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2002 FORESTER SERVICE MANUAL SUPPLEMENT

QUICK REFERENCE INDEX

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

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD. G8060GE

SPECIFICATIONS

SPC
1. Page Forester .......................................................................................................2

Specifications

FORESTER
SA08758

1. Forester

A: DIMENSIONS
Model Overall length Overall width Overall height (at CW) Compartment Length Width Height Wheelbase Tread Front Rear Minimum road clearance *1: With bushing bar *2: With fender flare *3: With sunroof *4: Australia spec. vehicles

SA08758G28

mm mm mm mm mm mm mm mm mm mm

(in) (in) (in) (in) (in) (in) (in) (in) (in) (in)

2.0 L Non-TURBO 2.0 L TURBO 4,460 (175.6), 4,530 (178.3)*1 1,735 (68.3), 1,765 (69.5)*2 1,595 (62.8) 1,585 (62.4) 1,745 (68.7) 1,435 (56.5) 1,245 (49.0), 1,220 (48.0)*3 2,525 (99.4) 1,475 (58.1) 1,465 (57.7) 190 (7.5), 200 (7.9)*4

B: ENGINE
Model Engine type Valve arrangement Bore Stroke Displacement Compression ratio Firing order Idle speed at Park/ Neutral position Maximum output Maximum torque

SA08758G29

mm (in) cm (cu in)


3

rpm

kW (HP)/rpm Nm (kgf-m, ft-lb)/rpm

2.0 L Non-TURBO 2.0 L TURBO Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Overhead camshaft type 92 75 (3.62 2.95) 1,994 (121.67) 10.0 8.0 1324 700100 700100 MT: 650100*1 AT: 675100*1 92 (123)/5,600 130 (174)/5,600 184 (18.8, 136)/3,600 245 (25, 181)/3,200 240 (24.5, 177)/3,200*2

*1: Without OBD *2: Australia spec. vehicle

C: ELECTRICAL

SA08758G30

Model Ignition timing at idling speed

BTDC/rpm

Spark plug Type and manufacturer

Generator Battery

Type and capacity (5HR)

For Europe For Australia Others

2.0 L Non-TURBO 1010/700 MT: 1010/650*1 AT: 1010/675*1 CHAMPION: RC10YC4 (with catalyst) NGK: BKR6E (without catalyst) NGK: BKR5E-11 (with catalyst) 12 V 75 A 5MT: 12 V 48AH 4AT: 12 V 52AH 12 V 40AH 12 V 40AH

2.0 L TURBO 1210/700

NGK: PFR6G

*1: Without OBD

SPC-2

FORESTER D: TRANSMISSION
Model Transmission type Clutch type Gear ratio
SA08758G31

Specifications

2.0 L Non-TURBO AWD 5MT*1 DSPD 3.454 2.062 1.448 1.088 0.871 3.333 1.000 1.447 Hypoid 4.111 Hypoid 1.000 Hypoid 4.111 4AT*2 TCC 2.785 1.545 1.000 0.694 2.272 Helical 1.000 Hypoid 4.444 Hypoid 4.444

2.0 L TURBO 5MT*3 DSPD 3.454 1.947 1.366 0.972 0.738 3.333 Hypoid 4.444 Hypoid 1.081*4, 1.000*5 Hypoid 4.111*4, 4.444*5 4AT*2 TCC 2.785 1.545 1.000 0.694 2.272 Helical 1.000 Hypoid 4.111 Hypoid 4.111

Auxiliary transmission gear ratio Reduction gear 1st reduction (Front drive) Final reduction Reduction gear Transfer reduc(Rear drive) tion Final reduction

1st 2nd 3rd 4th 5th Reverse High Low Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio

5MT*1: 5 2 forward speeds with synchromesh and 1-reverse with center differential and viscous coupling 4AT*2: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse with hydraulically controlled transfer clutch 5MT*3: 5-forward speeds with synchromesh and 1-reverse with center differential and viscous coupling DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch *4: For Europe *5: Others

E: STEERING
Model Type Turns, lock to lock Minimum turning circle

SA08758G32

LHD Rack and Pinion 3.4 m (ft) Curb to curb: 10.8 (35.4)

RHD 3.0

F: SUSPENSION
Front Rear

SA08758G33

MacPherson strut type, Independent, Coil spring Dual link strut type, Independent, Coil spring

SPC-3

Specifications

FORESTER
SA08758G34

G: BRAKE
Model

Service brake system Front Rear Parking brake

Australia spec. vehicles and 2000 Others TURBO Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Disc brake Drum brake Mechanical on rear brakes

H: TIRE
Rim size Tire size Type

SA08758G35

15 6J 205/70R15 Steel belted radial, Tubeless

16 61/2JJ 215/60R16

I: CAPACITY
Model

SA08758G36

Fuel tank Engine oil

Upper level Lower level Transmission gear oil Automatic transmission fluid AT differential gear oil AWD rear differential gear oil Power steering fluid Engine coolant

(US gal, Imp gal) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt)

2.0 L Non-TURBO AWD 5MT 4AT 60 (15.9, 13.2) 4.5 (4.8, 4.0) 3.5 (3.7, 3.1) 4.0 (4.2, 3.5) 8.4 (8.9, 7.4) 1.2 (1.3, 1.1) 0.8 (0.8, 0.7) 0.7 (0.7, 0.6) 6.4 (6.8, 5.6) 6.3 (6.7, 5.5)

2.0 L TURBO AWD 5MT 4AT 60 (15.9, 13.2) 5.0 (5.3, 4.4) 4.0 (4.2, 3.5) 3.5 (3.7, 3.1) 9.3 (9.8, 8.2) 1.2 (1.3, 1.1) 0.8 (0.8, 0.7) 0.7 (0.7, 0.6) 7.2 (7.6, 6.3) 7.2 (7.6, 6.3)

SPC-4

FORESTER J: WEIGHT
Model LHD Curb weight (CW) Front Rear Total Front Rear Total kg kg kg kg kg kg (lb) (lb) (lb) (lb) (lb) (lb) 5MT 730 (1,610) 615 (1,356) 1,345 (2,966) 920 (2,029) 990 (2,183) 1,875 (4,134) 4AT 745 (1,643) 615 (1,356) 1,360 (2,999) 930 (2,051) 990 (2,183) 1,890 (4,163) 5MT 745 (1,643) 620 (1,367) 1,365 (3,010) 920 (2,029) 990 (2,183) 1,875 (4,134)
SA08758G37

Specifications

1. EXCEPT AUSTRALIA SPEC. VEHICLE

SA08758G3706

2.0 L Non-TURBO AWD RHD 4AT 760 (1,676) 620 (1,367) 1,380 (3,043) 930 (2,051) 990 (2,183) 1,890 (4,167)

Maximum permissible axle weight (MPAW) Maximum permissible weight (MPW) Model

2.0 L TURBO AWD LHD RHD 4AT 815 (1,797) 630 (1,389) 1,445 (3,186) 995 (2,195) 1,010 (2,225) 1,970 (4,344) 5MT 790 (1,742) 630 (1,389) 1,420 (3,131) 975 (2,150) 1,010 (2,225) 1,950 (4,300) 4AT 810 (1,786) 630 (1,389) 1,440 (3,175) 995 (2,195) 1,010 (2,225) 1,970 (4,344) 5MT 795 (1,753) 635 (1,400) 1,430 (3,153) 975 (2,150) 1,010 (2,225) 1,950 (4,300)

Curb weight (CW)

Maximum permissible axle weight (MPAW) Maximum permissible weight (MPW)

Front Rear Total Front Rear Total

kg kg kg kg kg kg

(lb) (lb) (lb) (lb) (lb) (lb)

NOTE: When any of the following optional parts are installed, add the weight to the curb weight.
Weight of optional parts ABS (Turbo model) ABS (NonTurbo model) 11 (24) 1 (2) 10 (22) Cruise control Selflevelizer Fog lamp Air conditioner Sunroof SRS airbag (Driver & Passenger) 3 (7) 2 (4) 5 (11) SRS airbag (Side) Cold weather pack Cold weather pack (Leather seat) 2.6 (5.7) 4.4 (9.7) 7.0 (15.4)

Front kg (lb) Rear kg (lb) Total kg (lb)

10 (22) 1 (2) 9 (20)

2 (4) 0 (0) 2 (4)

1 (2) 2 (4) 1 (2)

3.6 (7.9) 1 (2) 2.6 (5.7)

17 (38) 3 (7) 14 (31)

9 (20) 14 (31) 23 (51)

2 (4.4) 2 (4.4) 4 (8.8)

2 (4) 1 (2) 1 (2)

SPC-5

Specifications

FORESTER
SA08758G3704

2. AUSTRALIA SPEC. VEHICLE


Model

Unladen mass (UM)

Gross vehicle mass (GVM )

Front Rear Total Front Rear Total

kg kg kg kg kg kg

(lb) (lb) (lb) (lb) (lb) (lb)

2.0 L Non-TURBO AWD RHD 5MT 4AT 740 (1,632) 755 (1,665) 625 (1,378) 625 (1,378) 1,365 (3,010) 1,380 (3,043) 885 (1,951) 910 (2,007) 990 (2,183) 980 (2,161) 1,875 (4,134) 1,890 (4,167)

2.0 L TURBO AWD RHD 5MT 810 (1,786) 630 (1,389) 1,440 (3,175) 960 (2,117) 990 (2,183) 1,950 (4,300) 4AT 835 (1,841) 625 (1,378) 1,460 (3,219) 980 (2,161) 990 (2,183) 1,970 (4,344)

NOTE: When any of the following optional parts are installed, add the weight to the unladen mass.
Weight of optional parts Front kg (lb) Rear kg (lb) Total kg (lb) ABS Cruise control 2 (4) 0 (0) 2 (4) Selflevelizer 1 (2) 2 (4) 1 (2) Fog lamp Air conditioner 17 (38) 3 (7) 14 (31) Sunroof Cold SRS airbag SRS airbag (Side) weather (Driver & pack Passenger) 3 (7) 2 (4.4) 2.6 (5.7) 2 (4) 2 (4.4) 4.4 (9.7) 5 (11) 4 (8.8) 7.0 ( 15.4)

10 (22) 1 (2) 9 (20)

3.6 (7.9) 1 (2) 2.6 (5.7)

9 (20) 14 (31) 23 (51)

SPC-6

IDENTIFICATION

ID
1. Page Identification ................................................................................................2

Identification

IDENTIFICATION
SA06679

1. Identification
2. MEANING OF V.I.N.

A: IDENTIFICATION

SA06679F70

SA06679F7002

The meaning of the VIN is as follows:

Europe, Australia and General (Except GCC)


]JF1SF5LJ32G002001[ The starting and ending brackets ( ][ ) are stop marks.
Digits 1 to 3 4 5 6 7 8 JF1 S F 5 L J Code Meaning Manufacturer body area Car line Body type Displacement Steering position Engine & transmission Details JF1: Passenger car, FHI made JF2: MPV, FHI made Forester F: Wagon 5: 2.0 L AWD K: RHD (Right-hand drive) L: LHD (Left-hand drive) J: SOHC MPI Full-time AWD 5-speed MT R: SOHC MPI 4-speed AT D: DOHC Turbo Full-time AWD 5-speed MT P: DOHC Turbo 4-speed AT 3: Full-time AWD 5-speed MT single range 4: Full-time AWD 5-speed MT dual range 5: Full-time AWD 4-speed AT 2: 2002MY 3: 2003MY G: FHI (Gunma)

Drive type

10 11 12 to 17

2 G 002001

Model year Factory location Serial number

GCC countries (Saudi Arabia, etc.)


]JF1SF53MX2J002001[ The starting and ending brackets ( ][ ) are stop marks.
Digits 1 to 3 4 5 6 7 8 9 10 11 12 to 17 JF1 S F 5 3 M X 2 J 002001 Code Meaning Manufacturer body area Car line Body type Displacement Grade Restraint Check digit Model year Transmission type Serial number Details JF1: Passenger car, FHI made Forester E: Wagon 5: 2.0 L AWD 3: BASE 5: NA SPRT M: Manual belts, dual airbag 2: 2002MY 3: 2003MY H: Full-time AWD 4-speed AT J: Full-time AWD 5-speed MT dual range

ID-2

IDENTIFICATION
3. MODEL NUMBER PLATE
SA06679F7003

Identification

The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts. SF5EL7R
Digits 1 2 3 S F 5 Code Meaning Series Body style Engine displacement Drive system Suspension system Minor change Destination Grade Details Forester F: Wagon 5: 2.0 L AWD

4 5 6

E L 7

Transmission, fuel feed system

2002MY K: Right-hand drive for general market L: Left-hand drive for general market 2: BASE 3: HUNTER Ver. 4: NA SPORT 5: TYPE-S P: DOHC MPI Turbo 4-speed AT D: DOHC MPI Turbo center differential MT J: SOHC MPI center differential MT R: SOHC MPI 4-speed AT

The engine and transmission type are as follows:

Engine
EJ202NXVBB
Digits 1 and 2 3 and 4 5 Code EJ 20 2 Meaning Engine type Displacement Fuel feed system Details EJ: 4 cylinders 20: 2.0 L 1: D-MPI SOHC-A 2: D-MPI SOHC-B 4: MPI DOHC 5: MPI Turbo Used when ordering parts. See the parts catalog for details. W: AWD MT X: AWD AT V: Current model Used when ordering parts. See the parts catalog for details.

6 7 8 9 to 10

N X V BB

Detailed specifications Transmission Minor change Detailed specifications

ID-3

Identification

IDENTIFICATION

Transmission
TZ1A3ZN3AA
Digits 1 2 3 and 4 5 6 T Z 1A 3 Z Code Meaning Transmission Transmission type Classification Series Transmission specifications Details T: Transmission Y: Full-time AWD MT center differential Z: Full-time AWD AT MPT 75: MT 1A: New AT 3: AT 5: MT V: Full-time AWD 5-speed MT with viscous coupling center differential single range X: Full-time AWD 5-speed MT with viscous coupling center differential dual range Z: Full-time AWD 4-speed AT with MPT Used when ordering parts. See the parts catalog for details.

7 to 10

N3AA

Detailed specifications

Rear differential 1
VA1RFF
Digits 1 2 3 4 5 6 V A 1 R F F Code Meaning For AWD Type Hypoid gear diameter Details

V: AWD A: A type 1: 152 dia. 2: 160 dia. Installation position R: Rear Reduction gear ratio F: 4.444 Specification differences F: Case A

Rear differential 2
T1
Code T1 T2 TP BK BP BL VB Reduction gear ratio 3.900 4.111 4.444 4.111 4.111 4.444 3.700 LSD No No No No Strengthened type Strengthened type No

Option code
ECPS
Digits 1 to 2 Code EC Meaning Destination Details EC: EC KO: KO K4: K4 KS: KS EK: EK KA: KA K1: K1

3 to 4

PS

Main options on vehicle

ID-4

FUEL INJECTION (FUEL SYSTEMS)

FU(SOHC)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Page General Description Throttle Body Intake Manifold Engine Coolant Temperature Sensor Crankshaft Position Sensor Camshaft Position Sensor Knock Sensor Throttle Position Sensor Intake Air Temperature and Pressure Sensor Atmospheric Pressure Sensor ....................................................................2 Idle Air Control Solenoid Valve Air Assist Injector Solenoid Valve Fuel Injector Front Oxygen (A/F) Sensor Rear Oxygen Sensor Engine Control Module Main Relay Fuel Pump Relay Fuel Fuel Tank Fuel Filler Pipe Fuel Pump Fuel Level Sensor Fuel Sub Level Sensor Fuel Filter Fuel Cut Valve Fuel Damper Valve Fuel Delivery, Return and Evaporation Lines Fuel System Trouble in General

Fuel Injection (Fuel Systems)

ATMOSPHERIC PRESSURE SENSOR B: INSTALLATION


S155045A11

10. Atmospheric Pressure Sensor


S155045

A: REMOVAL

S155045A18

NOTE: Not applicable to vehicles with option code KS. <Ref. to ID-3, MODEL NUMBER PLATE, IDENTIFICATION, Identification.> 1) Disconnect battery ground cable.

NOTE: Not applicable to vehicles with option code KS. <Ref. to ID-3, MODEL NUMBER PLATE, IDENTIFICATION, Identification.> Install in the reverse order of removal. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)

EN1001 G6M0095

2) Disconnect connector from atmospheric pressure sensor. 3) Remove atmospheric pressure sensor from bracket.

EN1001

FU(SOHC)-2

AUTOMATIC TRANSMISSION

AT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Page General Description.....................................................................................2 Automatic Transmission Fluid Differential Gear Oil Road Test Stall Test......................................................................................................3 Time Lag Test Line Pressure Test Transfer Clutch Pressure Test Automatic Transmission Assembly Transmission Mounting System Extension Case Oil Seal Inhibitor Switch Front Vehicle Speed Sensor Rear Vehicle Speed Sensor Torque Converter Turbine Speed Sensor Control Valve Body Shift Solenoids, Duty Solenoids and ATF Temperature Sensor ATF Filter Transmission Control Module (TCM) ATF Cooler Pipe and Hose

Automatic Transmission

GENERAL DESCRIPTION
S502001

1. General Description
A: SPECIFICATIONS
Model Type Stall torque ratio Nominal diameter Stall speed (at sea level) One-way clutch
S502001E49

1. TORQUE CONVERTER CLUTCH

S502001E4901

Non-turbo model Turbo model Symmetric, 3 element, single stage, 2 phase torque converter 2.0 2.2 2.1 2.3 236 mm (9.29 in) 246 mm (9.69 in) 2,000 2,500 2,350 3,150 rpm rpm Sprague type one-way clutch

AT-2

STALL TEST

Automatic Transmission

5. Stall Test

S502246

A: INSPECTION
2. TEST METHODS

S502246A10

S502246A1002

1) Preparations before test: (1) Check that throttle valve opens fully. (2) Check that engine oil level is correct. (3) Check that coolant level is correct. (4) Check that ATF level is correct. (5) Check that differential gear oil level is correct. (6) Increase ATF temperature to 50 to 80C (122 to 176F) by idling the engine for approximately 30 minutes (with select lever set to N or P). 2) Install an engine tachometer at a location visible from the driver s compartment and mark the stall speed range on the tachometer scale. 3) Place the wheel chocks at the front and rear of all wheels and engage the parking brake. 4) Move the manual linkage to ensure it operates properly, and shift the select lever to the 2 range. 5) While forcibly depressing the foot brake pedal, gradually depress the accelerator pedal until the engine operates at full throttle.

ATF to deteriorate and the clutch and brake to be adversely affected. Be sure to cool down the engine for at least one minute after each stall test with the select lever set in the P or N range and with the idle speed lower than 1,200 rpm. If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the automatic transmission from sustaining damage. Stall speed (at sea level): Non-turbo model: 2,000 2,500 rpm Turbo model: 2,350 3,150 rpm

B3M0286C

(A) (B)

Brake pedal Accelerator pedal

6) When the engine speed is stabilized, read that speed quickly and release the accelerator pedal. 7) Shift the select lever to Neutral, and cool down the engine by idling it for more than one minute. 8) Record the stall speed. 9) If stall speed in 2 range is higher than specifications, low clutch slipping and 2-4 brake slipping may occur. To identify it, conduct the same test as above in D range. 10) Perform the stall tests with the select lever in the R range. NOTE: Do not continue the stall test for MORE THAN FIVE SECONDS at a time (from closed throttle, fully open throttle to stall speed reading). Failure to follow this instruction causes the engine oil and

AT-3

Automatic Transmission

STALL TEST

MEMO:

AT-4

WIPER AND WASHER SYSTEMS

WW
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Page General Description Wiper and Washer System .........................................................................2 Combination Switch (Wiper)........................................................................3 Wiper Blade Washer Tank and Motor Front Wiper Arm Front Wiper Motor and Link Front Washer Rear Wiper Arm Rear Wiper Motor Rear Washer Wiper Control Relay Headlight Washer

Wiper and Washer Systems

WIPER AND WASHER SYSTEM


S902394

2. Wiper and Washer System


A: SCHEMATIC
S902394A21

2. WIPER AND WASHER (REAR)

S902394A2102

SG51-21

WW-2

COMBINATION SWITCH (WIPER)

Wiper and Washer Systems

3. Combination Switch (Wiper)


S902395

LHD model:
Switch position Test connection 7 16 7 16 7 17 8 17 2 11 2 10 12 2 13 2 10 2 10 12 Specified condition Continuity Continuity Continuity Continuity Continuity Continuity No continuity Continuity Continuity Continuity

C: INSPECTION

S902395A10

Inspect the continuity between each connector terminal.

FRONT

REAR

OFF INT LO HI Washer ON Washer ON OFF INT ON Washer ON

If continuity is not as specified, replace the switch. RHD model:


Switch position OFF INT LO HI Washer ON Washer ON OFF INT ON Washer ON Test connection 3 12 3 12 3 11 2 11 8 17 8 16 18 8 15 8 18 8 16 18 Specified condition Continuity Continuity Continuity Continuity Continuity Continuity No continuity Continuity Continuity Continuity

FRONT

REAR
S6M0137

If continuity is not as specified, replace the switch.

WW-3

Wiper and Washer Systems

COMBINATION SWITCH (WIPER)

Intermittent operation inspection 1) Turn the wiper switch to INT. 2) Adjust the intermittent control switch to MAX. 3) Apply battery voltage to switch terminals 16 and 2, and inspect the voltage of terminals 7 and 2. (Measure the voltage from after the second time the wiper stops.)

B6M1465B

If operation is not as specified, replace the switch.

WW-4

EXTERIOR/INTERIOR TRIM

EI
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Page General Description.....................................................................................2 Front Grille Front Under Cover Front Bumper Rear Bumper ...............................................................................................4 Mud Guard Protector Cowl Panel Front Door Trim Rear Door Trim Glove Box Roof Rail Console Box Instrument Panel Assembly Upper Inner Trim Lower Inner Trim Rear Quarter Trim Sun Visor Roof Trim Rear Gate Trim Floor Mat Luggage Floor Mat

Exterior/Interior Trim

GENERAL DESCRIPTION
S911001

1. General Description
A: COMPONENT
2. REAR BUMPER
S911001A05 S911001A0511

Vehicle without option code KS

S5M0392A

(1) (2) (3) (4)

Bumper beam Cushion Lower center bracket Rear bumper plate

(5) (6) (7) (8)

Lower bracket Side upper bracket Bumper face Bumper side plate

Tightening torque: Nm (kgf-m, ft-lb) T: 93 (9.5, 69)

: For option code, refer to ID section. <Ref. to ID-3, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

EI-2

GENERAL DESCRIPTION
Vehicle with option code KS

Exterior/Interior Trim

S5M0392A

(1) (2) (3) (4)

Bumper beam Cushion Lower center bracket Rear bumper plate

(5) (6) (7) (8)

Lower bracket Side upper bracket Bumper face Bumper side plate

Tightening torque: Nm (kgf-m, ft-lb) T: 93 (9.5, 69)

: For option code, refer to ID section. <Ref. to ID-3, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

EI-3

Exterior/Interior Trim

REAR BUMPER
S911370

5. Rear Bumper
A: REMOVAL
S911370A18

8) Remove bolts from bumper stay.

CAUTION: Handle bumper carefully to avoid damage to bumper face. Do not damage body during removal or installation of bumper. To avoid damage to bumper, lay removed bumper on sheet spread on the floor. Do not lay it directly on the floor. 1) Disconnect the ground cable from the battery. 2) Open rear gate. 3) Remove the five screws and the clip from the rear bumper. 9) Remove rear bumper beam.

G5M0161

S5M0399

4) Disconnect license plate light and rear fog light (if equipped) connectors. 5) Remove bolts and clips from under side of bumper.

S5M0157

6) Remove bumper face and E/A foam. 7) Remove the canister. (with OBD model) <Ref. to EC(DOHC TURBO)-6, REMOVAL, Canister.> and <Ref. to EC(SOHC)-7, REMOVAL, Canister.>

EI-4

WIRING SYSTEM

WI
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. Page Basic Diagnostics Procedure Working Precautions Power Supply Routing Ground Distribution Airbag System Air Conditioning System Anti-lock Brake System A/T Control System Audio System Back-up Light System Charging System Clearance Light and Illumination Light System Combination Meter Cruise Control System Door Lock System Engine Electrical System ...........................................................................3 Front Accessory Power Supply System Front Fog Light System Fuel Gauge System Full-Time Dual-Range System Headlight Beam Leveler System Headlight System Headlight Washer System Horn System Immobilizer System In Compartment Light System Keyless Entry System Oil Pressure and Temperature Gauge System Outside Temperature Display System Parking Brake and Brake Fluid Level Warning System Power Window System Radiator Fan System Rear Accessory Power Supply System Rear Differential Oil Temperature Warning System Rear Fog Light System Rear Window Defogger System Remote Controlled Rearview Mirror System Seat Belt Warning System Seat Heater System Starter System Stop Light System Sunroof System Turn Signal Light and Hazard Light System Wiper and Washer System (Front)

Wiring System

REAR BUMPER
45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. Wiper and Washer System (Rear) ............................................................12 Wiper Deicer System Overall Systems Front Wiring Harness Bulkhead Wiring Harness (In Engine Room) Bulkhead Wiring Harness (In Compartment) ............................................14 Engine Wiring Harness and Transmission Cord Instrument Panel Wiring Harness Rear Wiring Harness.................................................................................16 Door Cord Rear Gate Cord

WI-2

ENGINE ELECTRICAL SYSTEM

Wiring System

16. Engine Electrical System


A: SCHEMATIC
S903482A21

S903482

1. LHD SOHC MODEL

S903482A2121

SL10-23A

WI-3

Wiring System

ENGINE ELECTRICAL SYSTEM

SL10-23B

WI-4

ENGINE ELECTRICAL SYSTEM

Wiring System

SL10-23C

WI-5

Wiring System

ENGINE ELECTRICAL SYSTEM

SL10-23D

WI-6

ENGINE ELECTRICAL SYSTEM

Wiring System

SL10-23E

WI-7

Wiring System

ENGINE ELECTRICAL SYSTEM

SL10-23F

WI-8

ENGINE ELECTRICAL SYSTEM

Wiring System

SL10-23G

WI-9

Wiring System

ENGINE ELECTRICAL SYSTEM

SL10-23H

WI-10

ENGINE ELECTRICAL SYSTEM

Wiring System

SL10-23I

WI-11

Wiring System

WIPER AND WASHER SYSTEM (REAR)


S903443

45. Wiper and Washer System (Rear)


A: SCHEMATIC
S903443A21

SG51-21

WI-12

WIPER AND WASHER SYSTEM (REAR)


MEMO:

Wiring System

WI-13

Wiring System

BULKHEAD WIRING HARNESS (IN COMPARTMENT)


S903446

50. Bulkhead Wiring Harness (In Compartment)


A: LOCATION
1. LHD MODEL
Connector Pole Color
25 7 3 16 24 16 2 4 6 10 4 6 4 8 12 6 24 24 24 8 20 B62 16 B64 B65 B68 B69 B70 B71 B72 B74 B75 B76 B79 B81 B82 B83 B84 B85 B86 B87 B88 B90 B94 B97 B98 B99 B101 B104 B107 B108 B116 B118 B119 B120 B121 B122 2 4 5 4 18 17 4 2 2 2 14 12 6 6 17 2 6 2 3 8 20 10 12 20 25 4 2 20 4 2 1 14 1 6 5 Black Black Black 5 5 5 Blue Black Green Green Gray 5 Black 5 5 5 5 5 5 5 5 Blue 5 5 5 5 Blue 5 Black 5 5 5 Black 5 B-1 B-2 B-2 C-2 C-2 C-2 C-2 B-2 C-2 B-2 B-2 C-2 B-2 B-2 D-4 C-4 B-3 B-3 B-3 B-3 B-4 C-1 B-4 B-4 B-4 B-4 C-1 B-2 B-1 C-3 C-3 C-3 C-3 C-3 C-4 F46 F45 5 Yellow Black 5 Black Black 5 Blue Brown 5 Green Brown 5 Blue Blue 5 5 Gray Green 5 5
S903446A13 S903446A1308

No.
B30 B31 B32 B36 B37 B40 B41 B42 B43 B44 B46 B47 B50 B51 B52 B53 B54 B55 B56 B61

Area
C-1 C-1 B-1 B-2 B-2 C-2 B-1 B-1 B-4 C-2 B-1 B-1 B-1 C-1 C-1 B-2 C-2 C-2 C-2 B-1 B-1

No.
D1 AB1 i1 i2

Connecting to Name
Front door cord LH SRS (Airbag) harness Turn & hazard module Instrument panel meter harness Data link connector Power window circuit breaker Power window relay Illumination control module Seat belt timer Fuel pump relay Main relay Blower relay F/B Shield joint connector (AT)

No.
B125

Connector Pole Color


1 1 1 Black Green Black Green Black Blue 5 Gray 5 Gray 5 Gray 5 Black 5 5 5 5 Red 5 Gray Black Brown 5 5 5 5 5 5 Black 5 5 5 5 5 5 5 5 5 5 Blue Blue 5 Black 5 5 Black 5 Black Black Black 5 5 5

Area
B-2 B-4 B-2 B-4 B-2 B-2 C-4 C-4 C-4 C-4 C-4 C-4 C-4 B-4 B-2 B-2 B-2 B-1 B-1 B-1 B-1 C-1 C-1 C-2 C-2 C-3 B-3 B-3 B-3 B-4 C-1 C-3 C-2 B-1 B-2 B-2 B-4 B-4 C-1 C-1 C-2 B-4 B-4 C-2 C-1 B-3 B-3 C-2 B-3 B-1 B-1 B-2 B-1 C-2

No.
B126

Connecting to Name
Read memory connector (Without OBD) Line end connector (With OBD) Read memory connector (Without OBD) Line end connector (With OBD) Kick-down switch (AT) Rear fog light relay Engine control module (DOHC turbo model) Engine control module (SOHC model) Engine control module (DOHC turbo model) Engine control module (SOHC model) Engine control module (DOHC turbo model) Engine control module (SOHC model) Engine control module (DOHC turbo model) Headlight washer module Immobilizer control module (With OBD) Immobilizer control module (Without OBD) Immobilizer antenna F/B Ignition relay F/B C/B Front fog light switch Cruise control main switch Combination switch cord Combination switch cord Front accessory power supply socket illumination light A/C switch Blower fan switch Mode control panel illumination light Mirror heater relay IG power supply connector Ash tray illumination light Keyless entry control module Wiper deicer Joint connector (E/G) (SOHC without OBD) Joint connector (E/G) (MT) (SOHC without OBD) Joint connector (Keyless entry) Speed warning module Wiper deicer relay Wiper deicer timer Wiper deicer switch Rear fog light switch Diode (Rear fog light) Panel-center harness Noise filter Glove box illumination light Front wiring harness (DOHC turbo model) Key switch illumination light Flash memory connector (DOHC turbo model) Shield joint connector (AT)

B125

B126 1 B129 B131 B134 35 28 B135 28 24 2 4 22

Transmission control module (AT) F44 F45 Front wiring harness Front wiring harness (DOHC turbo model) Front wiring harness (SOHC model) Stop light switch (Without cruise control) Stop & brake switch (With cruise control) Cruise control sub switch Combination switch Ignition switch Key warning switch B76 B75 Test mode connector Check connector Diagnosis terminal (Ground) Diagnosis connector Shield joint connector (SOHCwithOBD) Engine control module (DOHC turbo model) Diode (Lighting) Blower motor resistor Blower motor Evaporator thermoswitch Roof cord Cruise control module Rear wiring harness Front door cord RH Seat heater/rear accessory power supply relay Clutch switch (MT-cruise control) Front wiring harness Select lever illumination light and power switch (AT) CD player illumination light Front accessory power supply socket Radio Audio ground Sensor ground joint connector (With OBD)

B136 30 B137 B140 B141 15 B142 B152 B157 B158 B159 B160 B161 B162 B164 B167 B168 B169 B170 B171 B173 B175 B176 B177 B179 B180 B181 B182 B183 B184 B190 B191 B192 B193 B195 B196 B200 B203 B208 B209 B210 B224 B250 2 7 4 12 10 6 6 8 18 3 3 6 2 4 1 2 18 2 12 12 1 1 1 1 5 4 4 6 6 2 14 4 2 24 6 2 3 31 6 12

B163 B165

B180 B179 B182 B181 B184 B183

R50 R1 R2 R3 D11

i4

F75 F76

B299 8 5: Non-colored

WI-14

BULKHEAD WIRING HARNESS (IN COMPARTMENT)

Wiring System

S6M0601A

WI-15

Wiring System

REAR WIRING HARNESS


S903431

53. Rear Wiring Harness


A: LOCATION
1. LHD MODEL
No. R1 R2 R3 R4 R8 R9 R11 R12 R14 R15 R16 R22 R26 R28 R30 R32 R37 R38 R39 R41 R42 R43 R44 R48 R50 R52 R56 R57 R58 R59 R63 R70 R72 R73 R79 R80 R81 R82 R92 R97 R98 R116 5: Non-colored
S903431A13 S903431A1306

Connector Pole Color 10 5 12 5 20 5 1 5 4 5 1 5 4 5 1 5 4 5 6 Black 1 Brown 1 Brown 6 5 6 5 2 5 2 5 2 5 6 5 4 5 4 Blue 4 5 4 Blue 4 Blue 12 5 8 5 2 5 3 5 2 5 8 5 6 5 2 5 4 5 3 5 2 5 2 5 10 5 3 5 3 5 4 5 2 5 2 Brown 2 8 5 5

Area C-2 C-2 C-2 C-3 C-3 C-3 C-3 B-2 B-2 B-3 B-3 B-4 B-3 B-4 B-3 B-3 B-3 B-3 B-3 C-2 C-3 C-3 C-3 C-3 B-2 A-3 A-3 B-2 B-3 B-3 C-3 B-4 C-2 B-3 C-3 B-3 B-2 C-3 B-2 C-3 B-4 B-3 B-3

No. B97 B98 B99

Connecting to Name Bulkhead wiring harness Parking brake switch Seat belt switch Front door switch LH Rear door cord LH Front door switch RH Rear door cord RH Fuel tank cord Rear door switch RH Rear door switch LH Rear combination light RH Rear combination light LH Diode (Luggage room light) Rear accessory power supply Rear gate cord Seat heater RH Seat heater switch RH Seat heater switch LH Seat heater LH Front wiring harness (ABS) Bulkhead wiring harness Room light (With sunroof model) Room light (Without sunroof model) Spot light Rear wiring harness Fuel gauge module & fuel pump assembly Fuel gauge sub module License plate light ABS G sensor Rear ABS sensor RH Rear ABS sensor LH Trailer connector Rear door cord RH Rear door cord LH Clock Hold mode switch (AT) Antenna amplifier Rear differential oil temp switch (Turbo model for Europe) Rear wiper intermittent module

D21 D27 R57

D33 D34 D35

F55 B90

R15

D64 D63

WI-16

REAR WIRING HARNESS

Wiring System

S6M0602A

WI-17

Wiring System

REAR WIRING HARNESS


S903431A1301

2. RHD MODEL
No. R1 R2 R3 R4 R8 R9 R11 R12 R14 R15 R16 R22 R26 R28 R30 R32 R37 R38 R39 R41 R42 R43 R44 R50 R52 R55 R56 R57 R58 R59 R63 R70 R72 R73 R79 R80 R81 R82 R92 R97 R98 R116 5: Non-colored

Connector Pole Color 10 5 18 5 20 Blue 1 5 4 5 1 5 4 5 1 5 4 5 6 Black 1 Brown 1 Brown 6 5 6 5 2 5 2 5 2 5 6 5 4 5 4 Blue 4 5 4 Blue 4 Blue 8 5 2 5 3 5 1 5 2 5 8 5 6 5 2 5 4 5 3 5 2 5 2 5 10 5 3 5 3 5 4 5 2 5 2 Brown 2 8 5 5

Area B-2 B-2 B-2 C-3 C-3 C-3 C-3 B-2 B-2 B-3 B-3 B-4 B-3 B-4 B-3 B-3 A-3 B-3 B-3 B-2 C-3 C-3 C-3 B-2 A-3 A-3 B-3 B-2 B-3 B-3 B-3 B-4 C-3 B-3 C-3 B-3 B-2 C-3 B-3 C-3 B-4 B-3 B-3

No. B97 B98 B99

Connecting to Name Bulkhead wiring harness Parking brake switch Seat belt switch Front door switch LH Rear door cord LH Front door switch RH Rear door cord RH Fuel tank cord Rear door switch RH Rear door switch LH Rear combination light RH Rear combination light LH Diode (Luggage room light) Rear accessory power supply Rear gate cord Seat heater RH Seat heater switch RH Seat heater switch LH Seat heater LH Bulkhead wiring harness Room light (With sunroof model) Room light (Without sunroof model) Sunroof motor Spot light Rear wiring harness Fuel gauge module & fuel pump assembly Fuel gauge sub module License plate light ABS G sensor Rear ABS sensor RH Rear ABS sensor LH Trailer connector Rear door cord RH Rear door cord LH Clock Hold mode switch (AT) Antenna amplifier Rear differential oil temp switch (Turbo model for Europe) Rear wiper intermittent module

D21 D27 R57

D33 D34 D35

B90

R15

D64 D63

WI-18

REAR WIRING HARNESS

Wiring System

S6M0603A

WI-19

Wiring System

REAR WIRING HARNESS

MEMO:

WI-20

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