VDCCM&H/U
CLOSING VALVE 2 MALFUNCTION, Diagnostic
C0071
2130H
offset is too big
Excessive steering
angle sensor output
offset
<Ref. to VDC(diag)-76, DTC C0071 STEERING
ANGLE SENSOR OFFSET IS TOO BIG, Diag-
(DTC).>
2134H
Change range of steer-
ing angle sensor is too
big
Excessive variation
amount of steering
angle sensor output
<Ref. to VDC(diag)-78, DTC C0071 CHANGE
RANGE OF STEERING ANGLE SENSOR IS
TOO BIG, Diagnostic Procedure with Diagnostic
212EH
2132H
2136H
2138H
213CH
2150H
2151H
2152H
2153H
2154H
2155H
2156H
2157H
2158H
2159H
215AH
malfunction
output
ANGLE SENSOR MALFUNCTION, Diagnostic
2104H
power supply malfunc-
tion
power supply malfunc-
tion
ANGLE SENSOR MALFUNCTION, Diagnostic
C0072
1E03H
1E1AH
1E1EH
1E22H
1E26H
1E28H
1E2CH
1E34H
1E38H
1E3AH
1E3CH
1E3FH
1EACH
Abnormal yaw rate
sensor output
Yaw rate sensor output
<Ref. to VDC(diag)-84, DTC C0072 ABNORMAL
YAW RATE SENSOR OUTPUT, Diagnostic Pro-
1E04H
1E05H
1E07H
Yaw rate sensor
power/output
Yaw rate sensor power
supply/output
<Ref. to VDC(diag)-86, DTC C0072 VOLTAGE
INPUTTED TO YAW RATE SENSOR EXCEEDS
SPECIFICATION, Diagnostic Procedure with
1EAAH
Abnormal yaw rate sen-
sor reference voltage
Yaw rate sensor refer-
ence
YAW RATE SENSOR REFERENCE VOLTAGE,
Code (DTC).>
1E30H
Change range of yaw
rate sensor signal is too
big
Excessive variation
amount of yaw rate
sensor output
<Ref. to VDC(diag)-90, DTC C0072 CHANGE
RANGE OF YAW RATE SENSOR SIGNAL IS
TOO BIG, Diagnostic Procedure with Diagnostic
1E06H
1EABH
1EAEH
Yaw rate sensor
communication
Yaw rate sensor com-
munication
<Ref. to VDC(diag)-93, DTC C0072 YAW RATE
SENSOR COMMUNICATION, Diagnostic Proce-
DTC
Detailed
code
VDC(diag)-38
C0073
1D46H
1D47H
Lateral G sensor offset
is too big
Excessive amount of
lateral G sensor output
offset
<Ref. to VDC(diag)-95, DTC C0073 LATERAL G
SENSOR OFFSET IS TOO BIG, Diagnostic Pro-
1D44H
1D45H
1DA0H
1DA2H
Abnormal lateral
G sensor output
Lateral G sensor output
LATERAL G SENSOR OUTPUT, Diagnostic Pro-
1D49H
Excessive lateral
G sensor signal
Excessive lateral
G sensor output
<Ref. to VDC(diag)-96, DTC C0073 EXCESSIVE
LATERAL G SENSOR SIGNAL, Diagnostic Pro-
1DA4H
Lateral G sensor
communication
Lateral G sensor
communication
<Ref. to VDC(diag)-92, DTC C0073 LATERAL G
SENSOR COMMUNICATION, Diagnostic Proce-
C0074
1F4EH
1F90H
1FA1H
1FB0H
1FB1H
1FC0H
Pressure sensor Pressure sensor
<Ref. to VDC(diag)-98, DTC C0074 PRESSURE
SENSOR, Diagnostic Procedure with Diagnostic
C0081
2201H
2202H
System malfunction System malfunction
<Ref. to VDC(diag)-99, DTC C0081 SYSTEM
FAILURE, Diagnostic Procedure with Diagnostic
DTC
Detailed
code
VDC(diag)-39
A: DTC C0021 FRONT RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT
NOTE:
For the diagnostic procedure, refer to DTC C0027 RL WHEEL SPEED SENSOR CIRCUIT OPEN/HIGH IN-
PUT. <Ref. to VDC(diag)-40, DTC C0027 REAR LEFT ABS SENSOR CIRCUIT OPEN OR SHORT, Diag-
B: DTC C0023 FRONT LEFT ABS SENSOR CIRCUIT OPEN OR SHORT
NOTE:
C: DTC C0025 REAR RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT
NOTE:
VDC(diag)-40
D: DTC C0027 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:
4 3 1
2
6
2
7
2
2
5
B98
R72
R2
E
12
1
5
1
4
6 5
R73
12
B6 B15
R73
R72
1 2
1 2 2 1
6 5
B310
21
B15
B6
VDCCM & H/U
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00501
B98
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
FRONT ABS
WHEEL SPEED
SENSOR LH
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
VDC(diag)-41
Step Check Yes No
Check if there is poor contact between
VDCCM&H/U and ABS wheel speed sensor.
tor.
Go to step 2.
VDCCM&H/U AND ABS WHEEL SPEED
SENSOR.
VDCCM&H/U.
2) Disconnect the connector from the ABS
wheel speed sensor.
VDCCM&H/U connector and ABS wheel speed
sensor connector.
DTC C0021
(B310) No. 6 (B6) No. 1:
(B310) No. 5 (B6) No. 2:
DTC C0023
(B310) No. 1 (B15) No. 1:
(B310) No. 26 (B15) No. 2:
DTC C0025
(B310) No. 3 (R72) No. 1:
(B310) No. 4 (R72) No. 2:
DTC C0027
(B310) No. 2 (R73) No. 1:
(B310) No. 27 (R73) No. 2:
connector between
VDCCM&H/U and
ABS wheel speed
sensor.
DTC C0021
DTC C0023
DTC C0025
DTC C0027
connector between
VDCCM&H/U and
ABS wheel speed
sensor.
1) Connect the VDCCM&H/U connector.
3) Measure the voltage between ABS wheel
speed sensor connector and chassis ground.
DTC C0021
DTC C0023
DTC C0025
DTC C0027
VDC(diag)-42
E: DTC C0022 FRONT RIGHT ABS SENSOR SIGNAL
NOTE:
For the diagnostic procedure, refer to DTC C0028 RL WHEEL SPEED SENSOR SIGNAL. <Ref. to VDC(di-
ag)-43, DTC C0028 REAR LEFT ABS SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
F: DTC C0024 FRONT LEFT ABS SENSOR SIGNAL
NOTE:
Code (DTC).>
G: DTC C0026 REAR RIGHT ABS SENSOR SIGNAL
NOTE:
Code (DTC).>
5 CHECK THE VDCCM&H/U POWER SUPPLY
CIRCUIT.
2) Disconnect the VDCCM&H/U connector.
4) Measure the voltage between VDCCM&H/U
(B310) No. 28 (+) (B310) No. 25 ():
Is the voltage 10 15 V? Go to step 6. Check the genera-
tor, battery and
VDCCM&H/U
power supply cir-
cuit.
SIGNAL.
INSPECTION, Rear ABS Wheel Speed Sen-
sor.>
Is the pattern the same wave-
form as shown in the figure?
Go to step 7. Replace the ABS
wheel speed sen-
sor.
7 CHECK THE VDCCM&H/U.
Mode.>
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 8.
nosis according to
DTC.
It results from a
temporary noise
interference.
Step Check Yes No
VDC(diag)-43
H: DTC C0028 REAR LEFT ABS SENSOR SIGNAL
Defective ABS wheel speed sensor signal (noise, irregular signal, etc.)
TROUBLE SYMPTOM:
WIRING DIAGRAM:
4 3 1
2
6
2
7
2
2
5
B98
R72
R2
E
12
1
5
1
4
6 5
R73
12
B6 B15
R73
R72
1 2
1 2 2 1
6 5
B310
21
B15
B6
VDCCM & H/U
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00501
B98
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
FRONT ABS
WHEEL SPEED
SENSOR LH
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
VDC(diag)-44
Step Check Yes No
1 CHECK OUTPUT OF ABS WHEEL SPEED
SENSOR USING SUBARU SELECT
MONITOR.
2) Read the defective ABS wheel speed sen-
sor output.
Does the speed indicated on
the display change in response
to the speedometer reading
during acceleration/decelera-
tion when the steering wheel is
in the straight-ahead position?
tors between VDCCM&H/U and
ABS wheel speed sensor?
Repair the connec-
tor.
Go to step 3.
wave devices and
electronic compo-
nents properly.
Are noise sources installed? Install the noise
sources apart from
sensor harness.
Go to step 5.
Mode.>
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 6.
nosis according to
DTC.
It results from a
temporary noise
interference.
SPEED SENSOR.
Is the ABS wheel speed sensor
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?
wheel speed sen-
sor installation
bolts.
SIGNAL.
sor.>
9 CHECK ABS WHEEL SPEED SENSOR OR
MAGNETIC ENCODER.
netic encoder?
Remove dirt thor-
oughly. Also
replace the ABS
wheel speed sen-
sor or magnetic
encoder as a unit
with hub unit bear-
damaged.
Go to step 10.
wave devices and
electronic compo-
nents properly.
Is the noise sources installed? Go to step 12. Install the noise
sources apart from
sensor harness.
VDC(diag)-45
Mode.>
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 13.
nosis according to
DTC.
It results from a
temporary noise
interference.
NOTE:
Though the ABS
warning light re-
mains on at this
time, it is normal.
12 km/h (7 MPH)
or more in order to
turn ABS warning
drive the vehicle
and check that the
warning light goes
off.
Step Check Yes No
VDC(diag)-46
I: DTC C0029 ANY OF WHEEL SENSORS SIGNAL
Defective ABS wheel speed sensor signal (noise, irregular signal, etc.)
Defective magnetic encoder
When a wheel is turned freely for a long time
TROUBLE SYMPTOM:
NOTE:
Brake warning light illuminates as well as ABS warning light when EBD does not operate.
WIRING DIAGRAM:
4 3 1
2
6
2
7
2
2
5
B98
R72
R2
E
12
1
5
1
4
6 5
R73
12
B6 B15
R73
R72
1 2
1 2 2 1
6 5
B310
21
B15
B6
VDCCM & H/U
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00501
B98
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
FRONT ABS
WHEEL SPEED
SENSOR LH
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
VDC(diag)-47
Step Check Yes No
OR NOT.
Check if the wheels have been turned freely for
one minute or more, such as when the vehicle is
jacked-up, under full-lock cornering or when the
wheels are not in contact with road surface.
Did the wheels turn freely? VDC is normal.
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 jacked-
up, or when steer-
ing wheel is contin-
uously turned all
the way.
Go to step 2.
2 CHECK TIRE SPECIFICATIONS.
Are the tire specifications
correct?
3 CHECK WEAR OF TIRE. Is the tire worn excessively? Replace the tire. Go to step 4.
4 CHECK TIRE INFLATION PRESSURE. Is the tire pressure correct? Go to step 5. Adjust the tire
pressure.
SPEED SENSOR.
Are the ABS wheel speed sen-
sor installation bolts tightened
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?
(For four wheels)
wheel speed sen-
sor installation
bolts.
SIGNAL.
sor.>
7 CHECK ABS WHEEL SPEED SENSOR OR
MAGNETIC ENCODER.
netic encoder?
Remove dirt thor-
oughly. Also
replace the ABS
wheel speed sen-
sor or magnetic
encoder as a unit
with hub unit bear-
damaged.
Go to step 8.
Mode.>
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 9.
VDC(diag)-48
J: DTC C0031 FR HOLD VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC C0064 VDC SWITCHING VALVE 2 (P). <Ref. to VDC(diag)-50,
DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
K: DTC C0032 FR PRESSURE REDUCING VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC C0064 VDC SWITCHING VALVE 2 (P). <Ref. to VDC(diag)-50,
DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
L: DTC C0033 FL HOLD VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to C0064 VDC SWITCHING VALVE 2 (P). <Ref. to VDC(diag)-50, DTC
C0064 NORMAL CLOSING VALVE 2 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
M: DTC C0034 FL PRESSURE REDUCING VALVE MALFUNCTION
NOTE:
(DTC).>
N: DTC C0035 RR HOLD VALVE MALFUNCTION
NOTE:
(DTC).>
O: DTC C0036 RR PRESSURE REDUCING VALVE MALFUNCTION
NOTE:
(DTC).>
nosis according to
DTC.
It results from a
temporary noise
interference.
NOTE:
Though the ABS
warning light re-
mains on at this
time, it is normal.
12 km/h (7 MPH)
or more in order to
turn ABS warning
drive the vehicle
and check that the
warning light goes
off.
Step Check Yes No
VDC(diag)-49
P: DTC C0037 RL HOLD VALVE MALFUNCTION
NOTE:
(DTC).>
Q: DTC C0038 RL PRESSURE REDUCING VALVE MALFUNCTION
NOTE:
(DTC).>
R: DTC C0039 ANY ONE OF FOUR SOLENOID VALVES
NOTE:
(DTC).>
S: DTC C0061 NORMAL OPENING VALVE 1 MALFUNCTION
NOTE:
(DTC).>
T: DTC C0062 NORMAL OPENING VALVE 2 MALFUNCTION
NOTE:
(DTC).>
U: DTC C0063 NORMAL CLOSING VALVE 1 MALFUNCTION
NOTE:
(DTC).>
VDC(diag)-50
V: DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION
Defective VDCH/U solenoid valve
TROUBLE SYMPTOM:
WIRING DIAGRAM:
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
3
3
B310
E
E
2
5
2
8
VDCCM & H/U
BATTERY
GENERATOR
IGNITION
SWITCH
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00463
VDC(diag)-51
Step Check Yes No
1 CHECK THE VDCCM&H/U INPUT VOLTAGE.
VDCCM&H/U.
Is the voltage 10 15 V? Go to step 2. Repair the power
supply circuit.
2 CHECK THE VDCCM&H/U GROUND CIRCUIT.
VDCCM&H/U
ground harness.
3 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connec-
and VDCCM&H/U?
Repair the connec-
tor.
Go to step 4.
4) Read the DTC.
VDCCM&H/U.
<Ref. to VDC-7,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 5.
nosis according to
DTC.
Temporary poor
contact occurs.
VDC(diag)-52
W: DTC C0041 ECM
Defective VDCCM&H/U
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDCCM & H/U
2
5
B310
E
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00464
VDC(diag)-53
Step Check Yes No
VDCCM&H/U.
VDCCM&H/U and chassis ground.
VDCCM&H/U
ground harness.
2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact of the con-
nector between the battery, igni-
tion switch and VDCCM&H/U?
Repair the connec-
tor.
Go to step 3.
3 CHECK CAUSE OF SIGNAL NOISE. Are the radio wave devices and
wave devices and
electronic compo-
nents properly.
4 CHECK CAUSE OF SIGNAL NOISE. Is there a noise source (such as
an antenna) installed near the
sensor harness?
Install the noise
sources apart from
the sensor har-
ness.
Go to step 5.
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 6.
nosis according to
DTC. <Ref. to
VDC(diag)-34, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
VDC(diag)-54
X: DTC C0041 PARAMETER SELECTION ERROR
VDCCM parameter selection failure
TROUBLE SYMPTOM:
NOTE:
When the VDCCM or VDCCM&H/U is replaced, this DTC may be memorized.
Step Check Yes No
1 CHECK VDCCM&H/U REPLACEMENT
HISTORY.
Is there replacement history of
VDCCM alone?
2 CHECK VDCCM IDENTIFICATION NUMBER.
Check the identification number on the sticker
attached on the VDCCM side.
Is the identification number cor-
rect?
AT: T3
MT: T4
VDCCM only.
3 CHECK VDCCM&H/U IDENTIFICATION
NUMBER.
Check the identification number stamped on the
upper side of the H/U.
rect?
AT: T3
MT: T4
VDCCM&H/U.
4 CHECK PARAMETER SELECTED FOR
VDCCM.
<Ref. to VDC(diag)-17, PARAMETER CHECK,
Does the parameter registered
to the VDCCM match with the
target vehicle?
Replace the
VDCCM only.
Select and register
the correct param-
eter. <Ref. to
VDC(diag)-17,
PARAMETER
SELECTION,
OPERATION, Sub-
aru Select Moni-
tor.>
VDC(diag)-55
Y: DTC C0042 POWER SUPPLY VOLTAGE FAILURE
CHECK THE VDCCM&H/U power supply voltage.
TROUBLE SYMPTOM:
NOTE:
Warning lights go off if voltage returns.
WIRING DIAGRAM:
M
A
I
N

S
B
F
S
B
F
-
6
N
o
.
3
3
B310
E
E
2
5
2
8
VDCCM & H/U
BATTERY
GENERATOR
IGNITION
SWITCH
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00463
VDC(diag)-56
Step Check Yes No
1 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 ():
Is the voltage 10 15 V? Go to step 2. Repair the genera-
tor.
2 CHECK BATTERY TERMINAL.
Are the positive and negative
battery terminals clamped
tightly?
Go to step 3. Tighten the termi-
nal.
VDCCM&H/U.
3) Operate devices such as headlights, air
conditioner, defogger, etc. which produce an
electrical load.
supply circuit.
VDCCM&H/U
ground harness.
and VDCCM&H/U?
Repair the connec-
tor.
Go to step 6.
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 7.
nosis according to
DTC. <Ref. to
VDC(diag)-34, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
VDC(diag)-57
Z: DTC C0044 TCM COMMUNICATION CIRCUIT
No CAN signal from TCM.
TROUBLE SYMPTOM:
Step Check Yes No
1 CHECK LAN SYSTEM.
tem?
Perform the diag-
nosis according to
DTC for LAN sys-
tem.
Go to step 2.
connector?
Repair the connec-
tor.
Go to step 3.
3 CHECK TCM. Is the TCM normal? Go to step 4. Replace the TCM.
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).> <Ref. to
5AT-59, Transmis-
sion Control Mod-
ule (TCM).>
4) Read the DTC.
VDCCM only.
Go to step 5.
nosis according to
DTC.
It results from a
temporary noise
interference.
VDC(diag)-58
AA:DTC C0045 INCORRECT VDC CONTROL MODULE SPECIFICATIONS
Different control module specification
TROUBLE SYMPTOM:
NOTE:
When parameter selection for VDCCM is improper, this DTC may be memorized.
Step Check Yes No
1 CHECK VDCCM REPLACEMENT HISTORY. Is there replacement history of
VDCCM alone?
2 CHECK VDCCM IDENTIFICATION NUMBER.
Check the identification number on the sticker
attached on the VDCCM side.
rect?
AT: T3
MT: T4
VDCCM only.
3 CHECK VDCCM&H/U IDENTIFICATION
NUMBER.
Check the identification number stamped on the
upper side of the H/U.
rect?
AT: T3
MT: T4
VDCCM&H/U.
4 CHECK PARAMETER SELECTED FOR VDCCM.
<Ref. to VDC(diag)-17, PARAMETER CHECK,
Does the parameter registered
to the VDCCM match with the
target vehicle?
Go to step 5. Select and register
the correct param-
eter. <Ref. to
VDC(diag)-17,
PARAMETER
SELECTION,
OPERATION, Sub-
aru Select Moni-
tor.>
5 CHECK TCM SPECIFICATION.
Check the TCM specification.
Is the specification of TCM
same as vehicle specification?
<Ref. to 4AT-64,
Transmission Con-
trol Module
(TCM).> <Ref. to
5AT-59, Transmis-
sion Control Mod-
ule (TCM).>
6 CHECK AT SYSTEM.
2) Check the DTC in AT system.
Is DTC of AT system displayed? Repair the AT sys-
tem.
Go to step 7.
7 CHECK ECM SPECIFICATION.
Check the ECM specification.
Is the specification of ECM
same as vehicle specification?
Go to step 8. Replace the ECM.
<Ref. to
FU(H4SO)-37,
Engine Control
Module (ECM).>
<Ref. to
FU(H4DOTC)-45,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-37,
Engine Control
Module (ECM).>
4) Read the DTC.
VDCCM only.
Go to step 9.
VDC(diag)-59
AB:DTC C0045 TCM MALFUNCTION
Defective TCM
TROUBLE SYMPTOM:
nosis according to
DTC.
It results from a
temporary noise
interference.
Step Check Yes No
1 CHECK AT SYSTEM.
2) Check the DTC in AT system.
Is DTC of AT system displayed? Repair the AT sys-
tem.
Go to step 2.
4) Read the DTC.
VDCCM only.
Go to step 3.
nosis according to
DTC.
It results from a
temporary noise
interference.
Step Check Yes No
VDC(diag)-60
AC:DTC C0047 CAN COMMUNICATION
CAN communication line circuit is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDC00473
1 2 3 4
B310 VDCCM & H/U
2
5
1
0
3
5
B231
B230
24 114 2 3
3
STEERING
ANGLE
SENSOR
YAW RATE &
LATERAL G
SENSOR
E
E
B231
S
B
F
-
6
MAIN SBF
N
o
.
3
3
E
IGNITION
SWITCH
BATTERY
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
B230
1
2
3
4
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
B365
B170
CAN
JOINT
CONNECTOR
4
*
3
*
4
3
*
*
2
1 :
:
*
*
CAN
JOINT
CONNECTOR
ARRANGEMENT AMONG
1, 2, 3,11,12 AND 13
ARRANGEMENT AMONG
8, 9, 10, 18, 19 AND 20
4
3 :
:
*
*
ARRANGEMENT AMONG
1, 2, 5 AND 6
ARRANGEMENT AMONG
3, 4, 7 AND 8
2 1
**
2 1
**
2
1
*
*
TWISTED
PAIR LINE
B170
3 4
5 6
1 2
7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B365
VDC(diag)-61
Step Check Yes No
1 CHECK LAN SYSTEM.
tem?
Perform the diag-
nosis according to
DTC for LAN sys-
tem.
Go to step 2.
2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in
VDCCM&H/U connector?
Repair the connec-
tor.
Go to step 3.
3 CHECK OUTPUT OF STEERING ANGLE
SENSOR.
Connect the Subaru Select Monitor and check
output of the steering angle sensor.
Does the output signal change? Go to step 4. Check output of
the steering angle
sensor. <Ref. to
VDC(diag)-80,
DTC C0071
STEERING
ANGLE SENSOR
MALFUNCTION,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
4 CHECK OUTPUT OF YAW RATE & LATERAL
G SENSOR.
Connect the Subaru Select Monitor and check
output of the yaw rate & lateral G sensor.
Does the output signal change? Go to step 5. Check output of
the yaw rate & lat-
eral G sensor.
<Ref. to
VDC(diag)-93,
DTC C0072 YAW
RATE SENSOR
COMMUNICA-
TION, Diagnostic
Procedure with
Diagnostic Trouble
Code (DTC).>
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Temporary poor
contact occurs.
VDC(diag)-62
AD:DTC C0051 VALVE RELAY
Defective valve relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
E
2
4
2
5
VDCCM & H/U
2
8
P
U
M
P

M
O
T
O
R
M
F
L

I
N
L
E
T
MAIN SBF
S
B
F
-
6
N
o
.
1
N
o
.
3
3
E
BATTERY
IGNITION
SWITCH
S
O
L
E
N
O
I
D

V
A
L
V
E

F
R

I
N
L
E
T
R
L

I
N
L
E
T
R
R

I
N
L
E
T
F
L

O
U
T
L
E
T
F
R

O
U
T
L
E
T
R
L

O
U
T
L
E
T
R
R

O
U
T
L
E
T
P
R
I
M
A
R
Y

C
U
T
S
E
C
O
N
D
A
R
Y

C
U
T
P
R
I
M
A
R
Y

S
U
C
T
I
O
N
M
O
T
O
R

R
E
L
A
Y
VALVE RELAY
S
E
C
O
N
D
A
R
Y

S
U
C
T
I
O
N
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00466
VDC(diag)-63
Step Check Yes No
VDCCM&H/U.
supply circuit.
Calculate the voltage difference measured in
step 1.
A: (B310) No. 28 (+) Chassis ground ():
B: (B310) No. 24 (+) Chassis ground ():
Is the voltage difference
between A and B 2 V or more?
Repair the power
supply circuit.
Go to step 3.
VDCCM&H/U
ground harness.
4 CHECK THE VDCCM&H/U VALVE RELAY.
(B310) No. 24 (B310) No. 25:
VDCCM&H/U.
and VDCCM&H/U?
Repair the connec-
tor.
Go to step 6.
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 7.
nosis according to
DTC.
Temporary poor
contact occurs.
VDC(diag)-64
AE:DTC C0052 MOTOR AND MOTOR RELAY OFF FAILURE
Defective motor and motor relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
E
2
3
2
5
VDCCM & H/U
2
8
P
U
M
P

M
O
T
O
R
M
F
L

I
N
L
E
T
MAIN SBF
S
B
F
-
6
N
o
.
3
3
E
BATTERY
IGNITION
SWITCH
S
O
L
E
N
O
I
D

V
A
L
V
E
M
O
T
O
R

R
E
L
A
Y
VALVE RELAY
F
R

I
N
L
E
T
R
L

I
N
L
E
T
R
R

I
N
L
E
T
F
L

O
U
T
L
E
T
F
R

O
U
T
L
E
T
R
L

O
U
T
L
E
T
R
R

O
U
T
L
E
T
P
R
I
M
A
R
Y

C
U
T
S
E
C
O
N
D
A
R
Y

C
U
T
P
R
I
M
A
R
Y

S
U
C
T
I
O
N
SBF-1
E
2
2
S
E
C
O
N
D
A
R
Y

S
U
C
T
I
O
N
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00467
VDC(diag)-65
Step Check Yes No
VDCCM&H/U.
VDCCM&H/U
power supply cir-
cuit.
2 CHECK INSTALLATION OF MOTOR
GROUND.
Is the motor ground terminal
33 Nm (3.4 kgf-m, 24.3 ft-lb)?
Go to step 3. Tighten the motor
ground terminal
installation bolt.
VDCCM&H/U
ground harness.
4 CHECK VDCCM&H/U MOTOR RELAY.
Terminals
No. 23 No. 22:
VDCCM&H/U.
5 CHECK POOR CONTACT IN CONNECTORS.
and VDCCM&H/U?
Repair the connec-
tor.
Go to step 6.
4) Read the DTC.
VDCCM&H/U.
<Ref. to VDC-7,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 7.
nosis according to
DTC. <Ref. to
VDC(diag)-34, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
NOTE:
Though the ABS
warning light re-
mains on at this
time, it is normal.
12 km/h (7 MPH)
or more in order to
turn ABS warning
drive the vehicle
and check that the
warning light goes
off.
VDC(diag)-66
AF:DTC C0052 MOTOR AND MOTOR RELAY ON FAILURE
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
E
2
3
2
5
VDCCM & H/U
2
8
P
U
M
P

M
O
T
O
R
M
F
L

I
N
L
E
T
MAIN SBF
S
B
F
-
6
N
o
.
3
3
E
BATTERY
IGNITION
SWITCH
S
O
L
E
N
O
I
D

V
A
L
V
E
M
O
T
O
R

R
E
L
A
Y
VALVE RELAY
F
R

I
N
L
E
T
R
L

I
N
L
E
T
R
R

I
N
L
E
T
F
L

O
U
T
L
E
T
F
R

O
U
T
L
E
T
R
L

O
U
T
L
E
T
R
R

O
U
T
L
E
T
P
R
I
M
A
R
Y

C
U
T
S
E
C
O
N
D
A
R
Y

C
U
T
P
R
I
M
A
R
Y

S
U
C
T
I
O
N
SBF-1
E
2
2
S
E
C
O
N
D
A
R
Y

S
U
C
T
I
O
N
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00467
VDC(diag)-67
AG:DTC C0052 MOTOR MALFUNCTION
Defective motor
TROUBLE SYMPTOM:
NOTE:
For the diagnostic procedure, refer to DTC C0052 MOTOR/MOTOR RELAY OFF FAILURE. <Ref. to
VDC(diag)-64, DTC C0052 MOTOR AND MOTOR RELAY OFF FAILURE, Diagnostic Procedure with Diag-
Step Check Yes No
1 CHECK VDCCM&H/U MOTOR RELAY.
VDCCM&H/U.
VDCCM&H/U connector terminals.
Terminals
No. 23 No. 22:
VDCCM&H/U.
<Ref. to VDC-7,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 3.
nosis according to
DTC. <Ref. to
VDC(diag)-34, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
NOTE:
Though the ABS
warning light re-
mains on at this
time, it is normal.
12 km/h (7 MPH)
or more in order to
turn ABS warning
drive the vehicle
and check that the
warning light goes
off.
VDC(diag)-68
AH:DTC C0054 BLS CIRCUIT OPEN
TROUBLE SYMPTOM:
WIRING DIAGRAM:
1 2
3 4
9
4
7 6
2 1
5
3
8
B65 B159
B310
3
0
VDCCM & H/U
5
9
B159
B225
B65
3
2
E
M
A
I
N

S
B
F
S
B
F
-
2
N
o
.
8
7
.
5
A
3
4
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00502
B225
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
BATTERY
STOP LIGHT
SWITCH
FUSE
(RELAY BLOCK)
VDC(diag)-69
Step Check Yes No
WITH SUBARU SELECT MONITOR.
2) Release the brake pedal.
Select Monitor.
Is OFF displayed on the display
screen?
Select Monitor.
Is ON displayed on the display
screen?
3 CHECK IF STOP LIGHTS COME ON.
Depress the brake pedal.
Does the stop light illuminate? Go to step 4. Repair the stop
light circuit.
4 CHECK FUSE.
Check the fuse (B225).
Is the fuse OK? Go to step 5. Replace the fuse.
5 CHECK OPEN CIRCUIT OF HARNESS.
VDCCM&H/U.
between stop light
switch and
VDCCM&H/U con-
nector.
tor between stop light switch
and VDCCM&H/U?
Repair the connec-
tor.
Go to step 7.
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 8.
nosis according to
DTC.
Temporary poor
contact occurs.
VDC(diag)-70
AI: DTC C0054 BLS ON MALFUNCTION
TROUBLE SYMPTOM:
WIRING DIAGRAM:
1 2
3 4
9
4
7 6
2 1
5
3
8
B65 B159
B310
3
0
VDCCM & H/U
5
9
B159
B225
B65
3
2
E
M
A
I
N

S
B
F
S
B
F
-
2
N
o
.
8
7
.
5
A
3
4
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00502
B225
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
BATTERY
STOP LIGHT
SWITCH
FUSE
(RELAY BLOCK)
VDC(diag)-71
Step Check Yes No
2) Disconnect the stop light switch connector.
3) Measure the resistance of stop light switch
terminals.
Is the resistance 1 M or more
when switch is OFF
(when pedal is not depressed)?
light switch.
2 INTERVIEWING CUSTOMERS.
Make sure that the operation was performed in
which accelerator pedal and brake pedal were
depressed simultaneously (with depressing
brake pedal with left foot).
Were the acceleration pedal
and brake pedal depressed
simultaneously?
System is normal.
(DTC may be
recorded while
brake is applied
during driving.)
Go to step 3.
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 4.
nosis according to
DTC. <Ref. to
VDC(diag)-34, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
VDC(diag)-72
AJ:DTC C0054 BLS OFF MALFUNCTION
TROUBLE SYMPTOM:
WIRING DIAGRAM:
1 2
3 4
9
4
7 6
2 1
5
3
8
B65 B159
B310
3
0
VDCCM & H/U
5
9
B159
B225
B65
3
2
E
M
A
I
N

S
B
F
S
B
F
-
2
N
o
.
8
7
.
5
A
3
4
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
VDC00502
B225
13
14
15 16
17
27
24
25
26
20
21
22
23
29
30
31 28 32 35
33
34
37
38
39 36 40
8
9
10
11 12
1 2
5
3 4
7
6
19
18
BATTERY
STOP LIGHT
SWITCH
FUSE
(RELAY BLOCK)
VDC(diag)-73
Step Check Yes No
2) Disconnect the stop light switch connector.
3) Measure the resistance of stop light switch
terminals.
Is the resistance 0.5 or less
when the switch is ON
(when pedal is depressed)?
light switch.
2 CHECK POWER SUPPLY OF STOP LIGHT
SWITCH.
Measure the voltage between the stop light
switch terminal and chassis ground.
supply circuit of
stop light.
3 CHECK STOP LIGHT SWITCH HARNESS.
VDCCM&H/U.
VDCCM&H/U and stop light switch.
(B65) No. 3 (B310) No. 30:
Is the resistance less than 0.5 ? Go to step 4. Repair the stop
light switch circuit.
tor between stop light switch
and VDCCM&H/U?
Repair the connec-
tor.
Go to step 5.
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 6.
nosis according to
DTC.
Temporary poor
contact occurs.
VDC(diag)-74
AK:DTC C0057 ECM COMMUNICATION CIRCUIT
No CAN signal from ECM.
TROUBLE SYMPTOM:
Step Check Yes No
1 CHECK LAN SYSTEM.
tem?
Perform the diag-
nosis according to
DTC for LAN sys-
tem.
Go to step 2.
2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in ECM
connector?
Repair the connec-
tor.
Go to step 3.
3 CHECK ECM. Is ECM normal? Go to step 4. Replace the ECM.
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 5.
nosis according to
DTC.
It results from a
temporary noise
interference.
VDC(diag)-75
AL:DTC C0057 ECM CONTROL SYSTEM
ECM coordinate control prohibition
TROUBLE SYMPTOM:
NOTE:
Warning lights go off if ECM coordinate control is recovered.
Step Check Yes No
1 CHECK WARNING LIGHT.
Check whether the VDC warning light illumi-
nates after driving for more than 1 minute at a
speed of 10 km/h or more.
Does the VDC warning light illu-
minate?
Go to step 2. VDC is normal.
Perform the Clear
Memory Mode.
NOTE:
If cranking opera-
tion is performed
while driving, DTC
may be memo-
rized.
2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in ECM
connector?
Repair the connec-
tor.
Go to step 3.
3 CHECK ECM. Is ECM normal? Go to step 4. Replace the ECM.
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 5.
nosis according to
DTC.
It results from a
temporary noise
interference.
VDC(diag)-76
AM:DTC C0071 STEERING ANGLE SENSOR OFFSET IS TOO BIG
Defective steering angle sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDC00473
1 2 3 4
B310 VDCCM & H/U
2
5
1
0
3
5
B231
B230
24 114 2 3
3
STEERING
ANGLE
SENSOR
YAW RATE &
LATERAL G
SENSOR
E
E
B231
S
B
F
-
6
MAIN SBF
N
o
.
3
3
E
IGNITION
SWITCH
BATTERY
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
B230
1
2
3
4
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
B365
B170
CAN
JOINT
CONNECTOR
4
*
3
*
4
3
*
*
2
1 :
:
*
*
CAN
JOINT
CONNECTOR
ARRANGEMENT AMONG
1, 2, 3,11,12 AND 13
ARRANGEMENT AMONG
8, 9, 10, 18, 19 AND 20
4
3 :
:
*
*
ARRANGEMENT AMONG
1, 2, 5 AND 6
ARRANGEMENT AMONG
3, 4, 7 AND 8
2 1
**
2 1
**
2
1
*
*
TWISTED
PAIR LINE
B170
3 4
5 6
1 2
7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B365
VDC(diag)-77
Step Check Yes No
1 CHECK STEERING WHEEL.
1) Drive the vehicle on a flat road.
2) Park the vehicle straight.
3) Check the steering wheel for deviation from
center.
Is the deviation from the center
of steering wheel less than 5?
Go to step 2. Perform the cen-
tering adjustment
of steering wheel.
5) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 3.
nosis according to
DTC. <Ref. to
VDC(diag)-34, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
VDC(diag)-78
AN:DTC C0071 CHANGE RANGE OF STEERING ANGLE SENSOR IS TOO BIG
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDC00473
1 2 3 4
B310 VDCCM & H/U
2
5
1
0
3
5
B231
B230
24 114 2 3
3
STEERING
ANGLE
SENSOR
YAW RATE &
LATERAL G
SENSOR
E
E
B231
S
B
F
-
6
MAIN SBF
N
o
.
3
3
E
IGNITION
SWITCH
BATTERY
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
B230
1
2
3
4
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
B365
B170
CAN
JOINT
CONNECTOR
4
*
3
*
4
3
*
*
2
1 :
:
*
*
CAN
JOINT
CONNECTOR
ARRANGEMENT AMONG
1, 2, 3,11,12 AND 13
ARRANGEMENT AMONG
8, 9, 10, 18, 19 AND 20
4
3 :
:
*
*
ARRANGEMENT AMONG
1, 2, 5 AND 6
ARRANGEMENT AMONG
3, 4, 7 AND 8
2 1
**
2 1
**
2
1
*
*
TWISTED
PAIR LINE
B170
3 4
5 6
1 2
7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B365
VDC(diag)-79
Step Check Yes No
5) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 2.
nosis according to
DTC. <Ref. to
VDC(diag)-34, List
of Diagnostic Trou-
ble Code (DTC).>
Temporary poor
contact occurs.
VDC(diag)-80
AO:DTC C0071 STEERING ANGLE SENSOR MALFUNCTION
Signal does not come from steering angle sensor.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
Step Check Yes No
1 CHECK POWER SUPPLY FOR STEERING
ANGLE SENSOR.
2) Disconnect the connector from steering
angle sensor.
4) Measure the voltage between the steering
angle sensor and chassis ground.
supply circuit of
steering angle sen-
sor.
VDC00473
1 2 3 4
B310 VDCCM & H/U
2
5
1
0
3
5
B231
B230
24 114 2 3
3
STEERING
ANGLE
SENSOR
YAW RATE &
LATERAL G
SENSOR
E
E
B231
S
B
F
-
6
MAIN SBF
N
o
.
3
3
E
IGNITION
SWITCH
BATTERY
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
B230
1
2
3
4
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
B365
B170
CAN
JOINT
CONNECTOR
4
*
3
*
4
3
*
*
2
1 :
:
*
*
CAN
JOINT
CONNECTOR
ARRANGEMENT AMONG
1, 2, 3,11,12 AND 13
ARRANGEMENT AMONG
8, 9, 10, 18, 19 AND 20
4
3 :
:
*
*
ARRANGEMENT AMONG
1, 2, 5 AND 6
ARRANGEMENT AMONG
3, 4, 7 AND 8
2 1
**
2 1
**
2
1
*
*
TWISTED
PAIR LINE
B170
3 4
5 6
1 2
7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B365
VDC(diag)-81
2 CHECK GROUND CIRCUIT OF STEERING
ANGLE SENSOR.
Measure the resistance between steering angle
sensor and chassis ground.
Is the resistance less than 0.5 ? Go to step 3. Repair ground cir-
cuit in the steering
angle sensor.
3 CHECK STEERING ANGLE SENSOR
HARNESS.
VDCCM&H/U.
VDCCM&H/U and steering angel sensor.
(B231) No. 1 (B310) No. 10:
(B231) No. 2 (B310) No. 35:
between the steer-
ing angle sensor
and VDCCM&H/U.
4 CHECK GROUND SHORT CIRCUIT OF
STEERING ANGLE SENSOR HARNESS.
between the steer-
ing angle sensor
and VDCCM&H/U.
5 CHECK STEERING ANGLE SENSOR.
5) Read the DTC.
Is the same DTC displayed? Go to step 6. Go to step 8.
2) Replace the steering angle sensor.
5) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 9.
5) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 8.
nosis according to
DTC.
Temporary poor
contact occurs.
nosis according to
DTC.
Original steering
angle sensor mal-
function
Step Check Yes No
VDC(diag)-82
AP:DTC C0071 STEERING ANGLE SENSOR MALFUNCTION
TROUBLE SYMPTOM:
NOTE:
Warning light does not illuminate though problem is detected.
The ABS and VDC operate normally if voltage returns.
WIRING DIAGRAM:
VDC00473
1 2 3 4
B310 VDCCM & H/U
2
5
1
0
3
5
B231
B230
24 114 2 3
3
STEERING
ANGLE
SENSOR
YAW RATE &
LATERAL G
SENSOR
E
E
B231
S
B
F
-
6
MAIN SBF
N
o
.
3
3
E
IGNITION
SWITCH
BATTERY
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
B230
1
2
3
4
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
B365
B170
CAN
JOINT
CONNECTOR
4
*
3
*
4
3
*
*
2
1 :
:
*
*
CAN
JOINT
CONNECTOR
ARRANGEMENT AMONG
1, 2, 3,11,12 AND 13
ARRANGEMENT AMONG
8, 9, 10, 18, 19 AND 20
4
3 :
:
*
*
ARRANGEMENT AMONG
1, 2, 5 AND 6
ARRANGEMENT AMONG
3, 4, 7 AND 8
2 1
**
2 1
**
2
1
*
*
TWISTED
PAIR LINE
B170
3 4
5 6
1 2
7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B365
VDC(diag)-83
Step Check Yes No
1 CHECK POWER SUPPLY FOR STEERING
ANGLE SENSOR.
2) Disconnect the connector from steering
angle sensor.
4) Measure the voltage between the steering
angle sensor and chassis ground.
supply circuit of
steering angle sen-
sor.
2 CHECK GROUND CIRCUIT OF STEERING
ANGLE SENSOR.
Is the resistance less than 0.5 ? Go to step 3. Repair ground cir-
cuit in the steering
angle sensor.
5) Read the DTC.
2) Replace the steering angle sensor.
5) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 6.
nosis according to
DTC.
Temporary poor
contact occurs.
nosis according to
DTC.
Original steering
angle sensor mal-
function
VDC(diag)-84
AQ:DTC C0072 ABNORMAL YAW RATE SENSOR OUTPUT
Defective yaw rate sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDC00473
1 2 3 4
B310 VDCCM & H/U
2
5
1
0
3
5
B231
B230
24 114 2 3
3
STEERING
ANGLE
SENSOR
YAW RATE &
LATERAL G
SENSOR
E
E
B231
S
B
F
-
6
MAIN SBF
N
o
.
3
3
E
IGNITION
SWITCH
BATTERY
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
B230
1
2
3
4
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
B365
B170
CAN
JOINT
CONNECTOR
4
*
3
*
4
3
*
*
2
1 :
:
*
*
CAN
JOINT
CONNECTOR
ARRANGEMENT AMONG
1, 2, 3,11,12 AND 13
ARRANGEMENT AMONG
8, 9, 10, 18, 19 AND 20
4
3 :
:
*
*
ARRANGEMENT AMONG
1, 2, 5 AND 6
ARRANGEMENT AMONG
3, 4, 7 AND 8
2 1
**
2 1
**
2
1
*
*
TWISTED
PAIR LINE
B170
3 4
5 6
1 2
7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B365
VDC(diag)-85
Step Check Yes No
1 CHECK DRIVING PLACE.
Check if the vehicle ran the road with banks or
sandy surface (which does not mean a dirt
road).
Did the vehicle run the road
with banks or sandy surface
(which does not mean a dirt
road)?
VDCCM&H/U may
record DTC when
the vehicle ran the
road with banks or
sandy surface
(which does not
mean a dirt road).
Go to step 2.
2 CHECK YAW RATE & LATERAL G SENSOR
INSTALLATION.
Is the yaw rate & lateral G sen-
sor installation bolt tightened to
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?
Go to step 3. Tighten the yaw
rate & lateral G
sensor installation
bolt.
3 CHECK OUTPUT OF YAW RATE & LATERAL G
SENSOR WITH SUBARU SELECT MONITOR.
4) Read the yaw rate output displayed on dis-
play.
monitor display 4 4 deg/s?
Go to step 4. Replace the yaw
rate & lateral G
sensor.
4 CHECK OUTPUT OF STEERING ANGLE
4) Read the steering angle sensor output dis-
played on display.
monitor display 5 5?
Go to step 5. Perform the cen-
tering adjustment
of steering wheel.
5) Read the DTC.
2) Replace the yaw rate & lateral G sensor.
5) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 8.
nosis according to
DTC.
Temporary poor
contact occurs.
nosis according to
DTC.
Malfunction is
found in original
yaw rate & lateral
G sensor.
VDC(diag)-86
AR:DTC C0072 VOLTAGE INPUTTED TO YAW RATE SENSOR EXCEEDS
SPECIFICATION
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDC00473
1 2 3 4
B310 VDCCM & H/U
2
5
1
0
3
5
B231
B230
24 114 2 3
3
STEERING
ANGLE
SENSOR
YAW RATE &
LATERAL G
SENSOR
E
E
B231
S
B
F
-
6
MAIN SBF
N
o
.
3
3
E
IGNITION
SWITCH
BATTERY
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
B230
1
2
3
4
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
B365
B170
CAN
JOINT
CONNECTOR
4
*
3
*
4
3
*
*
2
1 :
:
*
*
CAN
JOINT
CONNECTOR
ARRANGEMENT AMONG
1, 2, 3,11,12 AND 13
ARRANGEMENT AMONG
8, 9, 10, 18, 19 AND 20
4
3 :
:
*
*
ARRANGEMENT AMONG
1, 2, 5 AND 6
ARRANGEMENT AMONG
3, 4, 7 AND 8
2 1
**
2 1
**
2
1
*
*
TWISTED
PAIR LINE
B170
3 4
5 6
1 2
7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B365
VDC(diag)-87
Step Check Yes No
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.
supply circuit of the
yaw rate & lateral
G sensor.
GROUND CIRCUIT.
Measure the resistance between the yaw rate
Is the resistance less than 0.5 ? Go to step 3. Repair the ground
circuit of the yaw
rate & lateral G
sensor.
5) Read the DTC.
Is the same DTC displayed? Replace the yaw
rate & lateral G
sensor.
Go to step 4.
nosis according to
DTC.
Temporary poor
contact occurs.
VDC(diag)-88
AS:DTC C0072 ABNORMAL YAW RATE SENSOR REFERENCE VOLTAGE
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDC00473
1 2 3 4
B310 VDCCM & H/U
2
5
1
0
3
5
B231
B230
24 114 2 3
3
STEERING
ANGLE
SENSOR
YAW RATE &
LATERAL G
SENSOR
E
E
B231
S
B
F
-
6
MAIN SBF
N
o
.
3
3
E
IGNITION
SWITCH
BATTERY
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
B230
1
2
3
4
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
B365
B170
CAN
JOINT
CONNECTOR
4
*
3
*
4
3
*
*
2
1 :
:
*
*
CAN
JOINT
CONNECTOR
ARRANGEMENT AMONG
1, 2, 3,11,12 AND 13
ARRANGEMENT AMONG
8, 9, 10, 18, 19 AND 20
4
3 :
:
*
*
ARRANGEMENT AMONG
1, 2, 5 AND 6
ARRANGEMENT AMONG
3, 4, 7 AND 8
2 1
**
2 1
**
2
1
*
*
TWISTED
PAIR LINE
B170
3 4
5 6
1 2
7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B365
VDC(diag)-89
Step Check Yes No
1 CHECK POWER SUPPLY FOR YAW RATE
& LATERAL G SENSOR.
2) Disconnect the connector from yaw rate &
lateral G sensor.
4) Measure the voltage between yaw rate &
lateral G sensor and chassis ground.
yaw rate & lateral
G sensor.
GROUND CIRCUIT.
Measure the resistance between the yaw rate
circuit of the yaw
rate & lateral G
sensor.
5) Read the DTC.
Is the same DTC displayed? Replace the yaw
rate & lateral G
sensor.
Go to step 4.
nosis according to
DTC.
Temporary poor
contact occurs.
VDC(diag)-90
AT:DTC C0072 CHANGE RANGE OF YAW RATE SENSOR SIGNAL IS TOO BIG
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDC00473
1 2 3 4
B310 VDCCM & H/U
2
5
1
0
3
5
B231
B230
24 114 2 3
3
STEERING
ANGLE
SENSOR
YAW RATE &
LATERAL G
SENSOR
E
E
B231
S
B
F
-
6
MAIN SBF
N
o
.
3
3
E
IGNITION
SWITCH
BATTERY
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
B230
1
2
3
4
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
B365
B170
CAN
JOINT
CONNECTOR
4
*
3
*
4
3
*
*
2
1 :
:
*
*
CAN
JOINT
CONNECTOR
ARRANGEMENT AMONG
1, 2, 3,11,12 AND 13
ARRANGEMENT AMONG
8, 9, 10, 18, 19 AND 20
4
3 :
:
*
*
ARRANGEMENT AMONG
1, 2, 5 AND 6
ARRANGEMENT AMONG
3, 4, 7 AND 8
2 1
**
2 1
**
2
1
*
*
TWISTED
PAIR LINE
B170
3 4
5 6
1 2
7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B365
VDC(diag)-91
Step Check Yes No
1 CHECK DRIVING PLACE.
Check if the vehicle ran the road with banks or
sandy surface (which does not mean a dirt road).
Did the vehicle run the road
with banks or sandy surface
(which does not mean a dirt
road)?
VDCCM&H/U may
record DTC when
the vehicle ran the
road with banks or
sandy surface
(which does not
mean a dirt road).
Go to step 2.
INSTALLATION.
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?
rate & lateral G
sensor installation
bolt.
POWER SUPPLY.
2) Disconnect the connector from yaw rate
& lateral G sensor.
4) Measure the voltage between yaw rate
yaw rate & lateral
G sensor.
GROUND CIRCUIT.
Measure the resistance between the yaw rate &
circuit of the yaw
rate & lateral G
sensor.
5 CHECK OUTPUT OF YAW RATE & LATERAL G
4) Read the yaw rate output displayed on dis-
play.
monitor display 4 4 deg/s?
rate & lateral G
sensor.
5) Read the DTC.
5) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 9.
nosis according to
DTC.
Temporary poor
contact occurs.
nosis according to
DTC.
Malfunction is
found in original
yaw rate & lateral
G sensor.
VDC(diag)-92
AU:DTC C0073 LATERAL G SENSOR COMMUNICATION
Communication failure between lateral G sensor and VDCCM
TROUBLE SYMPTOM:
NOTE:
For the diagnostic procedure, refer to DTC C0072 YAW RATE SENSOR COMMUNICATION. <Ref. to
VDC(diag)-93, DTC C0072 YAW RATE SENSOR COMMUNICATION, Diagnostic Procedure with Diagnos-
VDC(diag)-93
AV:DTC C0072 YAW RATE SENSOR COMMUNICATION
Communication failure between yaw rate sensor and VDCCM
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDC00473
1 2 3 4
B310 VDCCM & H/U
2
5
1
0
3
5
B231
B230
24 114 2 3
3
STEERING
ANGLE
SENSOR
YAW RATE &
LATERAL G
SENSOR
E
E
B231
S
B
F
-
6
MAIN SBF
N
o
.
3
3
E
IGNITION
SWITCH
BATTERY
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
B230
1
2
3
4
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
B365
B170
CAN
JOINT
CONNECTOR
4
*
3
*
4
3
*
*
2
1 :
:
*
*
CAN
JOINT
CONNECTOR
ARRANGEMENT AMONG
1, 2, 3,11,12 AND 13
ARRANGEMENT AMONG
8, 9, 10, 18, 19 AND 20
4
3 :
:
*
*
ARRANGEMENT AMONG
1, 2, 5 AND 6
ARRANGEMENT AMONG
3, 4, 7 AND 8
2 1
**
2 1
**
2
1
*
*
TWISTED
PAIR LINE
B170
3 4
5 6
1 2
7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B365
VDC(diag)-94
Step Check Yes No
1 CHECK POWER SUPPLY FOR YAW RATE
& LATERAL G SENSOR.
2) Disconnect the connector from yaw rate &
lateral G sensor.
4) Measure the voltage between yaw rate &
yaw rate & lateral
G sensor.
GROUND CIRCUIT.
circuit of the yaw
rate & lateral G
sensor.
HARNESS.
VDCCM&H/U.
2) Measure the resistance between VDCCM&
H/U and yaw rate & lateral G sensor.
(B230) No. 3 (B310) No. 10:
(B230) No. 2 (B310) No. 35:
between yaw rate
& lateral G sensor
and VDCCM& H/U.
4 CHECK GROUND SHORT CIRCUIT FOR
YAW RATE & LATERAL G SENSOR HAR-
NESS.
between yaw rate
& lateral G sensor
and VDCCM& H/U.
5) Read the DTC.
5) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 8.
nosis according to
DTC.
Temporary poor
contact occurs.
nosis according to
DTC.
Malfunction is
found in original
yaw rate & lateral
G sensor.
VDC(diag)-95
AW:DTC C0073 LATERAL G SENSOR OFFSET IS TOO BIG
NOTE:
For the diagnostic procedure, refer to DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL. <Ref. to
VDC(diag)-96, DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL, Diagnostic Procedure with Diag-
AX:DTC C0073 ABNORMAL LATERAL G SENSOR OUTPUT
NOTE:
For the diagnostic procedure, refer to DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL. <Ref. to
VDC(diag)-96, DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL, Diagnostic Procedure with Diag-
VDC(diag)-96
AY:DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL
Lateral G sensor malfunction
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDC00473
1 2 3 4
B310 VDCCM & H/U
2
5
1
0
3
5
B231
B230
24 114 2 3
3
STEERING
ANGLE
SENSOR
YAW RATE &
LATERAL G
SENSOR
E
E
B231
S
B
F
-
6
MAIN SBF
N
o
.
3
3
E
IGNITION
SWITCH
BATTERY
B310
4 5 6 7 8 9
26 27 28 29 30
2 3 1
31 32 33 34 35 36
10 11 14 15 16 17 18 19
37 38 39 40
12 13
41 42 43 44 45 46
20 21
23 24 22 25
B230
1
2
3
4
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
T
W
I
S
T
E
D

P
A
I
R

L
I
N
E
B365
B170
CAN
JOINT
CONNECTOR
4
*
3
*
4
3
*
*
2
1 :
:
*
*
CAN
JOINT
CONNECTOR
ARRANGEMENT AMONG
1, 2, 3,11,12 AND 13
ARRANGEMENT AMONG
8, 9, 10, 18, 19 AND 20
4
3 :
:
*
*
ARRANGEMENT AMONG
1, 2, 5 AND 6
ARRANGEMENT AMONG
3, 4, 7 AND 8
2 1
**
2 1
**
2
1
*
*
TWISTED
PAIR LINE
B170
3 4
5 6
1 2
7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B365
VDC(diag)-97
Step Check Yes No
INSTALLATION.
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?
rate & lateral G
sensor installation
bolt.
2 CHECK LATERAL G SENSOR OUTPUT.
3) Read the lateral G sensor output displayed
on screen.
Is the indicated reading on the
monitor display 1.5 1.5 m/s
2
?
rate & lateral G
sensor.
3 CHECK LATERAL G SENSOR OUTPUT.
2) Remove the yaw rate & lateral G sensors
from vehicle.
{Current Data Display & Save} in Subaru Select
Monitor.
4) Read the lateral G sensor output displayed
on screen.
When the yaw rate & lateral G
sensor is inclined 90 to the
right, is the indicated value
6.8 12.8 m/s
2
?
rate & lateral G
sensor.
Read the lateral G sensor output displayed on
screen.
When the yaw rate & lateral G
sensor is inclined 90 to the left,
is the indicated value
6.8 12.8 m/s
2
?
rate & lateral G
sensor.
5 CHECK POOR CONTACT IN CONNECTORS.
tor between VDCCM& H/U and
yaw rate & lateral G sensor?
Repair the connec-
tor.
Go to step 6.
4) Read the DTC.
VDCCM only.
<Ref. to VDC-10,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 7.
nosis according to
DTC.
Temporary poor
contact occurs.
VDC(diag)-98
AZ:DTC C0074 PRESSURE SENSOR
Defective pressure sensor
TROUBLE SYMPTOM:
Step Check Yes No
1 CHECK STOP LIGHT SWITCH CIRCUIT.
Check stop light switch open circuit.
Is the stop light switch circuit
OK?
Go to step 2. Repair the stop
light switch circuit.
NOTE:
If there is malfunc-
tion in the stop light
circuit, DTC may
be memorized.
2 CHECK OUTPUT OF PRESSURE SENSOR
1) Select {Current Data Display & Save}
in Subaru Select Monitor.
2) Read the pressure sensor output displayed
on display.
When the brake pedal is
released, is the displayed value
40 40 bar?
VDCCM&H/U.
<Ref. to VDC-7,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
3 CHECK OUTPUT OF PRESSURE SENSOR
1) Select {Current Data Display & Save}
in Subaru Select Monitor.
2) Read the pressure sensor output displayed
on display.
When operating the brake
pedal, does the pressure sen-
sor output value on the display
change according to the brake
pedal operation?
VDCCM&H/U.
<Ref. to VDC-7,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
4 CHECK PRESSURE SENSOR.
3) Read the DTC.
VDCCM&H/U.
<Ref. to VDC-7,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Go to step 5.
nosis according to
DTC. <Ref. to
VDC(diag)-34, List
of Diagnostic Trou-
ble Code (DTC).>
It results from a
temporary noise
interference.
VDC(diag)-99
BA:DTC C0081 SYSTEM FAILURE
VDC long time sequential control
TROUBLE SYMPTOM:
Step Check Yes No
1 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in the
VDCCM& H/U and yaw rate
& lateral G sensor connector?
Repair the connec-
tor.
Go to step 2.
5) Read the DTC.
VDCCM&H/U.
Malfunction is
found in original
yaw rate & lateral
G sensor.
VDC(diag)-100
A: INSPECTION
Symptom Main probable cause Other probable cause
Poor brake
performance
Long braking/
stopping dis-
tance
VDCCM&H/U
Brake pad
Aeration to brake line
Tire specifications, tire wear and air
pressures
Defective ABS wheel speed sensor or sensor gap
Defective steering angle sensor or improper
neutral position
Defective yaw rate & lateral G sensor or
improper installation
Master cylinder
Brake caliper
Disc rotor
Brake pipe
Brake booster
Wheel lock VDCCM&H/U
Defective ABS wheel speed sensor or
sensor gap
neutral position
Brake caliper
Brake pipe
Brake drag VDCCM&H/U
sensor gap
Master cylinder
Brake caliper
Parking brake
Axle and wheels
Brake pedal play
neutral position
Brake pad
Brake pipe
Long brake
pedal stroke
Aeration to brake line
Brake pedal play
VDCCM&H/U
Master cylinder
Brake caliper
Brake pad
Brake pipe
Brake booster
Vehicle vertical
pitching
VDCCM&H/U
(reduced damping)
neutral position
Poor brake
performance
Unstable or
uneven braking
VDCCM&H/U
sensor gap
Brake caliper
Brake pad
pressures
neutral position
Master cylinder
Disc rotor
Brake pipe
Axle and wheels
Road with crowns or banks
Suspension play or fatigue (poor damping)
VDC(diag)-101
Vibration or
noise
When braking
suddenly
When
accelerating
suddenly
While driving
on a slippery
road
Excessive
brake pedal
vibration
VDCCM&H/U
Brake booster
Noise from
VDCH/U
VDCCM&H/U (mount bushing)
sensor gap
Brake pipe
VDCCM&H/U
neutral position
Noise from the
front side of
vehicle
VDCCM&H/U (mount bushing)
sensor gap
Master cylinder
Brake caliper
Brake pad
Disc rotor
Brake pipe
Brake booster
(poor damping)
Axle and wheels
Noise from the
rear side of
vehicle
sensor gap
Brake caliper
Brake pad
Disc rotor
Parking brake
Brake pipe
(poor damping)
Axle and wheels
Engine does not accelerate or
goes into a stall when accelerat-
ing suddenly or driving on a slip-
pery surface.
VDCCM&H/U
sensor gap
Master cylinder
Brake caliper
Parking brake
Incorrect wiring or piping
neutral position
Brake pad
Brake pipe
VDC(diag)-102
Poor change-
direction-opera-
tion stability of
TCS
Deviation to
right or left
direction
VDCCM&H/U
sensor gap
Defective steering angle sensor or
improper neutral position
Defective yaw rate & lateral G sensor
or improper installation
Brake caliper
Brake pad
Wheel alignment
pressures
Disc rotor
Brake pipe
Axle and wheels
Vehicle spin VDCCM&H/U
sensor gap
Defective yaw rate & lateral G sensor
or improper installation
Brake pad
pressures
Brake caliper
Brake pipe
Steering wheel drag while driving VDCCM&H/U
sensor gap
Power steering system
Brake caliper
Brake pad
Disc rotor
Wheel alignment
VDC operates while driving
normally.
VDCCM&H/U
sensor gap
Wheel alignment
(poor damping)
pressures
Power steering system
VDC(diag)-103
VDC OFF indicator light does not
come on when the VDC OFF
switch is depressed.
NOTE:
When pressing VDC OFF switch
for 10 seconds or more, VDC OFF
indicator light goes off and cannot
operate any more. When turning
the ignition switch from OFF to ON,
the previous status is restored.
Harness
Indicator light bulb
VDC OFF switch
VDC(diag)-104
BR-2
General Description
BRAKE
A: SPECIFICATION
Model
2.5 i, 2.5 i-LTD,
OUTBACK 2.5i, -LTD,
OUTBACK 3.0 R, -LTD, -LLB,
OUTBACK 2.5XT -LTD
2.5GT-LTD, 3.0 R-LTD,
2.5GT-B
Front disc brake
Size 16-inch type 17-inch type
Type Disc (Floating type, ventilated)
Effective disc diameter mm (in) 244 (4.61) 261 (10.28)
Disc thickness Diameter mm (in) 24 294 (0.94 11.57) 30 316 (1.18 12.44)
Effective cylinder diameter 42.8 (1.685) 2
Pad dimensions
(Length Width Thickness)
mm (in)
117.8 50.5 11.0
(4.638 1.988 0.433)
130.0 53.5 11.0
(5.118 2.106 0.433)
Clearance adjustment Automatic adjustment
Rear disc brake
Size 15-inch type
Type Disc (Floating type,solid) Disc (Floating type, ventilated)
Effective disc diameter mm (in) 238 (9.37) 254 (10.0)
Disc thickness Diameter mm (in) 10 274 (0.39 10.79) 18 290 (0.71 11.42)
Effective cylinder diameter mm (in) 38.1 (1.500)
Pad dimensions
(Length Width Thickness)
mm (in)
92.0 33.0 9.0
(3.622 1.299 0.354)
82.4 33.7 9.0
(3.244 1.327 0.354)
Clearance adjustment Automatic adjustment
Master cylinder
Type Tandem
Effective diameter mm (in) 23.8 (15/16)
Reservoir type Sealed type
Brake fluid reservoir capacity cm
3
(cu in) 205 (12.51)
Brake booster
Type Vacuum suspended
Effective diameter mm (in) 208 + 229 (8.19 + 9.02)
Brake line Dual circuit system
Brake fluid
CAUTION:
Avoid mixing brake fluid of different brands to prevent
fluid performance from degrading.
When filling with brake fluid, be careful not to allow
any dust to enter the reservoir.
Use new SUBARU genuine brake fluid when replacing
or refilling the fluid.
FMVSS No. 116, DOT3, or DOT4
BR-3
General Description
BRAKE
NOTE:
Refer to PB section for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General Descrip-
tion.>
Item Standard Limit
Front brake
Excluding 17-inch type 11 (0.43) 1.5 (0.059)
17-inch type 11 (0.43) 1.5 (0.059)
Disc thickness mm (in)
Excluding 17-inch type 24 (0.94) 22 (0.87)
17-inch type 30 (1.18) 28 (1.10)
Disc runout mm (in) 0.05 (0.0020)
Rear brake (disc type)
Solid disc 9.0 (0.354) 1.5 (0.059)
Ventilated disc 9.0 (0.354) 1.5 (0.059)
Disc thickness mm (in)
Solid disc 10 (0.39) 8.5 (0.335)
Ventilated disc 18 (0.71) 16 (0.63)
Disc runout mm (in) 0.05 (0.0020)
Parking brake
Inside diameter mm (in) 170 (6.69) 171 (6.73)
Lining thickness mm (in) 3.2 (0.126) 1.5 (0.059)
Lever stroke 5 6 notches/200 N (20 kgf, 45 lb)
Brake pedal force N (kgf, lb) Fluid pressure kPa (kgf/cm
2
, psi)
Brake booster
Brake fluid pressure with engine stopped
147 (15, 33) 545 (6, 79)
294 (30, 66) 1,564 (16, 227)
Brake fluid pressure with engine running
and vacuum pressure at 66.7 kPa
(500 mmHg, 19.69 inHg)
147 (15, 33) 6,003 (61, 870)
294 (30, 66) 11,273 (115, 1,635)
Brake pedal Free play mm (in)
0.5 2 (0.02 0.08)
[When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lb).]
BR-4
General Description
BRAKE
B: COMPONENT
1. FRONT DISC BRAKE
(A) 16-inch type (B) 17-inch type

(1) Caliper body (9) Support (16) Disc cover
(2) Air bleeder screw (10) Pad clip (17) Bushing
(3) Guide pin (black) (11) Outer shim
(4) Pin boot (12) Inner shim Tightening torque:Nm (kgf-m, ft-lb)
(5) Piston seal (13) Pad (outside) T1: 8 (0.8, 5.8)
(6) Piston (14) Pad (inside) T2: 27 (2.8, 19.9)
(7) Piston boot (15) Disc rotor T3: 120 (12.2, 88.5)
(8) Lock pin (silver)
BR-00332
( 1)
( 2)
( 3)
( 4)
( 4)
( 17)
( 10)
( 11)
( 11)
( 12)
( 12)
( 16)
( A)
( B)
( 13)
( 14)
( 15)
( 5)
( 6)
( 7)
( 9)
( 8)
T2
T3
( 11)
( 11)
( 12)
( 12)
( 13)
( 14)
( 13)
T1
BR-5
General Description
BRAKE
2. REAR DISC BRAKE
(1) Caliper body (15) Shoe hold-down pin (29) Adjuster
(2) Air bleeder screw (16) Cover (30) Shoe hold-down cup
(3) Guide pin (black) (17) Back plate (31) Shoe hold-down spring
(4) Pin boot (18) Retainer (32) Disc rotor (solid type)
(5) Piston seal (19) Spring washer (33) Disc rotor (ventilated type)
(6) Piston (20) Parking brake lever (34) Bolt (for solid disc brake)
(7) Piston boot (21) Parking brake shoe (secondary) (35) Bolt (for ventilated disc brake)
(8) Support (22) Parking brake shoe (primary) (36) Shim (for solid disc brake)
(9) Lock pin (silver) (23) Strut
(10) Bushing (24) Strut shoe spring Tightening torque:Nm (kgf-m, ft-lb)
(11) Pad clip (25) Shoe guide plate T1: 8 (0.8, 5.8)
(12) Inner pad (26) Secondary shoe return spring T2: 27 (2.8, 19.9)
(13) Outer pad (27) Primary shoe return spring T3: 37 (3.7, 27.2)
(14) Shim (28) Adjusting spring T4: 66 (6.7, 48.7)
BR-00539
( 1)
( 2)
( 3)
( 4)
( 4)
( 10)
( 14)
( 11)
( 11)
( 18)
( 19)
( 20)
( 21)
( 22)
( 23)
( 24)
( 25)
( 26)
( 27)
( 28)
( 29)
( 30)
( 31)
( 32)
( 12)
( 13)
( 14)
( 17)
( 16)
( 5)
( 6)
( 7)
( 8)
( 9)
T2
T4
T1
( 33)
T3
( 15)
( 35)
( 34)
( 36)
BR-6
General Description
BRAKE
3. MASTER CYLINDER
(1) Cap (6) Secondary piston (11) O-ring
(2) Filter (7) Cylinder body
(3) Reservoir tank (8) Cylinder pin Tightening torque:Nm (kgf-m, ft-lb)
(4) C-ring (9) Seal T: 13 (1.3, 9.6)
(5) Primary piston (10) Pin
BR-00371
T
(1)
(2)
(3)
(7)
(8)
(9)
(10)
(4)
(11)
(5)
(6)
BR-7
General Description
BRAKE
4. FRONT BRAKE PIPES AND HOSES
(A) Model with ABS (B) Model with vehicle dynamics
control (VDC)
(1) Front brake pipe ASSY (7) ABS control module and hydraulic
(2) Two-way connector T1: 15 (1.5, 10.8)
(3) Front brake hose RH (8) Bracket T2: 18 (1.8, 13.0)
(4) Front brake hose LH (9) Master cylinder T3: 19 (1.9, 14.0)
(5) Clamp (10) VDC control module and hydraulic
T4: 33 (3.4, 24.3)
(6) Gasket
T1
T2
T4
T2
T2
T2
T4
T1
T1
(8)
(2)
(3)
(5)
(6)
(4)
(7)
(6)
(5)
T1
T2
T4
T2
T2
T2
T4
T3
(8)
(2)
(3)
(5)
(6)
(4)
(6)
(5)
(A)
(B)
T1
T1
T1
(1)
(9)
T3
T1
T1
(1)
(9)
T1
BR-00581
(10)
T3
BR-8
General Description
BRAKE
5. CENTER AND REAR BRAKE PIPES AND HOSES
(1) Center brake pipe ASSY (7) Rear brake pipe LH Tightening torque:Nm (kgf-m, ft-lb)
(2) Two-way connector (8) Rear brake hose rear RH T1: 15 (1.5, 10.8)
(3) Rear brake pipe ASSY (9) Rear brake hose rear LH T2: 18 (1.8, 13.0)
(4) Rear brake hose RH (10) Clamp T3: 33 (3.4, 24.3)
(5) Rear brake hose LH (11) Gasket
(6) Rear brake pipe RH (12) Bracket
BR-00337
(1)
T1
T1
T2
T1
T2
T3
T1
T3
T3
T3
T1
T2
T2
T1
(2)
(3)
(5)
(7)
(9)
(4)
(6)
(8)
(10)
(10)
(10)
(10)
(10)
(11)
(11)
(11)
(11)
(10)
T1
(12)
BR-9
General Description
BRAKE
6. BRAKE BOOSTER
(1) Brake booster
(1)
BR-00600
BR-10
General Description
BRAKE
7. BRAKE PEDAL
MT model
(1) Brake pedal ASSY (4) Clutch pedal Tightening torque:Nm (kgf-m, ft-lb)
(2) Stop light switch (5) Clutch pedal pad T1: 8 (0.8, 5.8)
(3) Brake pedal pad (6) Clutch switch T2: 18 (1.8, 13.0)
T2
(5)
(4)
(3)
(2)
(6)
(1)
T2
T2
T1
T1
T2
T1
BR-00595
BR-11
General Description
BRAKE
AT model
(1) Brake pedal ASSY (3) Brake pedal pad Tightening torque:Nm (kgf-m, ft-lb)
(2) Stop light switch T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
BR-00338
T2
T1
T2
T1
(1)
(2)
(3)
BR-12
General Description
BRAKE
C: CAUTION
forming any work.
ufacturers.
points.
D: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME REMARKS
Snap ring pliers Used for removing and installing snap rings.
BR-13
Front Brake Pad
BRAKE
2. Front Brake Pad
A: REMOVAL
1. 16-INCH TYPE
2) Remove the caliper bolt.
3) Raise the caliper body and support it.
NOTE:
Do not disconnect the brake hose from the caliper
body.
4) Remove the pad.
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.
(4) Attach a rod of 12 mm (0.47 in) diameter or
less to the shaded area of the brake pad, and
strike the rod with a hammer to drive brake pad
out.
2. 17-INCH TYPE
Refer to 16-inch type. <Ref. to BR-13, 16-INCH
TYPE, REMOVAL, Front Brake Pad.>
BR-00339
BR-00012
(1) Support
(2) Wooden block
(1)
(2)
BR-00013
BR-00014
BR-14
Front Brake Pad
BRAKE
B: INSTALLATION
1. 16-INCH TYPE
1) Apply a thin coat of Molykote M7439
(Part No. K0777YA000) to the pad clip.
2) Apply a thin coat of Molykote AS880N
(Part No. K0779YA010) to both surfaces of the pad
inner shim.
3) Install the pad to support.
4) Install the caliper body to the support.
Tightening torque:
27 Nm (2.8 kgf-m, 19.9 ft-lb)
2. 17-INCH TYPE
2) Apply a thin coat of Molykote AS880N (Part No.
K0779YA010) to both surfaces of the pad inner
shim.
NOTE:
Install the pad indicator in proper direction.
BR-00596
BR-00601
BR-00596
(1) LH IN
(2) LH OUT
(3) RH IN
(4) RH OUT
(5) Pad indicator
(6) Pad return spring
BR-00601
BR-00586
(6)
(6)
(6)
(1)
(2)
(3)
(4)
(5)
(6)
BR-15
Front Brake Pad
BRAKE
CAUTION:
Be sure to install so that the pad return
spring faces the input side of the direction of
brake rotor rotation, as shown in the figure.
Correctly install the pad return spring to the
supporting surface of the pad clip as shown in
the figure.
If the pad return spring is deformed or dam-
aged, replace the brake pad.
Tightening torque:
27 Nm (2.8 kgf-m, 19.9 ft-lb)
C: INSPECTION
1. 16-INCH TYPE
Check the pad thickness A.
NOTE:
Always replace the pads of both sides as a set.
Replace pad clips if they are twisted or worn.
Replace the pad if there is oil or grease on it.
2. 17-INCH TYPE
NOTE:
(2) Supporting surface of pad clip
(3) Direction of brake rotor rotation
BR-00483
(1)
(2)
(3)
Standard 11 (0.43)
Wear limit 1.5 (0.059)
Standard 11 (0.43)
Wear limit 1.5 (0.059)
BR-00360
A
BR-00360
A
BR-16
Front Disc Rotor
BRAKE
3. Front Disc Rotor
A: REMOVAL
1. 16-INCH TYPE
2) Remove the caliper body and the support from
housing, and suspend it from the strut using a wire.
3) Remove the disc rotor.
NOTE:
drive an 8 mm bolt into the threaded section (B) of
the rotor, then remove the rotor.
4) Remove mud and foreign matter from the caliper
body assembly and the support.
2. 17-INCH TYPE
TYPE, REMOVAL, Front Disc Rotor.>
B: INSTALLATION
1) Install the disc rotor.
2) Install the caliper body and the support to hous-
ing.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
C: INSPECTION
1) Check the front wheel bearing play and axle hub
runout before the inspection of disc rotor runout
limit. <Ref. to DS-16, 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 runout of disc rotor exceeds
the service limit, resurface the disc rotor. After re-
surfacing, check disc rotor thickness as in step 4).
0.05 mm (0.0020 in)
4) Set a micrometer 10 mm (0.39 in) inward from
the disc rotor outer perimeter, and then measure
the disc rotor thickness. If the thickness of the disc
rotor exceeds the service limit, replace with a new
disc rotor.
BR-00017
B
A
BR-00018
Standard Limit
Disc rotor
outer diameter
Disc rotor
thickness A
mm (in)
16 24 (0.94) 22 (0.87) 294 (11.57)
17 30 (1.18) 28 (1.10) 316 (12.44)
BR-00019
B
A
BR-00018
BR-17
Front Disc Brake Assembly
BRAKE
4. Front Disc Brake Assembly
A: REMOVAL
1. 16-INCH TYPE
CAUTION:
Do not allow brake fluid to come in contact with
vehicle body. If it does, wash off with water and
wipe away completely.
2) Remove the union bolt, and disconnect the
brake hose from the caliper body assembly.
3) Remove the bolt securing the lock pin to caliper
body.
4) Raise the caliper body, and then move it toward
vehicle center to separate it from the support.
5) 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.
2. 17-INCH TYPE
TYPE, REMOVAL, Front Disc Brake Assembly.>
BR-00021
BR-00022
BR-00023
BR-18
BRAKE
B: INSTALLATION
1. 16-INCH TYPE
(Part No. K0777YA000) to the support.
2) Install the support to the housing.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
shim.
Tightening torque:
27 Nm (2.8 kgf-m, 19.9 ft-lb)
7) Connect the brake hose using a new brake hose
gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
2. 17-INCH TYPE
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
shim.
BR-00597
BR-00596
BR-00601
BR-00597
BR-00596
BR-00601
BR-19
BRAKE
NOTE:
Install the pad indicator in proper direction.
CAUTION:
Be sure to install so that the pad return
spring faces the input side of the direction of
brake rotor rotation, as shown in the figure.
Correctly install the pad return spring to the
supporting surface of the pad clip as shown in
the figure.
If the pad return spring is deformed or dam-
aged, replace the brake pad.
gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
(1) LH IN
(2) LH OUT
(3) RH IN
(4) RH OUT
(5) Pad indicator
BR-00586
(6)
(6)
(6)
(1)
(2)
(3)
(4)
(5)
(6)
(2) Supporting surface of pad clip
(3) Direction of brake rotor rotation
BR-00483
(1)
(2)
(3)
BR-20
BRAKE
C: DISASSEMBLY
1. 16-INCH TYPE
CAUTION:
the brake hose connector.
2) Place a wooden block in the caliper body as
shown in the figure to prevent the piston from jump-
ing out and being damaged.
3) Gradually apply compressed air via the brake
hose installation hole to push the piston out.
4) Remove the piston boot.
5) Remove the piston seal from caliper body cylinder.
CAUTION:
Do not damage the cylinder and piston seal
groove.
6) Remove the guide pin and boot from caliper body.
2. 17-INCH TYPE
TYPE, DISASSEMBLY, Front Disc Brake Assem-
bly.>
D: ASSEMBLY
1. 16-INCH TYPE
1) Clean the inside of the caliper body using brake
fluid.
2) Apply a coat of brake fluid to piston seal and in-
stall piston seal in the groove on caliper body.
3) Apply a coat of brake fluid to the inner surface of
cylinder and the entire outer surface of the piston.
4) Apply a coat of specified grease to the boot, and
fit to the groove on the ends of the cylinder.
Grease:
NIGLUBE RX-2 (Part No. 000041000)
5) Insert the piston into cylinder.
CAUTION:
Do not force the piston into cylinder.
6) Position the boot in the grooves on cylinder and
piston.
(1) Place a wooden block of 30 mm (1.18 in) width.
(1) Piston seal
(1)
BR-00026
BR-00240
(1)
BR-00027
(1) Piston
(2) Piston boot
(1) Piston
(2) Piston boot
(3) Caliper body
(4) Piston seal
BR-00242
(1)
(2)
BR-00243
(1)
(2)
(3)
(4)
BR-21
BRAKE
7) Apply a coat of specified grease to the lock pin
and guide pin outer surface, cylinder inner surface,
and boot grooves.
Grease:
8) Insert the lock pin and guide pin boot into the
support.
2. 17-INCH TYPE
TYPE, ASSEMBLY, Front Disc Brake Assembly.>
E: INSPECTION
1) Repair or replace the faulty parts.
2) Check the caliper body and piston for uneven
wear, damage or rust.
3) Check the rubber parts for damage or deteriora-
tion.
(1) Pin boot
(2) Lock pin or guide pin
(3) Grease applied area
BR-00362
(1)
(2)
: (3)
BR-22
Rear Brake Pad
BRAKE
5. Rear Brake Pad
A: REMOVAL
2) Remove the caliper bolt.
3) Raise the caliper body and support it.
NOTE:
Do not disconnect the brake hose from the caliper
body.
4) 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-13, REMOVAL, Front Brake Pad.>
B: INSTALLATION
1) Apply a thin coat of Molykote M7439 (Part No.
K0777YA000) to the pad clip.
K0779YA010) to the contact surface between the
pad and shim.
Tightening torque:
Solid disc brake model
27 Nm (2.8 kgf-m, 19.9 ft-lb)
Ventilated disc brake model
37 Nm (3.7 kgf-m, 27.2 ft-lb)
C: INSPECTION
NOTE:
Replace pad clips if they are twisted or worn.
A wear indicator is installed on the inner disc
brake 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.
BR-00344
BR-00032
Type of disc rotor Solid Ventilated
Pad thickness Standard 9.0 (0.35) 9.0 (0.35)
mm (in) Wear limit 1.5 (0.059) 1.5 (0.059)
BR-00599
A
BR-00016
BR-23
Rear Disc Rotor
BRAKE
6. Rear Disc Rotor
A: REMOVAL
3) Remove the two mounting bolts, and remove the
disc brake assembly.
4) Suspend the disc brake assembly so that the
hose is not stretched.
5) Remove the disc rotor.
NOTE:
If it is difficult to remove the disc rotor, perform the
following two methods in order.
(1) Turn the adjusting screw using a flat tip
screwdriver until the brake shoe is far enough
away to allow removal of the disc rotor.
(2) If it is difficult to remove the disc rotor from
the hub, drive an 8 mm bolt into the threads B of
the rotor, then remove the rotor.
B: INSTALLATION
2) Adjust the parking brake. <Ref. to PB-8, AD-
JUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>
(1) Adjusting screw
(2) Cover
(3) Flat tip screwdriver
(4) Back plate
BR-00346
(1)
(4)
(2)
(3)
BR-00155
A
B
BR-00036
BR-24
Rear Disc Rotor
BRAKE
C: INSPECTION
1) Check the rear wheel bearing play and axle hub
runout before inspecting the disc rotor runout limit.
<Ref. to DS-22, INSPECTION, Rear Hub Unit
Bearing.>
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 runout of disc rotor exceeds
the service limit, resurface the disc rotor. After re-
surfacing, check disc rotor thickness as in step 4).
0.05 mm (0.0020 in)
4) Set a micrometer 10 mm (0.39 in) inward from
the disc rotor outer perimeter, and then measure
the disc rotor thickness. If the thickness of disc ro-
tor exceeds the service limit, replace with a new
disc rotor.
BR-00037
A
B
BR-00036
Standard Limit Disc outer dia.
Disc rotor thickness A Solid disc 10 (0.39) 8.5 (0.335) 274 (10.79)
mm (in) Ventilated disc 18 (0.71) 16 (0.63) 290 (11.42)
BR-25
Rear Disc Brake Assembly
BRAKE
7. Rear Disc Brake Assembly
A: REMOVAL
CAUTION:
Do not allow brake fluid to come in contact with
vehicle body. If it does, wash off with water and
wipe away completely.
2) Disconnect the brake hose from caliper body as-
sembly.
3) Remove the caliper lower bolt.
4) Raise the caliper body, and then move it toward
vehicle center to separate it from the support.
5) 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:
the brake hose connector.
B: INSTALLATION
Tightening torque:
66 Nm (6.7 kgf-m, 48.7 ft-lb)
K0779YA010) to the contact surface between the
pad and shim.
Tightening torque:
Solid disc brake model
27 Nm (2.8 kgf-m, 19.9 ft-lb)
Ventilated disc brake model
37 Nm (3.7 kgf-m, 27.2 ft-lb)
gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
BR-00347
BR-00597
BR-00599
BR-26
BRAKE
C: DISASSEMBLY
1) Remove the piston boot.
2) Place a wooden block in the caliper body as
shown in the figure to prevent the piston from jump-
ing out and being damaged.
3) Gradually apply compressed air via the brake
hose installation hole to push the piston out.
4) Remove the piston seal from caliper body cylin-
der.
CAUTION:
Do not damage the cylinder and piston seal
groove.
5) Remove the lock pin sleeve and boot from cali-
per body.
6) Remove the guide pin boot.
D: ASSEMBLY
1) Clean the inside of the caliper body using brake
fluid.
2) Apply a coat of brake fluid to piston seal and in-
stall piston seal in the groove on caliper body.
3) Apply a coat of brake fluid to the inner surface of
cylinder and the entire outer surface of the piston.
4) Apply a coat of specified grease to the boot and
fit to the groove on the ends of cylinder.
Grease:
5) Insert the piston into cylinder.
CAUTION:
Do not force the piston into cylinder.
6) Position the boot in the grooves on piston and
cylinder.
7) Apply a coat of specified grease to the guide pin,
outer surface, sleeve outer surface, cylinder inner
surface, and boot grooves.
Grease:
(1) Place a wooden block of 30 mm (1.18 in) width.
BR-00041
(1)
BR-00042
BR-00043
(1) Piston
(2) Piston boot
(3) Caliper body
(4) Piston seal
(1) Pin boot
(2) Lock pin or guide pin
(3) Grease applied area
BR-00243
(1)
(2)
(3)
(4)
BR-00362
(1)
(2)
: (3)
BR-27
BRAKE

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FW-2

PLUS Used for removing and installing camshaft cap.

bolts (e) through (j) in al-

BIT T70, and then drain differential gear

WRENCH Used for disassembling torque converter case.

BIT T70, and then drain differential gear

BIT T70, and then drain differential gear

BIT T70, remove the drain

BIT T70, tighten the transmis-

BIT T70, remove the drain

BIT T70, tighten the transmis-

BIT T70, remove the trans-

BIT T70, tighten the transmis-

bit T70 to remove and install the

bit T70 to remove and install the

bit T70 to remove the drain plug on

bit T70 to install the drain plug on

PLUS Used for removing and installing the flywheel.

Camber (front and rear wheels)

Caster (front wheel)

Front wheel toe-in

Rear wheel toe-in

bit E5 Used for replacing the ABSCM.

bit E5, remove the four screws of

bit E5, attach/tighten new

bit E5, tighten the screws in the

bit E5, remove the four screws of

bit E5, attach/tighten new

bit E5, tighten the screws in the

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