Subaru WRX Sti 2013 Pkfnpo - Ru 2

13IM_STI_US.
book 329 ページ２０１２年６月１２日　火曜日　午後２時４０分
Diagnostic Procedure with Diagnostic Trouble Code (DTC)

ENGINE (DIAGNOSTICS)
WIRING DIAGRAM:
• Engine electrical system, without SI-DRIVE <Ref. to WI-32, WITHOUT SI-DRIVE, WIRING DIAGRAM,
Engine Electrical System.>
• Engine electrical system, with SI-DRIVE <Ref. to WI-48, WITH SI-DRIVE, WIRING DIAGRAM, Engine
Electrical System.>
ECM
A: B134 D: B137
D10
A29
A19
A24
A23
D11
A26
A25
B21
27
28
30
29
16
19
6
8
E2
E51 E55
1
TUMBLE GENERATOR TUMBLE GENERATOR

VALVE ACTUATOR LH VALVE ACTUATOR RH
B21
A: B134 D: B137
1 2 3 4 5 6 7 8 9 10 11
E51 E55
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 1 2 3 4 5 6 7
23 24 25 26 27 28 29 30 31 32 33
1 2 3 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17
4 5 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25 34 35 36 37 38 39 40 41
28 29 30 31 32 33 34 26 27 28 29 30 31 42 43 44 45 46 47
48 49 50 51 52 53 54
EN-09253
EN(H4DOTC)(diag)-329
13IM_STI_US.book 330 ページ２０１２年６月１２日　火曜日　午後２時４０分

Step Check Yes No

1 CHECK CURRENT DATA. Is the value of «TGV Position Go to step 2. Even if DTC is
1) Start the engine. Sensor L» less than 0.2 V? detected, the cir-
2) Read the value of «TGV Position Sensor L» cuit has returned to
using the Subaru Select Monitor. a normal condition
NOTE: at this time. Repro-
For detailed operation procedures, refer to duce the failure,
“READ CURRENT DATA FOR ENGINE”. <Ref. and then perform
to EN(H4DOTC)(diag)-39, Subaru Select Moni- the diagnosis
tor.> again.
NOTE:
In this case, tem-
porary poor con-
tact of connector,
temporary open or
short circuit of har-
ness may be the
cause.
2 CHECK POWER SUPPLY OF TUMBLE GEN- Is the voltage 4.5 V or more? Go to step 3. Repair the harness
ERATOR VALVE ASSEMBLY LH. and connector.
1) Turn the ignition switch to OFF. NOTE:
2) Disconnect the connector from tumble gen- In this case, repair
erator valve assembly LH. the following item:
3) Turn the ignition switch to ON. • Open circuit in
4) Measure the voltage between tumble gener- harness between
ator valve assembly LH connector and engine ECM and tumble
ground. generator valve
Connector & terminal assembly LH con-
(E51) No. 3 (+) — Engine ground (–): nector
• Poor contact of
ECM connector
• Poor contact of
coupling connector
3 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. Repair the harness
TUMBLE GENERATOR VALVE ASSEMBLY and connector.
LH CONNECTOR. NOTE:
1) Turn the ignition switch to OFF. In this case, repair
2) Disconnect the connector from ECM. the following item:
3) Measure the resistance of harness between • Open circuit in
ECM and tumble generator valve assembly LH. harness between
Connector & terminal ECM and tumble
(B137) No. 10 — (E51) No. 1: generator valve
assembly LH con-
nector
• Poor contact of
coupling connector
4 CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or Go to step 5. Repair the short
TUMBLE GENERATOR VALVE ASSEMBLY more? circuit to ground in
LH CONNECTOR. harness between
Measure the resistance between ECM and ECM and tumble
chassis ground. generator valve
Connector & terminal assembly LH con-
(B137) No. 10 — Chassis ground: nector.

Step Check Yes No

5 CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Replace the tum-
Check for poor contact of ECM and tumble gen- the tumble generator valve contact of ECM or ble generator valve
erator valve assembly LH connector. assembly LH connector? tumble generator assembly LH.
valve assembly LH <Ref. to FU(STI)-
connector. 48, Tumble Gener-
ator Valve Assem-
bly.> <Ref. to
FU(w/o STI)-48,
Tumble Generator
Valve Assembly.>

EB:DTC P2022 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT

HIGH
DTC DETECTING CONDITION:
• Immediately at fault recognition
• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-230, DTC P2022 TUMBLE GENERATED VALVE PO-
SITION SENSOR 2 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
• Improper idling
• Engine stalls.
• Poor driving performance
CAUTION:
After servicing or replacing faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)-62,
OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-48, PROCE-
DURE, Inspection Mode.>.

WIRING DIAGRAM:
Electrical System.>
ECM
A: B134 D: B137
D10
A29
A19
A24
A23
D11
A26
A25
B21
27
28
30
29
16
19
6
8
E2
E51 E55
1
TUMBLE GENERATOR TUMBLE GENERATOR

VALVE ACTUATOR LH VALVE ACTUATOR RH
B21
A: B134 D: B137
1 2 3 4 5 6 7 8 9 10 11
E51 E55
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 1 2 3 4 5 6 7
23 24 25 26 27 28 29 30 31 32 33
1 2 3 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17
4 5 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25 34 35 36 37 38 39 40 41
28 29 30 31 32 33 34 26 27 28 29 30 31 42 43 44 45 46 47
48 49 50 51 52 53 54
EN-09253

Step Check Yes No

1 CHECK CURRENT DATA. Is the value of «TGV Position Go to step 2. Even if DTC is
1) Start the engine. Sensor L» 5 V or more? detected, the cir-
2) Read the value of «TGV Position Sensor L» cuit has returned to
using the Subaru Select Monitor. a normal condition
tor.> again.
NOTE:
In this case, tem-
porary poor con-
tact of connector,
temporary open or
ness may be the
cause.
2 CHECK HARNESS BETWEEN ECM AND Is the value of «TGV Position Repair the short Go to step 3.
TUMBLE GENERATOR VALVE ASSEMBLY Sensor L» 5 V or more? circuit to power in
LH CONNECTOR. harness between
1) Turn the ignition switch to OFF. ECM and tumble
2) Disconnect the connector from tumble gen- generator valve
erator valve assembly LH. assembly LH con-
3) Start the engine. nector.
4) Read the value of «TGV Position Sensor L»
using the Subaru Select Monitor.
NOTE:
For detailed operation procedures, refer to
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(H4DOTC)(diag)-39, Subaru Select Moni-
tor.>
TUMBLE GENERATOR VALVE ASSEMBLY and connector.
LH CONNECTOR. NOTE:
2) Measure the resistance of harness between the following item:
tumble generator valve assembly LH connector • Open circuit in
and engine ground. harness between
Connector & terminal ECM and tumble
(E51) No. 2 — Engine ground: generator valve
assembly LH con-
nector
• Poor contact of
ECM connector
• Poor contact of
coupling connector
4 CHECK FOR POOR CONTACT. Is there poor contact of the tum- Repair the poor Replace the tum-
Check for poor contact of tumble generator ble generator valve assembly contact of tumble ble generator valve
valve assembly LH connector. LH connector? generator valve assembly LH.
assembly LH con- <Ref. to FU(STI)-
nector. 48, Tumble Gener-
ator Valve Assem-
bly.> <Ref. to
FU(w/o STI)-48,
Tumble Generator
Valve Assembly.>

EC:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

LOW (BANK 1)
• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-232, 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:
Electrical System.>
ECM
17
16
34
27
B134
B21
32
33
21
22
E2
E37 E38
1
2
1
2
INTAKE OIL FLOW INTAKE OIL FLOW

CONTROL SOLENOID CONTROL SOLENOID
VALVE LH VALVE RH
B21
B134
1 2 3 4 5 6 7 8 9 10 11
E37 E38
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 23 24 25 26 27 28 29 30 31 32 33
1 2 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 34 35 36 37 38 39 40 41
28 29 30 31 32 33 34 42 43 44 45 46 47
48 49 50 51 52 53 54
EN-09254

Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 2. Repair the harness
FLOW CONTROL SOLENOID VALVE RH and connector.
CONNECTOR. NOTE:
2) Disconnect the connectors from ECM and the following item:
oil flow control solenoid valve RH. • Open circuit in
3) Measure the resistance of harness between harness between
ECM and oil flow control solenoid valve RH con- ECM and oil flow
nector. control solenoid
Connector & terminal valve RH connec-
(B134) No. 34 — (E38) No. 1: tor
(B134) No. 27 — (E38) No. 2: • Poor contact of
coupling connector
2 CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or Go to step 3. Repair the short
FLOW CONTROL SOLENOID VALVE RH more? circuit to ground in
CONNECTOR. harness between
Measure the resistance between ECM and ECM and oil flow
chassis ground. control solenoid
(B134) No. 34 — Chassis ground: tor.
(B134) No. 27 — Chassis ground:
3 CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? Repair the poor Replace the oil
VALVE. contact of ECM flow control sole-
Measure the resistance between oil flow control and oil flow control noid valve RH.
solenoid valve terminals. solenoid valve RH <Ref. to ME(STI)-
Terminals connector. 60, Camshaft.>
No. 1 — No. 2: <Ref. to ME(w/o
STI)-59, Cam-
shaft.>

ED: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:
Electrical System.>
ECM
17
16
34
27
B134
B21
32
33
21
22
E2
E37 E38
1
2
1
2

VALVE LH VALVE RH
B21
B134
1 2 3 4 5 6 7 8 9 10 11
E37 E38
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 23 24 25 26 27 28 29 30 31 32 33
1 2 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 34 35 36 37 38 39 40 41
28 29 30 31 32 33 34 42 43 44 45 46 47
48 49 50 51 52 53 54
EN-09254

Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. Repair the short
FLOW CONTROL SOLENOID VALVE RH circuit to power
CONNECTOR. supply in harness
1) Turn the ignition switch to OFF. between ECM and
2) Disconnect the connectors from ECM and oil flow control
oil flow control solenoid valve RH. solenoid valve RH
3) Measure the voltage between ECM and connector.
chassis ground.
Connector & terminal
(B134) No. 34 (+) — Chassis ground (–):
CONNECTOR. NOTE:
Measure the resistance of harness between In this case, repair
ECM and oil flow control solenoid valve RH con- the following item:
nector. • Open circuit in
Connector & terminal harness between
(B134) No. 34 — (E38) No. 1: ECM and oil flow
(B134) No. 27 — (E38) No. 2: control solenoid
valve RH connec-
tor
• Poor contact of
coupling connector
solenoid valve terminals. solenoid valve RH <Ref. to ME(STI)-
STI)-59, Cam-
shaft.>

EE:DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-

CUIT LOW (BANK 1)
• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-234, DTC P2090 EXHAUST CAMSHAFT POSITION
ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
Engine electrical system, with SI-DRIVE <Ref. to WI-48, WITH SI-DRIVE, WIRING DIAGRAM, Engine Elec-
trical System.>
ECM
14
15
B134
5
B21
42
43
17
7
E2
E66 E63
1
2
1
2
EXHAUST OIL FLOW EXHAUST OIL FLOW

CONTROL CONTROL
SOLENOID VALVE LH SOLENOID VALVE RH
B21
B134
1 2 3 4 5 6 7 8 9 10 11
E63 E66
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 23 24 25 26 27 28 29 30 31 32 33
1 2 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 34 35 36 37 38 39 40 41
28 29 30 31 32 33 34 42 43 44 45 46 47
48 49 50 51 52 53 54
EN-09255

Step Check Yes No

CONNECTOR. NOTE:
oil flow control solenoid valve RH. • Open circuit in
ECM and oil flow control solenoid valve RH con- ECM and oil flow
(B134) No. 7 — (E63) No. 1: tor
coupling connector
FLOW CONTROL SOLENOID VALVE RH more? circuit to ground in
solenoid valve terminals. solenoid valve RH <Ref. to FU(STI)-
Terminals connector. 50, Oil Flow Con-
No. 1 — No. 2: trol Solenoid
Valve.>

EF:DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-

CUIT HIGH (BANK 1)
ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
trical System.>
ECM
14
15
B134
5
B21
42
43
17
7
E2
E66 E63
1
2
1
2

CONTROL CONTROL
B21
B134
1 2 3 4 5 6 7 8 9 10 11
E63 E66
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 23 24 25 26 27 28 29 30 31 32 33
1 2 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 34 35 36 37 38 39 40 41
28 29 30 31 32 33 34 42 43 44 45 46 47
48 49 50 51 52 53 54
EN-09255

Step Check Yes No

FLOW CONTROL SOLENOID VALVE RH circuit to power
oil flow control solenoid valve RH. solenoid valve RH
chassis ground.
CONNECTOR. NOTE:
ECM and oil flow control solenoid valve RH con- the following item:
valve RH connec-
tor
• Poor contact of
coupling connector
solenoid valve terminals. solenoid valve RH <Ref. to FU(STI)-
Valve.>

EG: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:
Electrical System.>
ECM
17
16
34
27
B134
B21
32
33
21
22
E2
E37 E38
1
2
1
2

VALVE LH VALVE RH
B21
B134
1 2 3 4 5 6 7 8 9 10 11
E37 E38
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 23 24 25 26 27 28 29 30 31 32 33
1 2 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 34 35 36 37 38 39 40 41
28 29 30 31 32 33 34 42 43 44 45 46 47
48 49 50 51 52 53 54
EN-09254

Step Check Yes No

FLOW CONTROL SOLENOID VALVE LH and connector.
CONNECTOR. NOTE:
oil flow control solenoid valve LH. • Open circuit in
ECM and oil flow control solenoid valve LH con- ECM and oil flow
Connector & terminal valve LH connec-
(B134) No. 17 — (E37) No. 1: tor
coupling connector
FLOW CONTROL SOLENOID VALVE LH more? circuit to ground in
Measure the resistance between oil flow control and oil flow control noid valve LH.
solenoid valve terminals. solenoid valve LH <Ref. to ME(STI)-
STI)-59, Cam-
shaft.>

EH: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:
Electrical System.>
ECM
17
16
34
27
B134
B21
32
33
21
22
E2
E37 E38
1
2
1
2

VALVE LH VALVE RH
B21
B134
1 2 3 4 5 6 7 8 9 10 11
E37 E38
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 23 24 25 26 27 28 29 30 31 32 33
1 2 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 34 35 36 37 38 39 40 41
28 29 30 31 32 33 34 42 43 44 45 46 47
48 49 50 51 52 53 54
EN-09254

Step Check Yes No

FLOW CONTROL SOLENOID VALVE LH circuit to power
oil flow control solenoid valve LH. solenoid valve LH
chassis ground.
CONNECTOR. NOTE:
ECM and oil flow control solenoid valve LH con- the following item:
valve LH connec-
tor
• Poor contact of
coupling connector
solenoid valve terminals. solenoid valve LH <Ref. to ME(STI)-
STI)-59, Cam-
shaft.>

EI: DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-

CUIT LOW (BANK 2)
ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
trical System.>
ECM
14
15
B134
5
B21
42
43
17
7
E2
E66 E63
1
2
1
2

CONTROL CONTROL
B21
B134
1 2 3 4 5 6 7 8 9 10 11
E63 E66
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 23 24 25 26 27 28 29 30 31 32 33
1 2 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 34 35 36 37 38 39 40 41
28 29 30 31 32 33 34 42 43 44 45 46 47
48 49 50 51 52 53 54
EN-09255

Step Check Yes No

CONNECTOR. NOTE:
oil flow control solenoid valve LH. • Open circuit in
ECM and oil flow control solenoid valve LH con- ECM and oil flow
(B134) No. 5 — (E66) No. 1: tor
coupling connector
FLOW CONTROL SOLENOID VALVE LH more? circuit to ground in
solenoid valve terminals. solenoid valve LH <Ref. to FU(STI)-
Valve.>

EJ:DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-

CUIT HIGH (BANK 2)
ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
trical System.>
ECM
14
15
B134
5
B21
42
43
17
7
E2
E66 E63
1
2
1
2

CONTROL CONTROL
B21
B134
1 2 3 4 5 6 7 8 9 10 11
E63 E66
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 23 24 25 26 27 28 29 30 31 32 33
1 2 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 34 35 36 37 38 39 40 41
28 29 30 31 32 33 34 42 43 44 45 46 47
48 49 50 51 52 53 54
EN-09255

Step Check Yes No

FLOW CONTROL SOLENOID VALVE LH circuit to power
oil flow control solenoid valve LH. solenoid valve LH
chassis ground.
CONNECTOR. NOTE:
ECM and oil flow control solenoid valve LH con- the following item:
valve LH connec-
tor
• Poor contact of
coupling connector
solenoid valve terminals. solenoid valve LH <Ref. to FU(STI)-
Valve.>

EK:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
• Detected when two consecutive driving cycles with fault occur.
• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-237, DTC P2096 POST CATALYST FUEL TRIM SYS-
TEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
• Models without SI-DRIVE <Ref. to WI-32, WITHOUT SI-DRIVE, WIRING DIAGRAM, Engine Electrical
System.>
A/F, OXYGEN SENSOR FUSE E22 B138
B220 BATTERY
RELAY (RELAY BLOCK)
15A SBF-5 1 2 1 2 3
9 2 1 3 4 4 5 6
10
B21 B220
11
42
12
E2 1 2 9 13 17 21
B220 3 4 10 14 18 22
4
11 12 15 16 19 20 23 24
5 6
E
FRONT OXYGEN (A/F) 7 8 25 29 33 37
SENSOR 26 30 34 38
27 28 31 32 35 36 39 40
E22
B21
2
3
1
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E2 34 35 36 37 38 39 40 41
42 43 44 45 46 47
43
26
15
B21 48 49 50 51 52 53 54
E *
*
A: B134
B138
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
C18
C19
C9
C5
C6
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
A: B134
C: B136
C: B136 ECM
1 2 3 4 5 6
D: B137 7 8 9 10 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
D1
A3
A6
D3
A4
D: B137
1 2 3 4 5 6 7
B21 8 9 10 11 12 13 14 15 16 17
34
35
36
40
18 19 20 21 22 23 24 25
E2 26 27 28 29 30 31
: TERMINAL No. OPTIONAL ARRANGEMENT

*
E
EN-08720

A/F, OXYGEN SENSOR B220 FUSE B19 B83

RELAY (RELAY BLOCK) BATTERY
15A SBF-5 T6 B138
9 2 1
10 1 2 1 2 3
B19 3 4 4 5 6
11
2
12 B220
T5
B220 1 2 9 13 17 21
2
3 4 10 14 18 22
11 12 15 16 19 20 23 24
REAR 5 6
OXYGEN SENSOR
E
7 8 25 29 33 37
T6 26 30 34 38
27 28 31 32 35 36 39 40
1
3
4
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
T5 23 24 25 26 27 28 29 30 31 32 33
1
3
4
B83 34 35 36 37 38 39 40 41
B19
42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
A: B134
*
* 1 2 3 4 5 6 7
B138 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
B30
C20
C9
28 29 30 31 32 33 34
B6
A: B134 B: B135
B: B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
C: B136
D1
A3
A6
D3
A4
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
B21 17 18 19 20 21 22 23 24 25 26 27
34
35
36
40
: TERMINAL No. OPTIONAL ARRANGEMENT 28 29 30 31 32 33 34 35

E2 *
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
E 18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-08722

• Models with SI-DRIVE <Ref. to WI-48, WITH SI-DRIVE, WIRING DIAGRAM, Engine Electrical System.>
B379 B138
2 1 1 2 3
A/F, OXYGEN SENSOR FUSE 4 5 6
B220 (RELAY BLOCK) 4 3
RELAY BATTERY
15A SBF-5 B220
9 2 1
10
1 2 9 13 17 21
3 4 10 14 18 22
11
12 11 12 15 16 19 20 23 24
5 6
1
7 8 25 29 33 37
B220
26 30 34 38
FRONT OXYGEN (A/F) E 27 28 31 32 35 36 39 40
SENSOR
B379 B21
4
2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
*
* 34 35 36 37 38 39 40 41
42 43 44 45 46 47
B138 48 49 50 51 52 53 54
C18
C19
C9
C5
C6
A: B134
A: B134 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
C: B136 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
D: B137
C: B136
D1
A3
A6
D3
A4
1 2 3 4 5 6
7 8 9 10 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
B21
34
35
36
40
E2 D: B137
: TERMINAL No. OPTIONAL ARRANGEMENT 1 2 3 4 5 6 7

* 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
E
EN-08721

A/F, OXYGEN SENSOR FUSE

B220 (RELAY BLOCK) B19 B83
RELAY BATTERY
15A SBF-5 T6 B138
9 2 1
10 1 2 1 2 3
3 4 4 5 6
B19
11
2
12 B220
T5
B220 1 2 9 13 17 21
2
3 4 10 14 18 22
11 12 15 16 19 20 23 24
5 6
REAR
E
7 8 25 29 33 37
OXYGEN SENSOR
26 30 34 38
T6 27 28 31 32 35 36 39 40
B21
1
3
4
T5 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
1
3
4
B19 B83 23 24 25 26 27 28 29 30 31 32 33
* 34 35 36 37 38 39 40 41
* 42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
A: B134
B138
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B30
C20
C9
B6
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
A: B134
B: B135
B: B135
ECM
1 2 3 4 5 6 7
C: B136
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
D: B137
28 29 30 31 32 33 34 35
D1
A3
A6
D3
A4
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
34
35
36
40
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
*
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
E 18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-08723
Step Check Yes No

1 CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Go to step 2.
“List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(H4DOTC)(diag)
-87, List of Diagnos-
tic Trouble Code
(DTC).>
2 CHECK FRONT OXYGEN (A/F) SENSOR Has water entered the connec- Completely Go to step 3.
CONNECTOR AND COUPLING CONNEC- tor? remove any water
TOR. inside.

Step Check Yes No

FRONT OXYGEN (A/F) SENSOR CONNEC- and connector.
TOR. NOTE:
front oxygen (A/F) sensor. • Open circuit in
ECM and front oxygen (A/F) sensor connector. ECM and front oxy-
Connector & terminal gen (A/F) sensor
Models without SI-DRIVE connector
(B136) No. 18 — (E22) No. 3: front oxygen (A/F)
Models with SI-DRIVE sensor connector
(B136) No. 19 — (B379) No. 4: • Poor contact of
(B136) No. 18 — (B379) No. 3: ECM connector
• Poor contact of
coupling connector
4 CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or Go to step 5. Repair the ground
FRONT OXYGEN (A/F) SENSOR CONNEC- more? short circuit of har-
TOR. ness between
Measure the resistance between ECM and ECM and front oxy-
chassis ground. gen (A/F) sensor
Connector & terminal connector.
5 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 4.5 V or more? Go to step 7. Go to step 6.
1) Connect the connector to ECM.
2) Turn the ignition switch to ON.
3) Measure the voltage between front oxygen
(A/F) sensor connector and chassis ground.
Models without SI-DRIVE
(E22) No. 1 (+) — Chassis ground (–):
Models with SI-DRIVE
Measure the voltage between front oxygen (A/F)
sensor connector and chassis ground.
7 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 8 V or more? Repair the short Repair the poor
Measure the voltage between front oxygen (A/F) circuit to power in contact of ECM
sensor connector and chassis ground. the harness connector.
Connector & terminal between ECM and
Models without SI-DRIVE front oxygen (A/F)
(E22) No. 3 (+) — Chassis ground (–): sensor connector.
(E22) No. 1 (+) — Chassis ground (–): After repair,
Models with SI-DRIVE replace the ECM.
(B379) No. 3 (+) — Chassis ground (–): <Ref. to FU(STI)-
(B379) No. 4 (+) — Chassis ground (–): 59, Engine Control
Module (ECM).>
<Ref. to FU(w/o
STI)-57, Engine
Control Module
(ECM).>
8 CHECK EXHAUST SYSTEM. Are there holes or loose bolts Repair the exhaust Go to step 9.
on exhaust system? system.

Step Check Yes No

9 CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or Repair the air Go to step 10.
disconnection of hose on air intake system.
intake system?
10 CHECK FUEL PRESSURE. Is the measured value 284 — Go to step 11. Repair the follow-
WARNING: 314 kPa (2.9 — 3.2 kgf/cm2, 41 ing item.
Place “NO OPEN FLAMES” signs near the — 46 psi)? Fuel pressure is
working area. too high:
CAUTION: • Clogged fuel
Be careful not to spill fuel. return line or bent
1) Connect the front oxygen (A/F) sensor con- hose
nector. Fuel pressure is
2) Measure the fuel pressure while discon- too low:
necting pressure regulator vacuum hose from • Improper fuel
intake manifold. <Ref. to ME(STI)-24, INSPEC- pump discharge
TION, Fuel Pressure.> <Ref. to ME(w/o STI)- • Clogged fuel
24, INSPECTION, Fuel Pressure.> supply line
CAUTION:
Release fuel pressure before removing the
fuel pressure gauge.
NOTE:
If fuel pressure does not increase, squeeze the
fuel return hose 2 to 3 times, then measure fuel
pressure again.
After connecting the pressure regulator vacuum 260 kPa (2.35 — 2.65 kgf/cm2, ing item.
hose, measure fuel pressure. <Ref. to ME(STI)- 33 — 38 psi)? Fuel pressure is
24, INSPECTION, Fuel Pressure.> <Ref. to too high:
ME(w/o STI)-24, INSPECTION, Fuel Pres- • Faulty pressure
sure.> regulator
Release fuel pressure before removing the return line or bent
fuel pressure gauge. hose
NOTE: Fuel pressure is
• If fuel pressure does not increase, squeeze too low:
fuel return hose 2 to 3 times, then measure fuel • Faulty pressure
pressure again. regulator
• If the measured value at this step is out of • Improper fuel
specification, check or replace pressure regula- pump discharge
tor and pressure regulator vacuum hose. • Clogged fuel
supply line
12 CHECK ENGINE COOLANT TEMPERATURE Is the value of «Coolant Temp.» Go to step 13. Replace the
SENSOR. 75°C (167°F) or more? engine coolant
1) Start the engine and warm up completely. temperature sen-
2) Read the value of «Coolant Temp.» using sor. <Ref. to
the Subaru Select Monitor or a general scan FU(STI)-34,
tool. Engine Coolant
NOTE: Temperature Sen-
• Subaru Select Monitor sor.> <Ref. to
For detailed operation procedures, refer to FU(w/o STI)-34,
“READ CURRENT DATA FOR ENGINE”. <Ref. Engine Coolant
to EN(H4DOTC)(diag)-39, Subaru Select Moni- Temperature Sen-
tor.> sor.>
• General scan tool
For detailed operation procedures, refer to the
general scan tool operation manual.

Step Check Yes No

13 CHECK MASS AIR FLOW AND INTAKE AIR Is the value of «Mass Air Flow» Go to step 14. Replace the mass
TEMPERATURE SENSOR. 2.0 — 5.0 g/s (0.26 — 0.66 lb/m)? air flow and intake
1) Start the engine and warm up engine until air temperature
coolant temperature is higher than 75°C sensor. <Ref. to
(167°F). FU(STI)-42, Mass
2) Place the shift lever in neutral position. Air Flow and Intake
3) Turn the A/C switch to OFF. Air Temperature
4) Turn all the accessory switches to OFF. Sensor.> <Ref. to
5) Read the value of «Mass Air Flow» using FU(w/o STI)-42,
the Subaru Select Monitor or a general scan Mass Air Flow and
tool. Intake Air Temper-
NOTE: ature Sensor.>
• Subaru Select Monitor
tor.>
14 CHECK MASS AIR FLOW AND INTAKE AIR Subtract ambient temperature Go to step 15. Check the mass air
TEMPERATURE SENSOR. from «Intake Air Temp.». Is the flow and intake air
1) Start the engine and warm up engine until obtained value –10 — 50°C (–18 temperature sen-
coolant temperature is higher than 75°C — 90°F)? sor. <Ref. to
5) Open the front hood. FU(w/o STI)-42,
6) Measure the ambient temperature. Mass Air Flow and
7) Read the value of «Intake Air Temp.» using Intake Air Temper-
the Subaru Select Monitor or a general scan ature Sensor.>
tool.
NOTE:
tor.>
15 CHECK REAR OXYGEN SENSOR DATA. Is the value of «Rear O2 Sen- Go to step 16. Go to step 17.
1) Warm up the engine until engine coolant sor» 0.490 V or more?
temperature is higher than 75°C (167°F), and
keep the engine speed at 3,000 rpm. (2 minutes
maximum)
2) Read the value of «Rear O2 Sensor» using
the Subaru Select Monitor or a general scan
tool.
NOTE:
• Depress the clutch pedal.
tor.>

Step Check Yes No

1) Warm up the engine until engine coolant sor» 0.250 V or less?
rapidly reduce the engine speed from 3,000
rpm.
tool.
NOTE:
tor.>
17 CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely Go to step 19.
TOR AND COUPLING CONNECTOR. tor? remove any water
inside.
18 CHECK FRONT OXYGEN (A/F) SENSOR US- Is the value in «Rear O2 Sen- Replace the front Go to step 19.
ING REAR OXYGEN SENSOR SIGNAL. sor» kept at 0.250 V or less for 5 oxygen (A/F) sen-
1) Warm up the engine until engine coolant minutes or more? sor. <Ref. to
temperature is higher than 75°C (167°F), then FU(STI)-54, Front
keep the engine idling for 5 minutes or more. Oxygen (A/F) Sen-
2) Read the value of «Rear O2 Sensor» using sor.> <Ref. to
the Subaru Select Monitor or a general scan FU(w/o STI)-53,
tool. Front Oxygen (A/F)
NOTE: Sensor.>
tor.>
REAR OXYGEN SENSOR CONNECTOR. and connector.
2) Disconnect the connector from ECM and In this case, repair
rear oxygen sensor. the following item:
ECM and rear oxygen sensor connector. harness between
Connector & terminal ECM and rear oxy-
(B136) No. 20 — (T6) No. 3: gen sensor con-
(B135) No. 30 — (T6) No. 4: nector
• Poor contact of
coupling connector

Step Check Yes No

20 CHECK HARNESS BETWEEN ECM AND Is the voltage 0.2 — 0.5 V? Replace the rear Repair the harness
REAR OXYGEN SENSOR CONNECTOR. oxygen sensor. and connector.
1) Connect the connector to ECM. <Ref. to FU(STI)- NOTE:
2) Turn the ignition switch to ON. 56, Rear Oxygen In this case, repair
3) Measure the voltage between rear oxygen Sensor.> <Ref. to the following item:
sensor connector and chassis ground. FU(w/o STI)-55, • Open circuit in
Connector & terminal Rear Oxygen Sen- harness between
(T6) No. 3 (+) — Chassis ground (–): sor.> ECM and rear oxy-
gen sensor con-
nector
• Poor contact of
ECM connector
• Poor contact of
coupling connector

EL:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-239, DTC P2097 POST CATALYST FUEL TRIM SYS-
TEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
System.>
B220 BATTERY
RELAY (RELAY BLOCK)
15A SBF-5 1 2 1 2 3
9 2 1 3 4 4 5 6
10
B21 B220
11
42
12
E2 1 2 9 13 17 21
B220 3 4 10 14 18 22
4
11 12 15 16 19 20 23 24
5 6
E
FRONT OXYGEN (A/F) 7 8 25 29 33 37
SENSOR 26 30 34 38
27 28 31 32 35 36 39 40
E22
B21
2
3
1
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E2 34 35 36 37 38 39 40 41
42 43 44 45 46 47
43
26
15
B21 48 49 50 51 52 53 54
E *
*
A: B134
B138
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
C18
C19
C9
C5
C6
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
A: B134
C: B136
C: B136 ECM
1 2 3 4 5 6
D: B137 7 8 9 10 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
D1
A3
A6
D3
A4
D: B137
1 2 3 4 5 6 7
B21 8 9 10 11 12 13 14 15 16 17
34
35
36
40
18 19 20 21 22 23 24 25
E2 26 27 28 29 30 31

*
E
EN-08720


15A SBF-5 T6 B138
9 2 1
10 1 2 1 2 3
B19 3 4 4 5 6
11
2
12 B220
T5
B220 1 2 9 13 17 21
2
3 4 10 14 18 22
11 12 15 16 19 20 23 24
REAR 5 6
OXYGEN SENSOR
E
7 8 25 29 33 37
T6 26 30 34 38
27 28 31 32 35 36 39 40
1
3
4
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
T5 23 24 25 26 27 28 29 30 31 32 33
1
3
4
B83 34 35 36 37 38 39 40 41
B19
42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
A: B134
*
* 1 2 3 4 5 6 7
B138 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
B30
C20
C9
28 29 30 31 32 33 34
B6
A: B134 B: B135
B: B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
C: B136
D1
A3
A6
D3
A4
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
B21 17 18 19 20 21 22 23 24 25 26 27
34
35
36
40

E2 *
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
E 18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-08722

B379 B138
2 1 1 2 3
RELAY BATTERY
15A SBF-5 B220
9 2 1
10
1 2 9 13 17 21
3 4 10 14 18 22
11
12 11 12 15 16 19 20 23 24
5 6
1
7 8 25 29 33 37
B220
26 30 34 38
FRONT OXYGEN (A/F) E 27 28 31 32 35 36 39 40
SENSOR
B379 B21
4
2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
*
* 34 35 36 37 38 39 40 41
42 43 44 45 46 47
B138 48 49 50 51 52 53 54
C18
C19
C9
C5
C6
A: B134
A: B134 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
C: B136 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
D: B137
C: B136
D1
A3
A6
D3
A4
1 2 3 4 5 6
7 8 9 10 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
B21
34
35
36
40
E2 D: B137

* 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
E
EN-08721


RELAY BATTERY
15A SBF-5 T6 B138
9 2 1
10 1 2 1 2 3
3 4 4 5 6
B19
11
2
12 B220
T5
B220 1 2 9 13 17 21
2
3 4 10 14 18 22
11 12 15 16 19 20 23 24
5 6
REAR
E
7 8 25 29 33 37
OXYGEN SENSOR
26 30 34 38
T6 27 28 31 32 35 36 39 40
B21
1
3
4
T5 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
1
3
4
B19 B83 23 24 25 26 27 28 29 30 31 32 33
* 34 35 36 37 38 39 40 41
* 42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
A: B134
B138
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B30
C20
C9
B6
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
A: B134
B: B135
B: B135
ECM
1 2 3 4 5 6 7
C: B136
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
D: B137
28 29 30 31 32 33 34 35
D1
A3
A6
D3
A4
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
34
35
36
40
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
*
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
E 18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-08723
Step Check Yes No

1 CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Go to step 2.
Trouble Code
(DTC)”. <Ref. to
EN(H4DOTC)(diag)
tic Trouble Code
(DTC).>
TOR. inside.

Step Check Yes No

3 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. Repair the open
FRONT OXYGEN (A/F) SENSOR CONNEC- circuit of harness
TOR. between ECM and
1) Turn the ignition switch to OFF. front oxygen (A/F)
2) Disconnect the connectors from ECM and sensor connector.
front oxygen (A/F) sensor.
3) Measure the resistance of harness between
ECM and front oxygen (A/F) sensor connector.
(B136) No. 19 — (E22) No. 1:
(B136) No. 18 — (E22) No. 3:
(B136) No. 19 — (B379) No. 4:
(B136) No. 18 — (B379) No. 3:
TOR. ness between
Module (ECM).>
<Ref. to FU(w/o
STI)-57, Engine
Control Module
(ECM).>

Step Check Yes No

intake system?
WARNING: 314 kPa (2.9 — 3.2 kgf/cm2, 41 ing item.
Be careful not to spill fuel. return line or bent
1) Connect the front oxygen (A/F) sensor con- hose
nector. Fuel pressure is
2) Measure the fuel pressure while discon- too low:
necting pressure regulator vacuum hose from • Improper fuel
intake manifold. <Ref. to ME(STI)-24, INSPEC- pump discharge
TION, Fuel Pressure.> <Ref. to ME(w/o STI)- • Clogged fuel
24, INSPECTION, Fuel Pressure.> supply line
CAUTION:
NOTE:
pressure again.
After connecting the pressure regulator vacuum 260 kPa (2.35 — 2.65 kgf/cm2, ing item.
sure.> regulator
tor and pressure regulator vacuum hose. • Clogged fuel
supply line
tor.> sor.>

Step Check Yes No

tor.>
tool.
NOTE:
tor.>
maximum)
tool.
NOTE:
tor.>

Step Check Yes No

rpm.
tool.
NOTE:
tor.>
inside.
ING REAR OXYGEN SENSOR SIGNAL. sor» kept at 0.8 V or more for 5 oxygen (A/F) sen-
NOTE: Sensor.>
tor.>
(B135) No. 30 — (T6) No. 4: nector
• Poor contact of
coupling connector

Step Check Yes No

20 CHECK HARNESS BETWEEN ECM AND Is the voltage 0.2 — 0.5 V? Replace the rear Repair the harness
REAR OXYGEN SENSOR CONNECTOR. oxygen sensor. and connector.
1) Connect the connector to ECM. <Ref. to FU(STI)- NOTE:
2) Turn the ignition switch to ON. 56, Rear Oxygen In this case, repair
3) Measure the voltage between rear oxygen Sensor.> <Ref. to the following item:
sensor connector and chassis ground. FU(w/o STI)-55, • Open circuit in
Connector & terminal Rear Oxygen Sen- harness between
(T6) No. 3 (+) — Chassis ground (–): sor.> ECM and rear oxy-
gen sensor con-
nector
• Poor contact of
ECM connector
• Poor contact of
coupling connector

EM:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-241, DTC P2101 THROTTLE ACTUATOR CONTROL
MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
• Improper idling
• Engine stalls.
CAUTION:

WIRING DIAGRAM:
Electrical System.>
BATTERY
SBF-7
ELECTRONIC THROTTLE FUSE

B220 B220 (RELAY BLOCK)
CONTROL RELAY
29 15A
31 22 21 4 3
32
30 MAIN RELAY
B220
B17
B7
ECM
E
A: B134 B: B135 C: B136 D: B137
A19
A29
A28
A18
D3
A4
D1
A3
A6
A1
A2
C4
B122
*
B21
*
40
34
35
36
28
39
38
24
25
6
E2
*
5
1
2
3
E
ELECTRONIC THROTTLE
CONTROL
E
E57
E57 B122 B: B135 B21 B220
1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 1 2 9 13 17 21
8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11
5 6 7 8 3 4 10 14 18 22
20 21 22 23 24 25 26 27 12 13 14 15 16 17 18 19 20 21 22
11 12 15 16 19 20 23 24
28 29 30 31 32 33 34 35 23 24 25 26 27 28 29 30 31 32 33 5 6
7 8 25 29 33 37
34 35 36 37 38 39 40 41 26 30 34 38
42 43 44 45 46 47 27 28 31 32 35 36 39 40
A: B134 48 49 50 51 52 53 54
C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-08727

Step Check Yes No

1 CHECK ELECTRONIC THROTTLE CON- Is the resistance less than 1 Ω? Go to step 2. Replace the elec-
TROL RELAY. tronic throttle con-
1) Turn the ignition switch to OFF. trol relay. <Ref. to
2) Remove the electronic throttle control relay. FU(STI)-64, Elec-
3) Connect the battery to terminals No. 31 and tronic Throttle
No. 32 of electronic throttle control relay. Control Relay.>
4) Measure the resistance between electronic <Ref. to FU(w/o
throttle control relay terminals. STI)-62, Elec-
Terminals tronic Throttle
No. 29 — No. 30: Control Relay.>
2 CHECK POWER SUPPLY OF ELECTRONIC Is the voltage 10 V or more? Go to step 3. Repair the open or
THROTTLE CONTROL RELAY. ground short circuit
Measure the voltage between electronic throttle of power supply
control relay connector and chassis ground. circuit.
3 CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? Repair the short Go to step 4.
ELECTRONIC THROTTLE CONTROL RE- circuit to power in
LAY CONNECTOR. the harness
1) Disconnect the connector from ECM. between ECM and
2) Turn the ignition switch to ON. electronic throttle
3) Measure the voltage between electronic control relay con-
throttle control relay connector and chassis nector.
ground.
ELECTRONIC THROTTLE CONTROL RE- more? circuit in harness
LAY CONNECTOR. to ground between
1) Turn the ignition switch to OFF. ECM and elec-
2) Measure the resistance between electronic tronic throttle con-
throttle control relay connector and chassis trol relay
ground. connector.
ELECTRONIC THROTTLE CONTROL RE- circuit in harness
LAY CONNECTOR. between ECM and
Measure the resistance between ECM and electronic throttle
electronic throttle control relay connector. control relay con-
Connector & terminal nector.
(B135) No. 17 — (B220) No. 32:
(B135) No. 7 — (B220) No. 30:
ELECTRONIC THROTTLE CONTROL CON- more? circuit to ground in
NECTOR. harness between
2) Disconnect the connectors from electronic tronic throttle con-
throttle control. trol connector.
3) Measure the resistance between ECM and
chassis ground.
(B134) No. 18 — (B136) No. 4:

Step Check Yes No

7 CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 MΩ or Go to step 8. Repair the short
1) Connect the connector to ECM. more? circuit to ground in
2) Measure the resistance between electronic harness between
throttle control connector and engine ground. ECM and elec-
Connector & terminal tronic throttle con-
(E57) No. 6 — Engine ground: trol connector.
(E57) No. 4 — Engine ground: Replace the ECM if
defective. <Ref. to
FU(STI)-59,
Engine Control
Module (ECM).>
<Ref. to FU(w/o
STI)-57, Engine
Control Module
(ECM).>
ELECTRONIC THROTTLE CONTROL CON- and connector.
NECTOR. NOTE:
1) Disconnect the connector from ECM. In this case, repair
ECM and electronic throttle control connector. • Open circuit in
(B134) No. 18 — (E57) No. 6: ECM and electron-
(B134) No. 28 — (E57) No. 4: ic throttle control
(B134) No. 29 — (E57) No. 3: connector
• Poor contact of
coupling connector
NECTOR. NOTE:
1) Connect the connector to ECM. In this case, repair
2) Measure the resistance between electronic the following item:
throttle control connector and engine ground. • Open circuit of
(E57) No. 3 — Engine ground: ECM and engine
ground
• Poor contact of
ECM connector
• Poor contact of
coupling connector
ELECTRONIC THROTTLE CONTROL CON- circuit to power in
1) Turn the ignition switch to ON. ECM and elec-
2) Measure the voltage between electronic tronic throttle con-
throttle control connector and engine ground. trol connector.
(E57) No. 6 (+) — Engine ground (–):
ELECTRONIC THROTTLE CONTROL CON- more? circuit to power in
2) Disconnect the connector from ECM. tronic throttle con-
3) Measure the resistance between ECM control connector.
nectors.
(B134) No. 19 — (B134) No. 18:
(B134) No. 19 — (B134) No. 28:
gi13usen048.fm 373 ページ２０１２年１２月７日　金曜日　午後２時１８分

Step Check Yes No

12 CHECK SENSOR OUTPUT. Is the value of «Main-Throttle Go to step 13. Repair the poor
1) Connect all connectors. Sensor» 0.81 — 0.87 V? contact of elec-
2) Start the engine and warm up completely. tronic throttle con-
3) Stop the engine, and then turn the ignition trol connector.
switch to ON (engine OFF). Replace the elec-
4) Read the value of «Main-Throttle Sensor» tronic throttle con-
using Subaru Select Monitor. trol if defective.
NOTE: <Ref. to FU(STI)-
For detailed operation procedures, refer to 15, Throttle Body.>
“READ CURRENT DATA FOR ENGINE”. <Ref. <Ref. to FU(w/o
to EN(H4DOTC)(diag)-39, Subaru Select Moni- STI)-15, Throttle
tor.> Body.>
13 CHECK SENSOR OUTPUT. Is the value of «Sub-Throttle Go to step 14. Repair the poor
Read the value of «Sub-Throttle Sensor» using Sensor» 1.64 — 1.70 V? contact of elec-
Subaru Select Monitor. tronic throttle con-
NOTE: trol connector.
For detailed operation procedures, refer to Replace the elec-
“READ CURRENT DATA FOR ENGINE”. <Ref. tronic throttle con-
to EN(H4DOTC)(diag)-39, Subaru Select Moni- trol if defective.
tor.> <Ref. to FU(STI)-
15, Throttle Body.>
<Ref. to FU(w/o
STI)-15, Throttle
Body.>
14 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 ? Go to step 15. Repair the harness
ELECTRONIC THROTTLE CONTROL MO- and connector.
TOR. NOTE:
electronic throttle control. • Open circuit in
3) Measure the resistance between ECM and harness between
electronic throttle control connector. ECM and electron-
Connector & terminal ic throttle control
coupling connector
ELECTRONIC THROTTLE CONTROL MO- circuit to power in
TOR. harness between
1) Connect the connector to ECM. ECM and elec-
2) Turn the ignition switch to ON. tronic throttle con-
3) Measure the voltage between electronic trol connector.
throttle control connector and engine ground.
16 CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M or Go to step 17. Repair the short
ELECTRONIC THROTTLE CONTROL MO- more? circuit to ground in
3) Measure the resistance between electronic trol connector.
throttle control connector and engine ground.
(E57) No. 2 — Engine ground:
(E57) No. 1 — Engine ground:

Step Check Yes No

17 CHECK ELECTRONIC THROTTLE CON- Is the resistance 1 MΩ or Go to step 18. Repair the short
TROL MOTOR HARNESS. more? circuit of harness
Measure the resistance between electronic between ECM and
throttle control connectors. electronic throttle
Connector & terminal control connector.
(E57) No. 2 — (E57) No. 1:
18 CHECK ELECTRONIC THROTTLE CON- Is the resistance less than 5 Ω? Go to step 19. Repair the harness
TROL GROUND CIRCUIT. and connector.
Measure the resistance between ECM and NOTE:
chassis ground. In this case, repair
Connector & terminal the following item:
(B134) No. 3 — Chassis ground: • Open circuit of
(B134) No. 4 — Chassis ground: harness between
(B134) No. 6 — Chassis ground: ECM and engine
(B137) No. 1 — Chassis ground: ground
(B137) No. 3 — Chassis ground: • Poor contact of
coupling connector
19 CHECK ELECTRONIC THROTTLE CON- Is the resistance 50 Ω or less? Go to step 20. Replace the elec-
TROL. tronic throttle con-
Measure the resistance between electronic trol. <Ref. to
throttle control terminals. FU(STI)-15, Throt-
Terminals tle Body.> <Ref. to
No. 2 — No. 1: FU(w/o STI)-15,
Throttle Body.>
20 CHECK ELECTRONIC THROTTLE CON- Does the valve return to the Repair the poor Replace the elec-
TROL. specified position? Standard contact of ECM tronic throttle con-
Move the throttle valve to the fully open and fully value: 3 mm (0.12 in) from fully connector. trol. <Ref. to
closed positions with fingers. closed position FU(STI)-15, Throt-
Check that the valve returns to the specified tle Body.> <Ref. to
position when releasing fingers. FU(w/o STI)-15,
Throttle Body.>

EN: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:
Electrical System.>
BATTERY
SBF-7

CONTROL RELAY
29 15A
31 22 21 4 3
32
30 MAIN RELAY
B220
B17
B7
ECM
E
A: B134 B: B135 C: B136 D: B137
A19
A29
A28
A18
D3
A4
D1
A3
A6
A1
A2
C4
B122
*
B21
*
40
34
35
36
28
39
38
24
25
6
E2
*
5
1
2
3
E
ELECTRONIC THROTTLE
CONTROL
E
E57
E57 B122 B: B135 B21 B220
1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 1 2 9 13 17 21
8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11
5 6 7 8 3 4 10 14 18 22
20 21 22 23 24 25 26 27 12 13 14 15 16 17 18 19 20 21 22
11 12 15 16 19 20 23 24
28 29 30 31 32 33 34 35 23 24 25 26 27 28 29 30 31 32 33 5 6
7 8 25 29 33 37
34 35 36 37 38 39 40 41 26 30 34 38
42 43 44 45 46 47 27 28 31 32 35 36 39 40
A: B134 48 49 50 51 52 53 54
C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-08727

Step Check Yes No

1 CHECK ELECTRONIC THROTTLE CON- Is the resistance less than 1 Ω? Go to step 2. Replace the elec-
TROL RELAY. tronic throttle con-
3) Connect the battery to terminals No. 31 and tronic Throttle
No. 32 of electronic throttle control relay. Control Relay.>
4) Measure the resistance between electronic <Ref. to FU(w/o
throttle control relay terminals. STI)-62, Elec-
Terminals tronic Throttle
No. 29 — No. 30: Control Relay.>
2 CHECK POWER SUPPLY OF ELECTRONIC Is the voltage 10 V or more? Go to step 3. Repair the open or
THROTTLE CONTROL RELAY. ground short circuit
Measure the voltage between electronic throttle of power supply
control relay connector and chassis ground. circuit.
ELECTRONIC THROTTLE CONTROL RE- circuit to power in
LAY CONNECTOR. the harness
1) Disconnect the connector from ECM. between ECM and
2) Turn the ignition switch to ON. electronic throttle
3) Measure the voltage between electronic control relay con-
throttle control relay connector and chassis nector.
ground.
ELECTRONIC THROTTLE CONTROL RE- more? circuit in harness
LAY CONNECTOR. to ground between
2) Measure the resistance between electronic tronic throttle con-
throttle control relay connector and chassis trol relay
ground. connector.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Repair the poor Repair the open
ELECTRONIC THROTTLE CONTROL RE- contact of ECM circuit in harness
LAY CONNECTOR. connector. between ECM and
Measure the resistance between ECM and electronic throttle
electronic throttle control relay connector. control relay con-
(B135) No. 17 — (B220) No. 32:
(B135) No. 7 — (B220) No. 30:

EO:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

MOTOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
Electrical System.>
BATTERY
SBF-7

CONTROL RELAY
29 15A
31 22 21 4 3
32
30 MAIN RELAY
B220
B17
B7
ECM
E
A: B134 B: B135 C: B136 D: B137
A19
A29
A28
A18
D3
A4
D1
A3
A6
A1
A2
C4
B122
*
B21
*
40
34
35
36
28
39
38
24
25
6
E2
*
5
1
2
3
E
ELECTRONIC THROTTLE
CONTROL
E
E57
E57 B122 B: B135 B21 B220
1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 1 2 9 13 17 21
8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11
5 6 7 8 3 4 10 14 18 22
20 21 22 23 24 25 26 27 12 13 14 15 16 17 18 19 20 21 22
11 12 15 16 19 20 23 24
28 29 30 31 32 33 34 35 23 24 25 26 27 28 29 30 31 32 33 5 6
7 8 25 29 33 37
34 35 36 37 38 39 40 41 26 30 34 38
42 43 44 45 46 47 27 28 31 32 35 36 39 40
A: B134 48 49 50 51 52 53 54
C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-08727

Step Check Yes No

1 CHECK ELECTRONIC THROTTLE CON- Is the resistance 1 MΩ or Go to step 2. Replace the elec-
TROL RELAY. more? tronic throttle con-
3) Measure the resistance between electronic tronic Throttle
throttle control relay terminals. Control Relay.>
Terminals <Ref. to FU(w/o
No. 29 — No. 30: STI)-62, Elec-
tronic Throttle
Control Relay.>
2 CHECK SHORT CIRCUIT OF ELECTRONIC Is the voltage 10 V or more? Repair the short Go to step 3.
THROTTLE CONTROL RELAY POWER SUP- circuit to power in
PLY. the harness
1) Turn the ignition switch to ON. between ECM and
2) Measure the voltage between electronic electronic throttle
throttle control relay connector and chassis control relay con-
ground. nector.
3 CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or Repair the poor Repair the short
ELECTRONIC THROTTLE CONTROL RE- more? contact of ECM circuit in harness
LAY CONNECTOR. connector. to ground between
3) Measure the resistance between ECM and trol relay
chassis ground. connector.
EP:DTC P2109 THROTTLE/PEDAL POSITION SENSOR “A” MINIMUM STOP

PERFORMANCE
NOTE:
For the diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4DOTC)(diag)-369, DTC P2101 THROT-
TLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Di-
agnostic Trouble Code (DTC).>
EQ:DTC P2119 THROTTLE ACTUATOR CONTROL THROTTLE BODY RANGE/
PERFORMANCE
NOTE:
For the diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4DOTC)(diag)-369, DTC P2101 THROT-
TLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Di-

ER:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT

LOW INPUT
• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-252, DTC P2122 THROTTLE/PEDAL POSITION
SENSOR/SWITCH “D” CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
• Improper idling
CAUTION:
WIRING DIAGRAM:
Electrical System.>
B315
ACCELERATOR 1 2 3 4 5 6
PEDAL POSITION
SENSOR
B83
B122
4
B315
1 2 3
4 5 6
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 36 37 38 39 40 41
B83 42 43 44 45 46 47
B122
B21
B23
B29
B22
B31
B30
48 49 50 51 52 53 54
A: B134
A: B134
B: B135
1 2 3 4 5 6 7
C: B136 ECM 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
D: B137 28 29 30 31 32 33 34
D1
A3
C4
D3
A4
A6
B: B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B21 C: B136
40
34
35
36
E2 1 2 3 4 5 6
7 8 9 10 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
D: B137
: TERMINAL No.
E * OPTIONAL ARRANGEMENT 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-08749

Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 MΩ or Go to step 2. Repair the short
CELERATOR PEDAL POSITION SENSOR more? circuit to ground in
1) Turn the ignition switch to OFF. ECM and accelera-
2) Disconnect the connectors from ECM and tor pedal position
accelerator pedal position sensor. sensor connector.
chassis ground.
(B135) No. 23 — (B136) No. 4:
2 CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 MΩ or Replace the accel- Repair the short
1) Connect the connector to ECM. more? erator pedal. <Ref. circuit to ground in
2) Measure the resistance between accelera- to SP(STI)-4, harness between
tor pedal position sensor connector and chassis Accelerator ECM and accelera-
ground. Pedal.> tor pedal position
Connector & terminal sensor connector.
(B315) No. 6 — Chassis ground: Replace the ECM if
defective. <Ref. to
FU(STI)-59,
Engine Control
Module (ECM).>
<Ref. to FU(w/o
STI)-57, Engine
Control Module
(ECM).>

ES: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:
Electrical System.>
B315
PEDAL POSITION
SENSOR
B83
B122
4
B315
1 2 3
4 5 6
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 36 37 38 39 40 41
B83 42 43 44 45 46 47
B122
B21
B23
B29
B22
B31
B30
48 49 50 51 52 53 54
A: B134
A: B134
B: B135
1 2 3 4 5 6 7
C: B136 ECM 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
D: B137 28 29 30 31 32 33 34
D1
A3
C4
D3
A4
A6
B: B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B21 C: B136
40
34
35
36
E2 1 2 3 4 5 6
7 8 9 10 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
D: B137
: TERMINAL No.
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-08749

Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 Ω? Go to step 2. Repair the open
CELERATOR PEDAL POSITION SENSOR circuit in harness
CONNECTOR. between ECM and
1) Turn the ignition switch to OFF. accelerator pedal
2) Disconnect the connectors from ECM and position sensor
accelerator pedal position sensor. connector.
ECM and accelerator pedal position sensor
connector.
(B135) No. 23 — (B315) No. 6:
(B135) No. 29 — (B315) No. 5:
2 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 Ω? Go to step 3. Repair the harness
CELERATOR PEDAL POSITION SENSOR and connector.
CONNECTOR. NOTE:
2) Measure the resistance between accelera- the following item:
tor pedal position sensor connector and chassis • Open circuit of
ground. harness between
Connector & terminal ECM and engine
• Poor contact of
ECM connector
• Poor contact of
coupling connector
3 CHECK HARNESS BETWEEN ECM AND AC- Is the voltage 5 V or more? Repair the short Go to step 4.
CELERATOR PEDAL POSITION SENSOR circuit to power
CONNECTOR. supply in the har-
1) Turn the ignition switch to ON. ness between the
2) Measure the voltage between accelerator ECM and accelera-
pedal position sensor connector and chassis tor pedal position
ground. sensor connector.
4 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 MΩ or Repair the poor Repair the short
CELERATOR PEDAL POSITION SENSOR more? contact of acceler- circuit to power
CONNECTOR. ator pedal position supply in the har-
1) Turn the ignition switch to OFF. sensor connector. ness between the
2) Disconnect the connector from ECM. Replace the accel- ECM and accelera-
3) Measure the resistance between ECM con- erator pedal if tor pedal position
nectors. defective. <Ref. to sensor connector.
Connector & terminal SP(STI)-4, Accel-
(B135) No. 21 — (B135) No. 23: erator Pedal.>

ET: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:
Electrical System.>
B315
PEDAL POSITION
SENSOR
B83
B122
4
B315
1 2 3
4 5 6
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 36 37 38 39 40 41
B83 42 43 44 45 46 47
B122
B21
B23
B29
B22
B31
B30
48 49 50 51 52 53 54
A: B134
A: B134
B: B135
1 2 3 4 5 6 7
C: B136 ECM 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
D: B137 28 29 30 31 32 33 34
D1
A3
C4
D3
A4
A6
B: B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B21 C: B136
40
34
35
36
E2 1 2 3 4 5 6
7 8 9 10 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
D: B137
: TERMINAL No.
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-08749

Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 MΩ or Go to step 2. Repair the short
CELERATOR PEDAL POSITION SENSOR more? circuit to ground in
1) Turn the ignition switch to OFF. ECM and accelera-
2) Disconnect the connectors from ECM and tor pedal position
accelerator pedal position sensor. sensor connector.
chassis ground.
2 CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 MΩ or Replace the accel- Repair the short
1) Connect the connector to ECM. more? erator pedal. <Ref. circuit to ground in
2) Measure the resistance between accelera- to SP(STI)-4, harness between
tor pedal position sensor connector and chassis Accelerator ECM and accelera-
ground. Pedal.> tor pedal position
Connector & terminal sensor connector.
(B315) No. 3 — Chassis ground: Replace the ECM if
defective. <Ref. to
FU(STI)-59,
Engine Control
Module (ECM).>
<Ref. to FU(w/o
STI)-57, Engine
Control Module
(ECM).>

EU: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:
Electrical System.>
B315
PEDAL POSITION
SENSOR
B83
B122
4
B315
1 2 3
4 5 6
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 36 37 38 39 40 41
B83 42 43 44 45 46 47
B122
B21
B23
B29
B22
B31
B30
48 49 50 51 52 53 54
A: B134
A: B134
B: B135
1 2 3 4 5 6 7
C: B136 ECM 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
D: B137 28 29 30 31 32 33 34
D1
A3
C4
D3
A4
A6
B: B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B21 C: B136
40
34
35
36
E2 1 2 3 4 5 6
7 8 9 10 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
D: B137
: TERMINAL No.
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-08749

Step Check Yes No

CONNECTOR. NOTE:
accelerator pedal position sensor. • Open circuit in
ECM and accelerator pedal position sensor ECM and acceler-
connector. ator pedal position
Connector & terminal sensor connector
(B135) No. 31 — (B315) No. 3: • Poor contact of
(B135) No. 30 — (B315) No. 2: joint connector
CONNECTOR. NOTE:
2) Measure the resistance between accelera- the following item:
tor pedal position sensor connector and chassis • Open circuit of
ground. harness between
Connector & terminal ECM and engine
• Poor contact of
ECM connector
• Poor contact of
coupling connector
3 CHECK HARNESS BETWEEN ECM AND AC- Is the voltage 5 V or more? Repair the short Go to step 4.
CELERATOR PEDAL POSITION SENSOR circuit to power
CONNECTOR. supply in the har-
1) Turn the ignition switch to ON. ness between the
2) Measure the voltage between accelerator ECM and accelera-
pedal position sensor connector and chassis tor pedal position
ground. sensor connector.
4 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 MΩ or Repair the poor Repair the short
CELERATOR PEDAL POSITION SENSOR more? contact of acceler- circuit to power
CONNECTOR. ator pedal position supply in the har-
1) Turn the ignition switch to OFF. sensor connector. ness between the
2) Disconnect the connector from ECM. Replace the accel- ECM and accelera-
3) Measure the resistance between ECM con- erator pedal if tor pedal position
nectors. defective. <Ref. to sensor connector.
Connector & terminal SP(STI)-4, Accel-
(B135) No. 22 — (B135) No. 31: erator Pedal.>

EV:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLT-

AGE CORRELATION
SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
• Improper idling
CAUTION:
WIRING DIAGRAM:
Electrical System.>
BATTERY
SBF-7

CONTROL RELAY
29 15A
31 22 21 4 3
32
30 MAIN RELAY
B220
B17
B7
ECM
E
A: B134 B: B135 C: B136 D: B137
A19
A29
A28
A18
D3
A4
D1
A3
A6
A1
A2
C4
B122
*
B21
*
40
34
35
36
28
39
38
24
25
6
E2
*
5
1
2
3
E
ELECTRONIC THROTTLE
CONTROL
E
E57
E57 B122 B: B135 B21 B220
1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 1 2 9 13 17 21
8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11
5 6 7 8 3 4 10 14 18 22
20 21 22 23 24 25 26 27 12 13 14 15 16 17 18 19 20 21 22
11 12 15 16 19 20 23 24
28 29 30 31 32 33 34 35 23 24 25 26 27 28 29 30 31 32 33 5 6
7 8 25 29 33 37
34 35 36 37 38 39 40 41 26 30 34 38
42 43 44 45 46 47 27 28 31 32 35 36 39 40
A: B134 48 49 50 51 52 53 54
C: B136 D: B137
1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 26 27 28 29 30 31
EN-08727

Step Check Yes No

ELECTRONIC THROTTLE CONTROL CON- more? circuit to ground in
2) Disconnect the connectors from ECM and tronic throttle con-
electronic throttle control. trol connector.
chassis ground.
(B134) No. 18 — (B136) No. 4:
2 CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 MΩ or Go to step 3. Repair the short
1) Connect the connector to ECM. more? circuit to ground in
2) Measure the resistance between electronic harness between
throttle control connector and engine ground. ECM and elec-
Connector & terminal tronic throttle con-
(E57) No. 6 — Engine ground: trol connector.
(E57) No. 4 — Engine ground: Replace the ECM if
defective. <Ref. to
FU(STI)-59,
Engine Control
Module (ECM).>
<Ref. to FU(w/o
STI)-57, Engine
Control Module
(ECM).>
NECTOR. NOTE:
1) Disconnect the connector from ECM. In this case, repair
ECM and electronic throttle control connector. • Open circuit in
(B134) No. 18 — (E57) No. 6: ECM and electron-
(B134) No. 28 — (E57) No. 4: ic throttle control
• Poor contact of
coupling connector
NECTOR. NOTE:
2) Measure the resistance between electronic the following item:
throttle control connector and engine ground. • Open circuit of
(E57) No. 3 — Engine ground: ECM and engine
ground
• Poor contact of
ECM connector
• Poor contact of
coupling connector

Step Check Yes No

ELECTRONIC THROTTLE CONTROL CON- circuit to power in
1) Turn the ignition switch to ON. ECM and elec-
2) Measure the voltage between electronic tronic throttle con-
throttle control connector and engine ground. trol connector.
ELECTRONIC THROTTLE CONTROL CON- more? contact of elec- circuit to power in
NECTOR. tronic throttle con- harness between
1) Turn the ignition switch to OFF. trol connector. ECM and elec-
2) Disconnect the connector from ECM. Replace the electronic throttle con-
3) Measure the resistance between ECM con- tronic throttle control connector.
nectors. trol if defective.
Connector & terminal <Ref. to FU(STI)-
(B134) No. 19 — (B134) No. 18: 15, Throttle Body.>
(B134) No. 19 — (B134) No. 28: <Ref. to FU(w/o
STI)-15, Throttle
Body.>

EW:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLT-

AGE CORRELATION
SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
• Improper idling
CAUTION:
WIRING DIAGRAM:
Electrical System.>
B315
PEDAL POSITION
SENSOR
B83
B122
4
B315
1 2 3
4 5 6
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 36 37 38 39 40 41
B83 42 43 44 45 46 47
B122
B21
B23
B29
B22
B31
B30
48 49 50 51 52 53 54
A: B134
A: B134
B: B135
1 2 3 4 5 6 7
C: B136 ECM 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
D: B137 28 29 30 31 32 33 34
D1
A3
C4
D3
A4
A6
B: B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
B21 C: B136
40
34
35
36
E2 1 2 3 4 5 6
7 8 9 10 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
D: B137
: TERMINAL No.
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-08749

Step Check Yes No

1 CHECK ACCELERATOR PEDAL POSITION Is the difference in measured Go to step 3. Go to step 2.
SENSOR OUTPUT. values for the main accelerator
1) Turn the ignition switch to ON. pedal position sensor signal
2) Measure the voltage between ECM and and the sub accelerator pedal
chassis ground. position sensor signal 0 V?
Main accelerator pedal position sensor
signal
Sub accelerator pedal position sensor
signal
2 CHECK ACCELERATOR PEDAL POSITION Is the difference in measured Replace the accel- Repair the harness
SENSOR OUTPUT. values for the main accelerator erator pedal. <Ref. and connector.
1) Measure the voltage between accelerator pedal position sensor signal to SP(STI)-4, NOTE:
pedal position sensor connector and chassis and the sub accelerator pedal Accelerator In this case, repair
ground. position sensor signal 0 V? Pedal.> the following item:
Connector & terminal • Open circuit in
(B315) No. 6 (+) — Chassis ground (–): harness between
(B315) No. 3 (+) — Chassis ground (–): ECM and acceler-
ator pedal position
sensor connector
• Short circuit to
ground in harness
between ECM and
accelerator pedal
position sensor
connector
3 CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 Ω? Repair the poor Repair the harness
CELERATOR PEDAL POSITION SENSOR contact of ECM and connector.
CONNECTOR. connector. NOTE:
accelerator pedal position sensor connector the following item:
and chassis ground. • Open circuit in
(B315) No. 5 — Chassis ground: ECM and acceler-
(B315) No. 2 — Chassis ground: ator pedal position
sensor connector
• Open circuit of
harness between
ECM and engine
ground
• Poor contact of
ECM connector
• Poor contact of
coupling connector

EX:DTC P2195 O2 SENSOR SIGNAL BIASED/STUCK LEAN (BANK 1 SENSOR 1)

• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-264, DTC P2195 O2 SENSOR SIGNAL BIASED/
STUCK LEAN (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
System.>
B220 BATTERY
RELAY (RELAY BLOCK)
15A SBF-5 1 2 1 2 3
9 2 1 3 4 4 5 6
10
B21 B220
11
42
12
E2 1 2 9 13 17 21
B220 3 4 10 14 18 22
4
11 12 15 16 19 20 23 24
5 6
E
FRONT OXYGEN (A/F) 7 8 25 29 33 37
SENSOR 26 30 34 38
27 28 31 32 35 36 39 40
E22
B21
2
3
1
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E2 34 35 36 37 38 39 40 41
42 43 44 45 46 47
43
26
15
B21 48 49 50 51 52 53 54
E *
*
A: B134
B138
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
C18
C19
C9
C5
C6
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
A: B134
C: B136
C: B136 ECM
1 2 3 4 5 6
D: B137 7 8 9 10 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
D1
A3
A6
D3
A4
D: B137
1 2 3 4 5 6 7
B21 8 9 10 11 12 13 14 15 16 17
34
35
36
40
18 19 20 21 22 23 24 25
E2 26 27 28 29 30 31

*
E
EN-08720

B379 B138
2 1 1 2 3
RELAY BATTERY
15A SBF-5 B220
9 2 1
10
1 2 9 13 17 21
3 4 10 14 18 22
11
12 11 12 15 16 19 20 23 24
5 6
1
7 8 25 29 33 37
B220
26 30 34 38
FRONT OXYGEN (A/F) E 27 28 31 32 35 36 39 40
SENSOR
B379 B21
4
2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
*
* 34 35 36 37 38 39 40 41
42 43 44 45 46 47
B138 48 49 50 51 52 53 54
C18
C19
C9
C5
C6
A: B134
A: B134 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
C: B136 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
D: B137
C: B136
D1
A3
A6
D3
A4
1 2 3 4 5 6
7 8 9 10 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
B21
34
35
36
40
E2 D: B137

* 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
E
EN-08721

Step Check Yes No

TOR. inside.
FRONT OXYGEN (A/F) SENSOR CONNEC- circuit of harness
TOR. between ECM and
1) Turn the ignition switch to OFF. front oxygen (A/F)
2) Disconnect the connectors from ECM and sensor connector.
front oxygen (A/F) sensor.
ECM and front oxygen (A/F) sensor connector.
(B136) No. 19 — (E22) No. 1:
(B136) No. 18 — (E22) No. 3:
(B136) No. 19 — (B379) No. 4:
(B136) No. 18 — (B379) No. 3:
3 CHECK FOR POOR CONTACT. Is there poor contact of front Repair the poor Replace the front
Check for poor contact of the front oxygen (A/F) oxygen (A/F) sensor connec- contact of front oxygen (A/F) sen-
sensor connector. tor? oxygen (A/F) sensor. <Ref. to
sor connector. FU(STI)-54, Front
Oxygen (A/F) Sen-
sor.> <Ref. to
FU(w/o STI)-53,
Front Oxygen (A/F)
Sensor.>

EY:DTC P2196 O2 SENSOR SIGNAL BIASED/STUCK RICH (BANK 1 SENSOR 1)

• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-266, DTC P2196 O2 SENSOR SIGNAL BIASED/
STUCK RICH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
System.>
B220 BATTERY
RELAY (RELAY BLOCK)
15A SBF-5 1 2 1 2 3
9 2 1 3 4 4 5 6
10
B21 B220
11
42
12
E2 1 2 9 13 17 21
B220 3 4 10 14 18 22
4
11 12 15 16 19 20 23 24
5 6
E
FRONT OXYGEN (A/F) 7 8 25 29 33 37
SENSOR 26 30 34 38
27 28 31 32 35 36 39 40
E22
B21
2
3
1
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E2 34 35 36 37 38 39 40 41
42 43 44 45 46 47
43
26
15
B21 48 49 50 51 52 53 54
E *
*
A: B134
B138
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
C18
C19
C9
C5
C6
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
A: B134
C: B136
C: B136 ECM
1 2 3 4 5 6
D: B137 7 8 9 10 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
D1
A3
A6
D3
A4
D: B137
1 2 3 4 5 6 7
B21 8 9 10 11 12 13 14 15 16 17
34
35
36
40
18 19 20 21 22 23 24 25
E2 26 27 28 29 30 31

*
E
EN-08720

B379 B138
2 1 1 2 3
RELAY BATTERY
15A SBF-5 B220
9 2 1
10
1 2 9 13 17 21
3 4 10 14 18 22
11
12 11 12 15 16 19 20 23 24
5 6
1
7 8 25 29 33 37
B220
26 30 34 38
FRONT OXYGEN (A/F) E 27 28 31 32 35 36 39 40
SENSOR
B379 B21
4
2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
*
* 34 35 36 37 38 39 40 41
42 43 44 45 46 47
B138 48 49 50 51 52 53 54
C18
C19
C9
C5
C6
A: B134
A: B134 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
C: B136 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
D: B137
C: B136
D1
A3
A6
D3
A4
1 2 3 4 5 6
7 8 9 10 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
B21
34
35
36
40
E2 D: B137

* 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
E
EN-08721
Step Check Yes No

TOR. inside.
TOR. ness between
1) Turn the ignition switch to OFF. ECM and front oxy-
2) Disconnect the connector from ECM. gen (A/F) sensor
3) Measure the resistance between ECM and connector.
chassis ground.

Step Check Yes No

3) Measure the voltage between ECM and
chassis ground.
4 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 4.95 V or more? Go to step 5. Replace the front
Measure the voltage between ECM and chassis oxygen (A/F) sen-
ground. sor. <Ref. to
Connector & terminal FU(STI)-54, Front
(B136) No. 18 (+) — Chassis ground (–): Oxygen (A/F) Sen-
sor.> <Ref. to
FU(w/o STI)-53,
Front Oxygen (A/F)
Sensor.>
Measure the voltage between ECM and chassis circuit to power in contact of ECM
ground. the harness connector.
(B136) No. 19 (+) — Chassis ground (–): front oxygen (A/F)
(B136) No. 18 (+) — Chassis ground (–): sensor connector.
After repair,
replace the ECM.
<Ref. to FU(STI)-
59, Engine Control
Module (ECM).>
<Ref. to FU(w/o
STI)-57, Engine
Control Module
(ECM).>

EZ:DTC P219A BANK 1 AIR-FUEL RATIO IMBALANCE

• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-268, DTC P219A BANK 1 AIR-FUEL RATIO IMBAL-
ANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
• Engine stalls.
• Improper idling
CAUTION:
WIRING DIAGRAM:
System.>
B220 BATTERY
RELAY (RELAY BLOCK)
15A SBF-5 1 2 1 2 3
9 2 1 3 4 4 5 6
10
B21 B220
11
42
12
E2 1 2 9 13 17 21
B220 3 4 10 14 18 22
4
11 12 15 16 19 20 23 24
5 6
E
FRONT OXYGEN (A/F) 7 8 25 29 33 37
SENSOR 26 30 34 38
27 28 31 32 35 36 39 40
E22
B21
2
3
1
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E2 34 35 36 37 38 39 40 41
42 43 44 45 46 47
43
26
15
B21 48 49 50 51 52 53 54
E *
*
A: B134
B138
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
C18
C19
C9
C5
C6
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
A: B134
C: B136
C: B136 ECM
1 2 3 4 5 6
D: B137 7 8 9 10 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
D1
A3
A6
D3
A4
D: B137
1 2 3 4 5 6 7
B21 8 9 10 11 12 13 14 15 16 17
34
35
36
40
18 19 20 21 22 23 24 25
E2 26 27 28 29 30 31

*
E
EN-08720


15A SBF-5 T6 B138
9 2 1
10 1 2 1 2 3
B19 3 4 4 5 6
11
2
12 B220
T5
B220 1 2 9 13 17 21
2
3 4 10 14 18 22
11 12 15 16 19 20 23 24
REAR 5 6
OXYGEN SENSOR
E
7 8 25 29 33 37
T6 26 30 34 38
27 28 31 32 35 36 39 40
1
3
4
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
T5 23 24 25 26 27 28 29 30 31 32 33
1
3
4
B83 34 35 36 37 38 39 40 41
B19
42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
A: B134
*
* 1 2 3 4 5 6 7
B138 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
B30
C20
C9
28 29 30 31 32 33 34
B6
A: B134 B: B135
B: B135 1 2 3 4 5 6 7
ECM 8 9 10 11 12 13 14 15 16 17 18 19
C: B136 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
D: B137
C: B136
D1
A3
A6
D3
A4
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
B21 17 18 19 20 21 22 23 24 25 26 27
34
35
36
40

E2 *
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
E 18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-08722

FUSE
B220 (RELAY BLOCK)
MAIN RELAY BATTERY
15A SBF-7
21 4 3
22
23
24
B220 B134 ECM
E
10
11
12
13
B21
51
52
48
54
53
E2
E5 E16 E6 E17
1
1
2
1
#1 #2 #3 #4
FUEL INJECTOR
E5 E6 B21 B220 B134
E16 E17
1 2 3 4 5 6 7 8 9 10 11 1 2 9 13 17 21 1 2 3 4 5 6 7
12 13 14 15 16 17 18 19 20 21 22 10 14 18 22 8 9 10 11 12 13 14 15 16 17
1 2 3 4
23 24 25 26 27 28 29 30 31 32 33 11 12 15 16 19 20 23 24 18 19 20 21 22 23 24 25 26 27
5 6 28 29 30 31 32 33 34
34 35 36 37 38 39 40 41 7 8 25 29 33 37
42 43 44 45 46 47 26 30 34 38
48 49 50 51 52 53 54 27 28 31 32 35 36 39 40
EN-08718

B379 B138
2 1 1 2 3
RELAY BATTERY
15A SBF-5 B220
9 2 1
10
1 2 9 13 17 21
3 4 10 14 18 22
11
12 11 12 15 16 19 20 23 24
5 6
1
7 8 25 29 33 37
B220
26 30 34 38
FRONT OXYGEN (A/F) E 27 28 31 32 35 36 39 40
SENSOR
B379 B21
4
2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
*
* 34 35 36 37 38 39 40 41
42 43 44 45 46 47
B138 48 49 50 51 52 53 54
C18
C19
C9
C5
C6
A: B134
A: B134 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
C: B136 ECM 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
D: B137
C: B136
D1
A3
A6
D3
A4
1 2 3 4 5 6
7 8 9 10 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
B21
34
35
36
40
E2 D: B137

* 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
E
EN-08721


RELAY BATTERY
15A SBF-5 T6 B138
9 2 1
10 1 2 1 2 3
3 4 4 5 6
B19
11
2
12 B220
T5
B220 1 2 9 13 17 21
2
3 4 10 14 18 22
11 12 15 16 19 20 23 24
5 6
REAR
E
7 8 25 29 33 37
OXYGEN SENSOR
26 30 34 38
T6 27 28 31 32 35 36 39 40
B21
1
3
4
T5 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
1
3
4
B19 B83 23 24 25 26 27 28 29 30 31 32 33
* 34 35 36 37 38 39 40 41
* 42 43 44 45 46 47
48 49 50 51 52 53 54
*
*
A: B134
B138
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
B30
C20
C9
B6
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
A: B134
B: B135
B: B135
ECM
1 2 3 4 5 6 7
C: B136
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
D: B137
28 29 30 31 32 33 34 35
D1
A3
A6
D3
A4
C: B136
1 2 3 4 5 6
B21 7 8 9 10 11 12 13 14 15 16
34
35
36
40
17 18 19 20 21 22 23 24 25 26 27
E2 28 29 30 31 32 33 34 35
*
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
E 18 19 20 21 22 23 24 25
26 27 28 29 30 31
EN-08723

FUSE
B220 (RELAY BLOCK)
MAIN RELAY BATTERY
15A SBF-7
21 4 3
22
23
24
B220 B134 ECM
E
10
11
12
13
B21
51
52
48
54
53
E2
E5 E16 E6 E17
1
1
2
1
#1 #2 #3 #4
FUEL INJECTOR
E5 E6 B21 B220 B134
E16 E17
1 2 3 4 5 6 7 8 9 10 11 1 2 9 13 17 21 1 2 3 4 5 6 7
12 13 14 15 16 17 18 19 20 21 22 10 14 18 22 8 9 10 11 12 13 14 15 16 17
1 2 3 4
23 24 25 26 27 28 29 30 31 32 33 11 12 15 16 19 20 23 24 18 19 20 21 22 23 24 25 26 27
5 6 28 29 30 31 32 33 34
34 35 36 37 38 39 40 41 7 8 25 29 33 37
42 43 44 45 46 47 26 30 34 38
48 49 50 51 52 53 54 27 28 31 32 35 36 39 40
EN-08718
Step Check Yes No

TOR. inside.
FRONT OXYGEN (A/F) SENSOR CONNEC- and connector.
TOR. NOTE:
front oxygen (A/F) sensor. • Open circuit in
ECM and front oxygen (A/F) sensor connector. ECM and front oxy-
Connector & terminal gen (A/F) sensor
Models without SI-DRIVE connector
(B136) No. 18 — (E22) No. 3: coupling connector
(B136) No. 19 — (B379) No. 4:
(B136) No. 18 — (B379) No. 3:

Step Check Yes No

TOR. ness between
Module (ECM).>
<Ref. to FU(w/o
STI)-57, Engine
Control Module
(ECM).>
intake system?

Step Check Yes No

WARNING: 314 kPa (2.9 — 3.2 kg/cm2, 41 ing item.
CAUTION: • Clogged fuel line
Be careful not to spill fuel. or bent hose
1) Connect the front oxygen (A/F) sensor con- Fuel pressure is
nector. too low:
2) Measure the fuel pressure while discon- • Improper fuel
necting pressure regulator vacuum hose from pump discharge
intake manifold. <Ref. to ME(STI)-24, INSPEC- • Clogged fuel
TION, Fuel Pressure.> <Ref. to ME(w/o STI)- supply line
24, INSPECTION, Fuel Pressure.>
CAUTION:
NOTE:
pressure again.
After connecting the pressure regulator vacuum 260 kPa (2.35 — 2.65 kg/cm2, ing item.
sure.> regulator
tor vacuum hose. • Clogged fuel
supply line
tor.> sor.>

Step Check Yes No

tor.>
tool.
NOTE:
tor.>
maximum)
tool.
NOTE:
tor.>

Step Check Yes No

rpm.
tool.
NOTE:
tor.>
inside.
ING REAR OXYGEN SENSOR SIGNAL. sor» kept at 0.250 V or less for 5 oxygen (A/F) sen-
NOTE: Sensor.>
tor.>
(B135) No. 30 — (T6) No. 4: nector
• Poor contact of
coupling connector
19 CHECK HARNESS BETWEEN ECM AND Is the voltage 0.2 — 0.5 V? Replace the rear Go to step 20.
REAR OXYGEN SENSOR CONNECTOR. oxygen sensor.
1) Connect the connector to ECM. <Ref. to FU(STI)-
2) Turn the ignition switch to ON. 56, Rear Oxygen
3) Measure the voltage between rear oxygen Sensor.> <Ref. to
sensor connector and chassis ground. FU(w/o STI)-55,
Connector & terminal Rear Oxygen Sen-
(T6) No. 3 (+) — Chassis ground (–): sor.>

Step Check Yes No

20 CHECK OUTPUT SIGNAL OF ECM. Is the voltage 10 V or more? Go to step 25. Go to step 21.
chassis ground on faulty cylinders.
#1 (B134) No. 10 (+) — Chassis ground (–):
FUEL INJECTOR CONNECTOR. more? circuit to ground in
1) Turn the ignition switch to OFF. harness between
2) Disconnect the connector from fuel injector ECM and fuel
on faulty cylinders. injector connector.
3) Measure the resistance between fuel injec-
tor connector and engine ground on faulty cylin-
ders.
#1 (E5) No. 2 — Engine ground:
FUEL INJECTOR CONNECTOR. and connector.
Measure the resistance of harness between NOTE:
ECM and fuel injector connector on faulty cylin- In this case, repair
ders. the following item:
#1 (B134) No. 10 — (E5) No. 2: harness between
#2 (B134) No. 11 — (E16) No. 2: ECM and fuel in-
#3 (B134) No. 12 — (E6) No. 2: jector connector
#4 (B134) No. 13 — (E17) No. 2: • Poor contact of
coupling connector
23 CHECK FUEL INJECTOR. Is the resistance 5 — 20 Ω? Go to step 24. Replace the faulty
Measure the resistance between fuel injector fuel injector. <Ref.
terminals on faulty cylinder. to FU(STI)-45,
Terminals Fuel Injector.>
No. 1 — No. 2: <Ref. to FU(w/o
STI)-45, Fuel
Injector.>
24 CHECK POWER SUPPLY LINE. Is the voltage 10 V or more? Repair the poor Repair the harness
1) Turn the ignition switch to ON. contact of all con- and connector.
2) Measure the voltage between fuel injector nectors in fuel NOTE:
connector of faulty cylinders and engine injector circuit. In this case, repair
ground. the following item:
#1 (E5) No. 1 (+) — Engine ground (–): harness between
#2 (E16) No. 1 (+) — Engine ground (–): the main relay and
#3 (E6) No. 1 (+) — Engine ground (–): fuel injector con-
#4 (E17) No. 1 (+) — Engine ground (–): nector on faulty
cylinders
• Poor contact of
coupling connector
• Poor contact of
main relay connec-
tor

Step Check Yes No

FUEL INJECTOR CONNECTOR. circuit to power in
1) Turn the ignition switch to OFF. harness between
2) Disconnect the connector from fuel injector ECM and fuel
on faulty cylinders. injector connector.
chassis ground on faulty cylinders.
26 CHECK FUEL INJECTOR. Is the resistance 5 — 20 Ω? Go to step 27. Replace the faulty
1) Turn the ignition switch to OFF. fuel injector. <Ref.
2) Measure the resistance between fuel injec- to FU(STI)-45,
tor terminals on faulty cylinder. Fuel Injector.>
Terminals <Ref. to FU(w/o
No. 1 — No. 2: STI)-45, Fuel
Injector.>
27 CHECK INSTALLATION CONDITION OF Is the camshaft position sensor Tighten the cam- Go to step 28.
CAMSHAFT POSITION SENSOR/CRANK- or crankshaft position sensor shaft position sen-
SHAFT POSITION SENSOR. loosely installed? sor or crankshaft
position sensor.
<Ref. to FU(STI)-
37, Camshaft Posi-
tion Sensor.> <Ref.
to FU(STI)-35,
Crankshaft Posi-
tion Sensor.> <Ref.
to FU(w/o STI)-37,
Camshaft Position
Sensor.> <Ref. to
FU(w/o STI)-35,
Crankshaft Posi-
tion Sensor.>
28 CHECK CRANK SPROCKET. Is the crank sprocket rusted or Replace the crank Go to step 29.
Remove the timing belt cover. <Ref. to ME(STI)- does it have broken teeth? sprocket. <Ref. to
48, REMOVAL, Timing Belt Cover.> <Ref. to ME(STI)-59, Crank
ME(w/o STI)-47, REMOVAL, Timing Belt Sprocket.> <Ref. to
Cover.> ME(w/o STI)-58,
Crank Sprocket.>
29 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Go to step 30.
TIMING BELT. from its proper position? tion condition of
Turn the crankshaft using ST, and align the timing belt. <Ref. to
alignment mark on crank sprocket with align- ME(STI)-49, Tim-
ment mark on cylinder block. ing Belt.> <Ref. to
ST 499987500 CRANKSHAFT ME(w/o STI)-48,
SOCKET Timing Belt.>
30 CHECK FUEL LEVEL. Is the fuel meter indication Go to step 31. Refill the fuel so
higher than the “Lower” level? that the fuel meter
indication is higher
than the “Lower”
level, and proceed
to the next step. Go
to step 31.

Step Check Yes No

31 CHECK STATUS OF MALFUNCTION INDI- Does the malfunction indicator Go to step 33. Go to step 32.
CATOR LIGHT. light illuminate or blink?
1) Clear the memory using the Subaru Select
Monitor or general scan tool. <Ref. to
EN(H4DOTC)(diag)-62, Clear Memory Mode.>
2) Start the engine, and drive the vehicle 10
minutes or more.
32 CHECK CAUSE OF MISFIRE. Was the cause of misfire identi- Finish diagnostics Repair the poor
fied when the engine is run- operation, if the contact of connec-
ning? engine has no tor.
abnormality. NOTE:
In this case, repair
the following item:
• Poor contact of
ignition coil con-
nector
• Poor contact of
fuel injector con-
nector on faulty
cylinders
• Poor contact of
ECM connector
• Poor contact of
coupling connector
33 CHECK AIR INTAKE SYSTEM. Is there any fault in air intake Repair the air Go to step 34.
system? 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?
34 CHECK MISFIRE SYMPTOM. Does the Subaru Select Moni- Go to step 37. Go to step 35.
1) Turn the ignition switch to ON. tor or general scan tool indicate
2) Check for DTC. <Ref. to only one DTC?
EN(H4DOTC)(diag)-47, Read Diagnostic Trou-
ble Code (DTC).>
35 CHECK DTC. Is DTC P0301 and P0303 dis- Go to step 38. Go to step 36.
played on the Subaru Select
Monitor or general scan tool?
36 CHECK DTC. Is DTC P0302 and P0304 dis- Go to step 39. Go to step 40.
played on the Subaru Select
Monitor or general scan tool?
37 ONLY ONE CYLINDER. Is there any fault in the cylin- Repair or replace Go to DTC P0171.
der? faulty parts. <Ref. to
NOTE: EN(H4DOTC)(diag)
Check the follow- -170, DTC P0171
ing items. SYSTEM TOO
• Spark plug LEAN (BANK 1),
• Ignition coil Diagnostic Proce-
• Fuel injector dure with Diagnos-
• Compression ra- tic Trouble Code
tio (DTC).>

Step Check Yes No

38 GROUP OF #1 AND #3 CYLINDERS. Are there any faults in #1 and Repair or replace Go to DTC P0171.
#3 cylinders? faulty parts. <Ref. to
tio (DTC).>
• Skipping timing
belt teeth
39 GROUP OF #2 AND #4 CYLINDERS. Are there any faults in #2 and Repair or replace Go to DTC P0171.
#4 cylinders? faulty parts. <Ref. to
tio (DTC).>
• Skipping timing
belt teeth
40 CYLINDER AT RANDOM. Is the engine idle rough? Go to DTC P0171. Repair or replace
<Ref. to faulty parts.
EN(H4DOTC)(diag) NOTE:
-170, DTC P0171 Check the follow-
SYSTEM TOO ing items.
LEAN (BANK 1), • Spark plug
Diagnostic Proce- • Ignition coil
dure with Diagnos- • Fuel injector
tic Trouble Code • Compression ra-
(DTC).> tio

FA:DTC P2257 AIR SYSTEM CONTROL "A" CIRCUIT LOW

• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-271, DTC P2257 AIR SYSTEM CONTROL "A" CIR-
CUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
System.>
FUSE
B220
MAIN RELAY (RELAY BLOCK) BATTERY
B220
15A SBF-7
21 4 3
22
23
24
MAIN SBF
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
9 11 1 VALVE RELAY 1
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D9 4 8 AIR COMBINATION
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B144 F37 11 SECONDARY
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E41 E40 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE RH
(WITH BUILT-IN E
PRESSURE SENSOR) SECONDARY E
AIR COMBINATION
VALVE LH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 10 14 18 22
20 21 22 23 24 25 26 27 3 4 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 11 12 15 16 19 20 23 24
28 29 30 31 32 33 34 35 5 6 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9
11 F37 B143 F11 E40 E41 B144

5
12 13
1 9 14 1 2 3 4 5 6 7 8 9
3 4 6 7 8 1 2 3 4 5 6 7 8 9 1 2 1 2 3 1 2 3 4
2 10 10 11 12 13 14 15 16 17 18 19 20 1 2
10 11 12 13 14 15 16 17 18 19 20 4 5 6 5 6 7 8 9
15 16
EN-08734

FUSE
B220
B220
15A SBF-7
21 4 3
22
MAIN SBF
23
24
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E40 E41 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE LH
(WITH BUILT-IN
E
AIR COMBINATION
VALVE RH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
3 4 10 14 18 22 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
11 12 15 16 19 20 23 24 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 5 6
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9 F37 B143 F11 E41 E40 B144
1 2 3 4 5 6 7 8 9 1 2 3 4
11 1 2 3 4 5 6 7 8 9 1 2 1 2 3
5 10 11 12 13 14 15 16 17 18 19 20 1 2 5 6 7 8 9
12 13 10 11 12 13 14 15 16 17 18 19 20 4 5 6
1 9 14
3 4 6 7 8
2 10
15 16
EN-08735

Step Check Yes No

SECONDARY AIR PUMP RELAY CONNEC- and connector.
TOR. NOTE:
3) Remove the secondary air pump relay. • Open circuit in
ECM and secondary air pump relay connector. ECM and second-
Connector & terminal ary air pump relay
(B135) No. 27 — (F9) No. 13: connector
• Poor contact of
coupling connector
2 CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or Even if DTC is Repair the short
SECONDARY AIR PUMP RELAY CONNEC- more? detected, the cir- circuit to ground in
TOR. cuit has returned to harness between
Measure the resistance between ECM and a normal condition ECM and second-
chassis ground. at this time. Repro- ary air pump relay
Connector & terminal duce the failure, connector.
(B135) No. 27 — Chassis ground: and then perform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector,
temporary open or
ness may be the
cause.

FB:DTC P2258 AIR SYSTEM CONTROL "A" CIRCUIT HIGH

• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-272, DTC P2258 AIR SYSTEM CONTROL "A" CIR-
CUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
System.>
FUSE
B220
B220
15A SBF-7
21 4 3
22
23
24
MAIN SBF
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E41 E40 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE RH
(WITH BUILT-IN E
AIR COMBINATION
VALVE LH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 10 14 18 22
20 21 22 23 24 25 26 27 3 4 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 11 12 15 16 19 20 23 24
28 29 30 31 32 33 34 35 5 6 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9
11 F37 B143 F11 E40 E41 B144

5
12 13
1 9 14 1 2 3 4 5 6 7 8 9
3 4 6 7 8 1 2 3 4 5 6 7 8 9 1 2 1 2 3 1 2 3 4
2 10 10 11 12 13 14 15 16 17 18 19 20 1 2
10 11 12 13 14 15 16 17 18 19 20 4 5 6 5 6 7 8 9
15 16
EN-08734

FUSE
B220
B220
15A SBF-7
21 4 3
22
MAIN SBF
23
24
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E40 E41 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE LH
(WITH BUILT-IN
E
AIR COMBINATION
VALVE RH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
3 4 10 14 18 22 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
11 12 15 16 19 20 23 24 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 5 6
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9 F37 B143 F11 E41 E40 B144
1 2 3 4 5 6 7 8 9 1 2 3 4
11 1 2 3 4 5 6 7 8 9 1 2 1 2 3
5 10 11 12 13 14 15 16 17 18 19 20 1 2 5 6 7 8 9
12 13 10 11 12 13 14 15 16 17 18 19 20 4 5 6
1 9 14
3 4 6 7 8
2 10
15 16
EN-08735

Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? Repair the short Even if DTC is
SECONDARY AIR PUMP RELAY CONNEC- circuit to power in detected, the cir-
TOR. the harness cuit has returned to
1) Turn the ignition switch to OFF. between ECM and a normal condition
2) Disconnect the connector from ECM. secondary air at this time. Repro-
3) Remove the secondary air pump relay. pump relay con- duce the failure,
4) Measure the voltage between ECM and nector. and then perform
chassis ground. the diagnosis
Connector & terminal again.
(B135) No. 27 (+) — Chassis ground (–): NOTE:
In this case, tem-
porary poor con-
tact of connector,
temporary open or
ness may be the
cause.

FC:DTC P2401 EVAPORATIVE EMISSION SYSTEM LEAK DETECTION PUMP

CONTROL CIRCUIT LOW
• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-273, DTC P2401 EVAPORATIVE EMISSION SYS-
TEM LEAK DETECTION PUMP CONTROL CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
CAUTION:
WIRING DIAGRAM:
Electrical System.>
FUSE
MAIN RELAY B220 (RELAY BLOCK) BATTERY
SBF-7
21 4 3
22
23
24
ECM
B220
B: B135 C: B136 D: B137
B97
D27
B22
C21
B30
B4
10
R1 B83
*
*
R82 B92
13
14
16
15
17
8
R81 R5
R400
3
VACUUM E
PUMP SWITCHING PRESSURE
VALVE SENSOR

LEAK CHECK VALVE ASSY
*
B83
B: B135
B92 B220
1 2 3
1 2 3 4 5 6 7
4 5 6
1 2 3 4 5 6 7 8 9 8 9 10 11 12 13 14 15 16 17 18 19
10 11 12 13 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27 1 2 9 13 17 21
B97 R82 28 29 30 31 32 33 34 35 3 4 10 14 18 22
11 12 15 16 19 20 23 24
5 6
1 2 3 4 5
6 7 8 9 10 11 12 C: B136 D: B137 7 8 25 29 33 37
26 30 34 38
1 2 3 4 5 6 1 2 3 4 5 6 7 27 28 31 32 35 36 39 40
R400
7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
1 2 3 4
28 29 30 31 32 33 34 35 26 27 28 29 30 31
5 6 7 8
EN-09250

Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? Go to step 2. Go to step 3.
LEAK CHECK VALVE ASSEMBLY CONNEC-
TOR.
chassis ground.
2 CHECK FOR POOR CONTACT. Is there poor contact of ECM Repair the poor Even if DTC is
Check for poor contact of ECM connector. connector? contact of ECM detected, the cir-
connector. cuit has returned to
a normal condition
at this time. Repro-
duce the failure,
and then perform
the diagnosis
again.
NOTE:
In this case, tem-
porary open or
ness or temporary
poor contact of
connector may be
the cause.
3 CHECK POWER SUPPLY TO LEAK CHECK Is the voltage 10 V or more? Go to step 4. Repair the power
VALVE ASSEMBLY. supply circuit.
Measure the voltage between the leak check
valve assembly connector and engine ground.
(R400) No. 3 (+) — Engine ground (–):
LEAK CHECK VALVE ASSEMBLY CONNEC- more? circuit to ground in
1) Turn the ignition switch to OFF. ECM and leak
2) Disconnect the connector from ECM and check valve
the leak check valve assembly. assembly connec-
3) Measure the resistance between leak check tor.
valve assembly and chassis ground.
(R400) No. 4 — Chassis ground:
LEAK CHECK VALVE ASSEMBLY CONNEC- and connector.
TOR. NOTE:
ECM and the leak check valve assembly con- the following item:
(B137) No. 27 — (R400) No. 4: ECM and the leak
check valve as-
sembly connector
• Poor contact of
coupling connector

Step Check Yes No

6 CHECK LEAK CHECK VALVE ASSEMBLY. Is the vacuum pump of the leak Repair the poor Replace the leak
Check the vacuum pump of the leak check valve check valve assembly OK? contact in the leak check valve
assembly. <Ref. to EC(STI)-21, CHECK VAC- check valve assembly. <Ref. to
UUM PUMP, INSPECTION, Leak Check Valve assembly connec- EC(STI)-19, Leak
Assembly.> <Ref. to EC(w/o STI)-22, CHECK tor. Check Valve
VACUUM PUMP, INSPECTION, Leak Check Assembly.> <Ref.
Valve Assembly.> to EC(w/o STI)-20,
Leak Check Valve
Assembly.>

FD:DTC P2402 EVAPORATIVE EMISSION SYSTEM LEAK DETECTION PUMP

CONTROL CIRCUIT HIGH
TEM LEAK DETECTION PUMP CONTROL CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
CAUTION:
WIRING DIAGRAM:
Electrical System.>
FUSE
SBF-7
21 4 3
22
23
24
ECM
B220
B: B135 C: B136 D: B137
B97
D27
B22
C21
B30
B4
10
R1 B83
*
*
R82 B92
13
14
16
15
17
8
R81 R5
R400
3
VACUUM E
VALVE SENSOR

*
B83
B: B135
B92 B220
1 2 3
1 2 3 4 5 6 7
4 5 6
1 2 3 4 5 6 7 8 9 8 9 10 11 12 13 14 15 16 17 18 19
10 11 12 13 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27 1 2 9 13 17 21
B97 R82 28 29 30 31 32 33 34 35 3 4 10 14 18 22
11 12 15 16 19 20 23 24
5 6
1 2 3 4 5
6 7 8 9 10 11 12 C: B136 D: B137 7 8 25 29 33 37
26 30 34 38
1 2 3 4 5 6 1 2 3 4 5 6 7 27 28 31 32 35 36 39 40
R400
7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
1 2 3 4
28 29 30 31 32 33 34 35 26 27 28 29 30 31
5 6 7 8
EN-09250

Step Check Yes No

LEAK CHECK VALVE ASSEMBLY CONNEC- circuit to power in
2) Disconnect the connector from the leak check valve
check valve assembly. assembly connec-
3) Turn the ignition switch to ON. tor.
4) Measure the voltage between leak check
(R400) No. 4 (+) — Chassis ground (–):
2 CHECK LEAK CHECK VALVE ASSEMBLY. Is the vacuum pump of the leak Repair the poor Replace the leak
1) Turn the ignition switch to OFF. check valve assembly OK? contact in the leak check valve
2) Check the vacuum pump of the leak check check valve assembly. <Ref. to
valve assembly. <Ref. to EC(STI)-21, CHECK assembly connec- EC(STI)-19, Leak
VACUUM PUMP, INSPECTION, Leak Check tor. Check Valve
Valve Assembly.> <Ref. to EC(w/o STI)-22, Assembly.> <Ref.
CHECK VACUUM PUMP, INSPECTION, Leak to EC(w/o STI)-20,
Check Valve Assembly.> Leak Check Valve
Assembly.>

FE:DTC P2404 EVAPORATIVE EMISSION SYSTEM LEAK DETECTION PUMP

SENSE CIRCUIT RANGE/PERFORMANCE
TEM LEAK DETECTION PUMP SENSE CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code
(DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
Electrical System.>
FUSE
SBF-7
21 4 3
22
23
24
ECM
B220
B: B135 C: B136 D: B137
B97
D27
B22
C21
B30
B4
10
R1 B83
*
*
R82 B92
13
14
16
15
17
8
R81 R5
R400
3
VACUUM E
VALVE SENSOR

*
B83
B: B135
B92 B220
1 2 3
1 2 3 4 5 6 7
4 5 6
1 2 3 4 5 6 7 8 9 8 9 10 11 12 13 14 15 16 17 18 19
10 11 12 13 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27 1 2 9 13 17 21
B97 R82 28 29 30 31 32 33 34 35 3 4 10 14 18 22
11 12 15 16 19 20 23 24
5 6
1 2 3 4 5
6 7 8 9 10 11 12 C: B136 D: B137 7 8 25 29 33 37
26 30 34 38
1 2 3 4 5 6 1 2 3 4 5 6 7 27 28 31 32 35 36 39 40
R400
7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
1 2 3 4
28 29 30 31 32 33 34 35 26 27 28 29 30 31
5 6 7 8
EN-09250

Step Check Yes No

1 CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check the appropri- Go to step 2.
ate DTC using the
Trouble Code
(DTC)”. <Ref. to
EN(H4DOTC)(diag)
tic Trouble Code
(DTC).>
2 CHECK ELCM PUMP. Does the ELCM pump operate? Go to step 6. Go to step 3.
Operate the ELCM pump using the Subaru
Select Monitor.
NOTE:
Refer to “Compulsory Valve Operation Check
Mode” for more operation procedures. <Ref. to
EN(H4DOTC)(diag)-63, Compulsory Valve Op-
eration Check Mode.>
3 CHECK POWER SUPPLY OF LEAK CHECK Is the voltage 10 V or more? Go to step 4. Repair the harness
VALVE ASSEMBLY. and connector.
2) Disconnect the connector from the leak In this case, repair
check valve assembly. the following item:
4) Measure the voltage between the leak harness between
check valve assembly connector and chassis the main relay and
ground. the leak check
Connector & terminal valve assembly
(R400) No. 3 (+) — Chassis ground (–): connector
• Poor contact of
main relay connec-
tor
• Poor contact of
coupling connector
TOR. NOTE:
ECM and the leak check valve assembly con- harness between
nector. ECM and the leak
Connector & terminal check valve as-
(B137) No. 27 — (R400) No. 4: sembly connector
• Poor contact of
coupling connector
5 CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or Replace the leak Repair the short
LEAK CHECK VALVE ASSEMBLY CONNEC- more? check valve circuit to ground in
TOR. assembly. <Ref. to harness between
1) Measure the resistance of harness between EC(STI)-19, Leak ECM and leak
ECM and chassis ground. Check Valve check valve
Connector & terminal Assembly.> <Ref. assembly connec-
(B137) No. 27 — Chassis ground: to EC(w/o STI)-20, tor.
Leak Check Valve
Assembly.>

Step Check Yes No

6 CHECK ELCM SWITCHING VALVE. Does the ELCM switching valve Go to step 10. Go to step 7.
Operate the ELCM switching valve using the operate?
Subaru Select Monitor.
NOTE:
7 CHECK POWER SUPPLY OF LEAK CHECK Is the voltage 10 V or more? Go to step 8. Repair the harness
VALVE ASSEMBLY. and connector.
2) Disconnect the connector from the leak In this case, repair
check valve assembly. the following item:
4) Measure the voltage between the leak harness between
check valve assembly connector and chassis the main relay and
ground. the leak check
Connector & terminal valve assembly
(R400) No. 5 (+) — Chassis ground (–): connector
• Poor contact of
main relay connec-
tor
• Poor contact of
coupling connector
TOR. NOTE:
ECM and the leak check valve assembly con- harness between
nector. ECM and the leak
Connector & terminal check valve as-
(B135) No. 4 — (R400) No. 1: sembly connector
• Poor contact of
coupling connector
9 CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or Replace the leak Repair the short
LEAK CHECK VALVE ASSEMBLY CONNEC- more? check valve circuit to ground in
TOR. assembly. <Ref. to harness between
1) Measure the resistance of harness between EC(STI)-19, Leak ECM and leak
ECM and chassis ground. Check Valve check valve
Connector & terminal Assembly.> <Ref. assembly connec-
(B135) No. 4 — Chassis ground: to EC(w/o STI)-20, tor.
Leak Check Valve
Assembly.>

Step Check Yes No

10 CHECK EVAPORATIVE EMISSION CON- Is DTC P2404 displayed on the Replace the leak Even if DTC is
TROL SYSTEM. display? check valve detected, the cir-
Perform drive cycle I. <Ref. to assembly. <Ref. to cuit has returned to
EN(H4DOTC)(diag)-58, DRIVE CYCLE H, EC(STI)-19, Leak a normal condition
PROCEDURE, Drive Cycle.> Check Valve at this time. Repro-
Assembly.> <Ref. duce the failure,
to EC(w/o STI)-20, and then perform
Leak Check Valve the diagnosis
Assembly.> again.
NOTE:
In this case, tem-
porary poor con-
tact of connector,
temporary open or
ness may be the
cause.

FF:DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CON-

TROL CIRCUIT LOW
TEM SWITCHING VALVE CONTROL CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
Electrical System.>
FUSE
SBF-7
21 4 3
22
23
24
ECM
B220
B: B135 C: B136 D: B137
B97
D27
B22
C21
B30
B4
10
R1 B83
*
*
R82 B92
13
14
16
15
17
8
R81 R5
R400
3
VACUUM E
VALVE SENSOR

*
B83
B: B135
B92 B220
1 2 3
1 2 3 4 5 6 7
4 5 6
1 2 3 4 5 6 7 8 9 8 9 10 11 12 13 14 15 16 17 18 19
10 11 12 13 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27 1 2 9 13 17 21
B97 R82 28 29 30 31 32 33 34 35 3 4 10 14 18 22
11 12 15 16 19 20 23 24
5 6
1 2 3 4 5
6 7 8 9 10 11 12 C: B136 D: B137 7 8 25 29 33 37
26 30 34 38
1 2 3 4 5 6 1 2 3 4 5 6 7 27 28 31 32 35 36 39 40
R400
7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
1 2 3 4
28 29 30 31 32 33 34 35 26 27 28 29 30 31
5 6 7 8
EN-09250

Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? Go to step 2. Go to step 3.
LEAK CHECK VALVE ASSEMBLY CONNEC-
TOR.
chassis ground.
2 CHECK FOR POOR CONTACT. Is there poor contact of ECM Repair the poor Even if DTC is
Check for poor contact of ECM connector. connector? contact of ECM detected, the cir-
connector. cuit has returned to
a normal condition
at this time. Repro-
duce the failure,
and then perform
the diagnosis
again.
NOTE:
In this case, tem-
porary open or
ness or temporary
poor contact of
connector may be
the cause.
3 CHECK POWER SUPPLY TO LEAK CHECK Is the voltage 10 V or more? Go to step 4. Repair the power
VALVE ASSEMBLY. supply circuit.
Measure the voltage between the leak check
valve assembly connector and engine ground.
(R400) No. 5 (+) — Engine ground (–):
LEAK CHECK VALVE ASSEMBLY CONNEC- more? circuit to ground in
2) Disconnect the connector from ECM and check valve
the leak check valve assembly. assembly connec-
3) Measure the resistance between leak check tor.
TOR. NOTE:
ECM and the leak check valve assembly con- the following item:
(B135) No. 4 — (R400) No. 1: ECM and the leak
check valve as-
sembly connector
• Poor contact of
coupling connector

Step Check Yes No

6 CHECK LEAK CHECK VALVE ASSEMBLY. Is the switching valve of the Repair the poor Replace the leak
Check the switching valve of the leak check leak check valve assembly OK? contact in the leak check valve
valve assembly. <Ref. to EC(STI)-20, CHECK check valve assembly. <Ref. to
SWITCHING VALVE, INSPECTION, Leak assembly connec- EC(STI)-19, Leak
Check Valve Assembly.> <Ref. to EC(w/o STI)- tor. Check Valve
21, CHECK SWITCHING VALVE, INSPEC- Assembly.> <Ref.
TION, Leak Check Valve Assembly.> to EC(w/o STI)-20,
Leak Check Valve
Assembly.>

FG:DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CON-

TROL CIRCUIT HIGH
TEM SWITCHING VALVE CONTROL CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
Electrical System.>
FUSE
SBF-7
21 4 3
22
23
24
ECM
B220
B: B135 C: B136 D: B137
B97
D27
B22
C21
B30
B4
10
R1 B83
*
*
R82 B92
13
14
16
15
17
8
R81 R5
R400
3
VACUUM E
VALVE SENSOR

*
B83
B: B135
B92 B220
1 2 3
1 2 3 4 5 6 7
4 5 6
1 2 3 4 5 6 7 8 9 8 9 10 11 12 13 14 15 16 17 18 19
10 11 12 13 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27 1 2 9 13 17 21
B97 R82 28 29 30 31 32 33 34 35 3 4 10 14 18 22
11 12 15 16 19 20 23 24
5 6
1 2 3 4 5
6 7 8 9 10 11 12 C: B136 D: B137 7 8 25 29 33 37
26 30 34 38
1 2 3 4 5 6 1 2 3 4 5 6 7 27 28 31 32 35 36 39 40
R400
7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
1 2 3 4
28 29 30 31 32 33 34 35 26 27 28 29 30 31
5 6 7 8
EN-09250

Step Check Yes No

LEAK CHECK VALVE ASSEMBLY CONNEC- circuit to power in
2) Disconnect the connector from the leak check valve
check valve assembly. assembly connec-
4) Measure the voltage between leak check
2 CHECK LEAK CHECK VALVE ASSEMBLY. Is the switching valve of the Repair the poor Replace the leak
1) Turn the ignition switch to OFF. leak check valve assembly OK? contact in the leak check valve
2) Check the switching valve of the leak check check valve assembly. <Ref. to
valve assembly. <Ref. to EC(STI)-20, CHECK assembly connec- EC(STI)-19, Leak
SWITCHING VALVE, INSPECTION, Leak tor. Check Valve
Check Valve Assembly.> <Ref. to EC(w/o STI)- Assembly.> <Ref.
21, CHECK SWITCHING VALVE, INSPEC- to EC(w/o STI)-20,
TION, Leak Check Valve Assembly.> Leak Check Valve
Assembly.>

FH:DTC P2431 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE

SENSOR CIRCUIT RANGE/PERFORMANCE
• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-281, DTC P2431 SECONDARY AIR INJECTION SYS-
TEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code
CAUTION:
Step Check Yes No
1 CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check the appropri- Go to step 2.
ate DTC using the
Trouble Code
(DTC)”. <Ref. to
EN(H4DOTC)(diag)
tic Trouble Code
(DTC).>
2 CHECK CURRENT DATA. Does the displayed value differ Replace the sec- Even if DTC is
1) Turn the ignition switch to ON (engine OFF). from the actual atmospheric ondary air combi- detected, the cir-
2) Using the Subaru Select Monitor, read the pressure by 200 mmHg (27 nation valve (with cuit has returned to
values in «Sec. Air Piping Pressure», «Mani. kPa, 8 inHg, 3.9 psig) or more? built-in pressure a normal condition
Absolute Pressure» and «Atmosphere Pres- sensor). <Ref. to at this time. Repro-
sure», and compare them with actual atmo- EC(STI)-29, Sec- duce the failure,
spheric pressure. ondary Air Combi- and then perform
NOTE: nation Valve.> the diagnosis
For detailed operation procedures, refer to <Ref. to EC(w/o again.
“READ CURRENT DATA FOR ENGINE”. <Ref. STI)-30, Second- NOTE:
to EN(H4DOTC)(diag)-39, Subaru Select Moni- ary Air Combina- In this case, tem-
tor.> tion Valve.> porary poor con-
tact of connector,
temporary open or
ness may be the
cause.

FI: 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:
System.>
FUSE
B220
B220
15A SBF-7
21 4 3
22
23
24
MAIN SBF
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E41 E40 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE RH
(WITH BUILT-IN E
AIR COMBINATION
VALVE LH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 10 14 18 22
20 21 22 23 24 25 26 27 3 4 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 11 12 15 16 19 20 23 24
28 29 30 31 32 33 34 35 5 6 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9
11 F37 B143 F11 E40 E41 B144

5
12 13
1 9 14 1 2 3 4 5 6 7 8 9
3 4 6 7 8 1 2 3 4 5 6 7 8 9 1 2 1 2 3 1 2 3 4
2 10 10 11 12 13 14 15 16 17 18 19 20 1 2
10 11 12 13 14 15 16 17 18 19 20 4 5 6 5 6 7 8 9
15 16
EN-08734

FUSE
B220
B220
15A SBF-7
21 4 3
22
MAIN SBF
23
24
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E40 E41 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE LH
(WITH BUILT-IN
E
AIR COMBINATION
VALVE RH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
3 4 10 14 18 22 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
11 12 15 16 19 20 23 24 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 5 6
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9 F37 B143 F11 E41 E40 B144
1 2 3 4 5 6 7 8 9 1 2 3 4
11 1 2 3 4 5 6 7 8 9 1 2 1 2 3
5 10 11 12 13 14 15 16 17 18 19 20 1 2 5 6 7 8 9
12 13 10 11 12 13 14 15 16 17 18 19 20 4 5 6
1 9 14
3 4 6 7 8
2 10
15 16
EN-08735

Step Check Yes No

1 CHECK CURRENT DATA. Is the value of «Sec. Air Piping Go to step 2. Even if DTC is
1) Turn the ignition switch to ON. Pressure» less than 53.3 kPa detected, the cir-
2) Read the value of «Sec. Air Piping Pres- (400 mmHg, 15.8 inHg)? cuit has returned to
sure» using Subaru Select Monitor. a normal condition
tor.> again.
NOTE:
In this case, tem-
porary poor con-
tact of connector,
temporary open or
ness may be the
cause.
2 CHECK POWER SUPPLY OF SECONDARY Is the voltage 4.5 V or more? Go to step 3. Repair the harness
AIR COMBINATION VALVE. and connector.
2) Disconnect the connectors from secondary In this case, repair
air combination valve RH (models without SI- the following item:
DRIVE) or LH (models with SI-DRIVE). • Open circuit in
3) Turn the ignition switch to ON. harness between
4) Measure the voltage between the second- ECM and second-
ary air combination valve RH or LH connector ary air combination
and chassis ground. valve RH or LH
Connector & terminal connector
Models without SI-DRIVE • Poor contact of
(E41) No. 1 (+) — Chassis ground (–): ECM connector
Models with SI-DRIVE • Poor contact of
(E40) No. 1 (+) — Chassis ground (–): coupling connector
SECONDARY AIR COMBINATION VALVE and connector.
CONNECTOR. NOTE:
3) Measure the resistance of the harness • Open circuit in
between ECM and secondary air combination harness between
valve RH or LH connector. ECM and second-
Connector & terminal ary air combination
Models without SI-DRIVE valve RH or LH
Models with SI-DRIVE • Poor contact of
(B137) No. 9 — (E40) No. 2: coupling connector
SECONDARY AIR COMBINATION VALVE more? short circuit in har-
CONNECTOR. ness between
Measure the resistance between ECM and ECM and second-
chassis ground. ary air combination
Connector & terminal valve RH or LH
(B137) No. 9 — Chassis ground: connector.

Step Check Yes No

5 CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Replace the sec-
Check for poor contact of the ECM and second- secondary air combination contact of the ECM ondary air combi-
ary air combination valve RH or LH connector. valve RH or LH connector? or secondary air nation valve RH or
combination valve LH. <Ref. to
RH or LH connec- EC(STI)-29, Sec-
tor. ondary Air Combi-
nation Valve.>
<Ref. to EC(w/o
STI)-30, Second-
ary Air Combina-
tion Valve.>

FJ: 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:
System.>
FUSE
B220
B220
15A SBF-7
21 4 3
22
23
24
MAIN SBF
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E41 E40 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE RH
(WITH BUILT-IN E
AIR COMBINATION
VALVE LH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 10 14 18 22
20 21 22 23 24 25 26 27 3 4 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 11 12 15 16 19 20 23 24
28 29 30 31 32 33 34 35 5 6 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9
11 F37 B143 F11 E40 E41 B144

5
12 13
1 9 14 1 2 3 4 5 6 7 8 9
3 4 6 7 8 1 2 3 4 5 6 7 8 9 1 2 1 2 3 1 2 3 4
2 10 10 11 12 13 14 15 16 17 18 19 20 1 2
10 11 12 13 14 15 16 17 18 19 20 4 5 6 5 6 7 8 9
15 16
EN-08734

FUSE
B220
B220
15A SBF-7
21 4 3
22
MAIN SBF
23
24
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E40 E41 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE LH
(WITH BUILT-IN
E
AIR COMBINATION
VALVE RH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
3 4 10 14 18 22 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
11 12 15 16 19 20 23 24 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 5 6
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9 F37 B143 F11 E41 E40 B144
1 2 3 4 5 6 7 8 9 1 2 3 4
11 1 2 3 4 5 6 7 8 9 1 2 1 2 3
5 10 11 12 13 14 15 16 17 18 19 20 1 2 5 6 7 8 9
12 13 10 11 12 13 14 15 16 17 18 19 20 4 5 6
1 9 14
3 4 6 7 8
2 10
15 16
EN-08735

Step Check Yes No

1 CHECK CURRENT DATA. Is the value of «Sec. Air Piping Go to step 2. Even if DTC is
1) Turn the ignition switch to ON. Pressure» 133.3 kPa (1,000 detected, the cir-
2) Read the value of «Sec. Air Piping Pres- mmHg, 39.4 inHg) or more? cuit has returned to
sure» using Subaru Select Monitor. a normal condition
tor.> again.
NOTE:
In this case, tem-
porary poor con-
tact of connector,
temporary open or
ness may be the
cause.
2 CHECK HARNESS BETWEEN ECM AND Is the value of «Sec. Air Piping Repair the short Go to step 3.
SECONDARY AIR COMBINATION VALVE Pressure» 133.3 kPa (1,000 circuit to power
CONNECTOR. mmHg, 39.4 inHg) or more? supply in the har-
1) Turn the ignition switch to OFF. ness between
2) Disconnect the connectors from secondary ECM and second-
air combination valve RH (models without SI- ary air combination
DRIVE) or LH (models with SI-DRIVE). valve RH or LH
3) Turn the ignition switch to ON. connectors.
4) Read the value of «Sec. Air Piping Pres-
sure» using Subaru Select Monitor.
NOTE:
tor.>
CONNECTOR. NOTE:
2) Measure the resistance of the harness the following item:
between secondary air combination valve RH • Open circuit in
or LH connector and engine ground. harness between
Connector & terminal ECM and second-
Models without SI-DRIVE ary air combination
(E41) No. 3 — Engine ground: valve RH or LH
Models with SI-DRIVE connector
(E40) No. 3 — Engine ground: • Poor contact of
ECM connector
• Poor contact of
coupling connector
4 CHECK FOR POOR CONTACT. Is there poor contact of the sec- Repair the poor Replace the sec-
Check for poor contact of the secondary air ondary air combination valve contact of second- ondary air combi-
combination valve RH or LH connector. RH or LH connector? ary air combination nation valve RH or
valve RH or LH LH. <Ref. to
connector. EC(STI)-29, Sec-
ondary Air Combi-
nation Valve.>
<Ref. to EC(w/o
STI)-30, Second-
ary Air Combina-
tion Valve.>

FK:DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

STUCK OPEN (BANK1)
TEM SWITCHING VALVE STUCK OPEN (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
System.>
FUSE
B220
B220
15A SBF-7
21 4 3
22
23
24
MAIN SBF
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E41 E40 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE RH
(WITH BUILT-IN E
AIR COMBINATION
VALVE LH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 10 14 18 22
20 21 22 23 24 25 26 27 3 4 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 11 12 15 16 19 20 23 24
28 29 30 31 32 33 34 35 5 6 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9
11 F37 B143 F11 E40 E41 B144

5
12 13
1 9 14 1 2 3 4 5 6 7 8 9
3 4 6 7 8 1 2 3 4 5 6 7 8 9 1 2 1 2 3 1 2 3 4
2 10 10 11 12 13 14 15 16 17 18 19 20 1 2
10 11 12 13 14 15 16 17 18 19 20 4 5 6 5 6 7 8 9
15 16
EN-08734

FUSE
B220
B220
15A SBF-7
21 4 3
22
MAIN SBF
23
24
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E40 E41 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE LH
(WITH BUILT-IN
E
AIR COMBINATION
VALVE RH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
3 4 10 14 18 22 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
11 12 15 16 19 20 23 24 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 5 6
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9 F37 B143 F11 E41 E40 B144
1 2 3 4 5 6 7 8 9 1 2 3 4
11 1 2 3 4 5 6 7 8 9 1 2 1 2 3
5 10 11 12 13 14 15 16 17 18 19 20 1 2 5 6 7 8 9
12 13 10 11 12 13 14 15 16 17 18 19 20 4 5 6
1 9 14
3 4 6 7 8
2 10
15 16
EN-08735
Step Check Yes No

1 CHECK SECONDARY AIR COMBINATION Is the fuse blown out? Go to step 2. Go to step 3.
VALVE FUSE.
Check if the secondary air combination valve
fuse (10 A) is blown out.

Step Check Yes No

2 CHECK HARNESS BETWEEN FUSE BOX Is the resistance 1 MΩ or Replace the fuse Repair the short
AND SECONDARY AIR COMBINATION more? with a new part, circuit to ground in
VALVE RH CONNECTOR. and connect the harness between
1) Remove the secondary air combination secondary air com- the fuse box and
valve fuse (10 A) from the fuse box. bination valve RH the secondary air
2) Disconnect the connector from the second- connector. combination valve
ary air combination valve RH. Go to step 3. RH connector.
3) Measure the resistance between the sec-
ondary air combination valve fuse and second-
ary air combination valve RH connector, and
chassis ground.
(F9) No. 5 — Chassis ground:
(E41) No. 6 — Chassis ground:
3 CHECK SECONDARY AIR COMBINATION Does the secondary air combi- Go to step 4. Go to step 6.
VALVE RH OPERATION. nation valve RH repeatedly
1) Connect the delivery (test) mode connector. switch to ON and OFF?
3) Perform operation check for the secondary
air combination valve RH using the Subaru
Select Monitor.
NOTE:
4 CHECK DUCT BETWEEN SECONDARY AIR Is there damage, clog or dis- Replace, clean or Go to step 5.
PUMP AND SECONDARY AIR COMBINA- connection of the duct? connect the duct.
TION VALVE RH.
Check the duct between the secondary air
pump and secondary air combination valve RH.
5 CHECK PIPE BETWEEN SECONDARY AIR Is there damage, clog or dis- Replace, clean or Even if DTC is
COMBINATION VALVE RH AND CYLINDER connection of the pipe? connect the pipe. detected, the cir-
HEAD. cuit has returned to
Check the pipe between the secondary air com- a normal condition
bination valve RH and cylinder head. at this time. Repro-
duce the failure,
and then perform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector,
temporary open or
ness may be the
cause.

Step Check Yes No

6 CHECK POWER SUPPLY TO SECONDARY Does the voltage repeatedly Replace the sec- Go to step 7.
AIR COMBINATION VALVE RH. change between 10 V and 0 V? ondary air combi-
1) Disconnect the connector from the second- nation valve RH.
ary air combination valve RH. <Ref. to EC(STI)-
2) In the condition of step 3, measure the volt- 29, Secondary Air
age between secondary air combination valve Combination
RH connector and chassis ground. Valve.> <Ref. to
Connector & terminal EC(w/o STI)-30,
Models without SI-DRIVE Secondary Air
(E41) No. 6 (+) — Chassis ground (–): Combination
Models with SI-DRIVE Valve.>
7 CHECK HARNESS BETWEEN SECONDARY Is the resistance less than 5 Ω? • Models without Repair the open
AIR COMBINATION VALVE RH AND CHAS- SI-DRIVE: Go to circuit in harness
SIS GROUND. step 8. between second-
Measure the resistance between the secondary • Models with SI- ary air combination
air combination valve RH connector and chas- DRIVE: Go to step valve RH connec-
sis ground. 14. tor and chassis
Connector & terminal ground.
8 CHECK HARNESS BETWEEN SECONDARY Is the resistance less than 1 Ω? Go to step 9. Repair the open
AIR COMBINATION VALVE RELAY 1 AND circuit in harness
SECONDARY AIR COMBINATION VALVE between second-
RH CONNECTOR. ary air combination
1) Turn the ignition switch to OFF. valve relay 1 and
2) Remove the secondary air combination secondary air com-
valve relay 1 from the relay box. bination valve RH
3) Measure the resistance of the harness connector.
between secondary air combination valve relay
1 connector and secondary air combination
valve RH connector.
(F9) No. 3 — (E41) No. 6:
9 CHECK SECONDARY AIR COMBINATION Is the resistance less than 1 Ω? Go to step 10. Replace the sec-
VALVE RELAY 1. ondary air combina-
1) Connect the battery to terminals No. 1 and tion valve relay 1.
No. 2 of the secondary air combination valve <Ref. to
relay 1. EN(H4DOTC)(diag)
2) Measure the resistance between the sec- -8, Electrical Com-
ondary air combination valve relay 1 terminals. ponent Location.>
Terminals
No. 3 — No. 4:
10 CHECK SECONDARY AIR COMBINATION Is the resistance 1 MΩ or Go to step 11. Replace the sec-
VALVE RELAY 1. more? ondary air combina-
Measure the resistance between the secondary tion valve relay 1.
air combination valve relay 1 terminals with the <Ref. to
battery disconnected. EN(H4DOTC)(diag)
Terminals -8, Electrical Com-
No. 3 — No. 4: ponent Location.>

Step Check Yes No

11 CHECK SECONDARY AIR COMBINATION Is the voltage 10 V or more? Go to step 12. Repair the open or
VALVE RELAY 1 POWER SUPPLY. ground short circuit
1) Turn the ignition switch to ON. of power supply
2) Measure the voltage between the second- circuit.
ary air combination valve relay 1 connector and
chassis ground.
(F9) No. 4 (+) — Chassis ground (–):
RELAY 1 CONNECTOR. NOTE:
2) Disconnect the ECM connector. the following item:
ECM and secondary air combination valve relay harness between
1 connector. ECM and second-
(B135) No. 8 — (F9) No. 2: valve relay 1 con-
nector
• Poor contact of
coupling connector
SECONDARY AIR COMBINATION VALVE more? contact of ECM circuit to ground in
RELAY 1 CONNECTOR. connector. harness between
Measure the resistance between the secondary ECM and second-
air combination valve relay 1 connector and ary air combination
chassis ground. valve relay 1 con-
14 CHECK HARNESS BETWEEN SECONDARY Is the resistance less than 1 Ω? Go to step 15. Repair the open
AIR COMBINATION VALVE RELAY 2 AND circuit in harness
SECONDARY AIR COMBINATION VALVE between second-
RH CONNECTOR. ary air combination
1) Turn the ignition switch to OFF. valve relay 2 and
2) Remove the secondary air combination secondary air com-
valve relay 2 from the relay box. bination valve RH
3) Measure the resistance of the harness connector.
between secondary air combination valve relay
2 connector and secondary air combination
valve RH connector.
(F9) No. 8 — (E41) No. 2:
Terminals
No. 7 — No. 8:

Step Check Yes No

chassis ground.
nector
• Poor contact of
coupling connector
FL:DTC P2441 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

STUCK CLOSED (BANK1)
NOTE:
For the diagnostic procedure, refer to DTC P2440. <Ref. to EN(H4DOTC)(diag)-444, DTC P2440 SECOND-
ARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK1), Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>

FM: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:
System.>
FUSE
B220
B220
15A SBF-7
21 4 3
22
23
24
MAIN SBF
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E41 E40 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE RH
(WITH BUILT-IN E
AIR COMBINATION
VALVE LH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 10 14 18 22
20 21 22 23 24 25 26 27 3 4 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 11 12 15 16 19 20 23 24
28 29 30 31 32 33 34 35 5 6 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9
11 F37 B143 F11 E40 E41 B144

5
12 13
1 9 14 1 2 3 4 5 6 7 8 9
3 4 6 7 8 1 2 3 4 5 6 7 8 9 1 2 1 2 3 1 2 3 4
2 10 10 11 12 13 14 15 16 17 18 19 20 1 2
10 11 12 13 14 15 16 17 18 19 20 4 5 6 5 6 7 8 9
15 16
EN-08734

FUSE
B220
B220
15A SBF-7
21 4 3
22
MAIN SBF
23
24
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E40 E41 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE LH
(WITH BUILT-IN
E
AIR COMBINATION
VALVE RH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
3 4 10 14 18 22 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
11 12 15 16 19 20 23 24 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 5 6
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9 F37 B143 F11 E41 E40 B144
1 2 3 4 5 6 7 8 9 1 2 3 4
11 1 2 3 4 5 6 7 8 9 1 2 1 2 3
5 10 11 12 13 14 15 16 17 18 19 20 1 2 5 6 7 8 9
12 13 10 11 12 13 14 15 16 17 18 19 20 4 5 6
1 9 14
3 4 6 7 8
2 10
15 16
EN-08735

Step Check Yes No

1 CHECK SECONDARY AIR COMBINATION Is the fuse blown out? Go to step 2. Go to step 3.
VALVE FUSE.
Check if the secondary air combination valve
fuse (10 A) is blown out.
2 CHECK HARNESS BETWEEN FUSE BOX Is the resistance 1 MΩ or Replace the fuse Repair the ground
AND SECONDARY AIR COMBINATION more? with a new part, short circuit of har-
VALVE LH CONNECTOR. and connect the ness between the
1) Remove the secondary air combination secondary air com- fuse box and the
valve fuse (10 A) from the fuse box. bination valve LH secondary air com-
2) Disconnect the connector from the second- connector. bination valve LH
ary air combination valve LH. Go to step 3. connector.
ondary air combination valve fuse and second-
ary air combination valve LH connector, and
chassis ground.
3 CHECK SECONDARY AIR COMBINATION Does the secondary air combi- Go to step 4. Go to step 6.
VALVE LH OPERATION. nation valve LH repeatedly
1) Connect the delivery (test) mode connector. switch to ON and OFF?
3) Perform operation check for the secondary
air combination valve LH using the Subaru
Select Monitor.
NOTE:
4 CHECK DUCT BETWEEN SECONDARY AIR Is there damage, clog or dis- Replace, clean or Go to step 5.
PUMP AND SECONDARY AIR COMBINA- connection of the duct? connect the duct.
TION VALVE LH.
Check the duct between the secondary air
pump and secondary air combination valve LH.
5 CHECK PIPE BETWEEN SECONDARY AIR Is there damage, clog or dis- Replace, clean or Even if DTC is
COMBINATION VALVE LH AND CYLINDER connection of the pipe? connect the pipe. detected, the cir-
HEAD. cuit has returned to
Check the pipe between the secondary air com- a normal condition
bination valve LH and cylinder head. at this time. Repro-
duce the failure,
and then perform
the diagnosis
again.
NOTE:
In this case, tem-
porary poor con-
tact of connector,
temporary open or
ness may be the
cause.

Step Check Yes No

6 CHECK POWER SUPPLY TO SECONDARY Does the voltage repeatedly Replace the sec- Go to step 7.
AIR COMBINATION VALVE LH. change between 10 V and 0 V? ondary air combi-
1) Disconnect the connector from the second- nation valve LH.
ary air combination valve LH. <Ref. to EC(STI)-
2) In the condition of step 3, measure the volt- 29, Secondary Air
age between secondary air combination valve Combination
LH connector and chassis ground. Valve.> <Ref. to
Connector & terminal EC(w/o STI)-30,
Models without SI-DRIVE Secondary Air
(E40) No. 2 (+) — Chassis ground (–): Combination
Models with SI-DRIVE Valve.>
7 CHECK HARNESS BETWEEN SECONDARY Is the resistance less than 5 Ω? • Models without Repair the open
AIR COMBINATION VALVE LH AND CHAS- SI-DRIVE: Go to circuit in harness
SIS GROUND. step 8. between second-
Measure the resistance between the secondary • Models with SI- ary air combination
air combination valve LH connector and chassis DRIVE: Go to step valve LH connector
ground. 14. and chassis
8 CHECK HARNESS BETWEEN SECONDARY Is the resistance less than 1 Ω? Go to step 9. Repair the harness
AIR COMBINATION VALVE RELAY 2 AND and connector.
SECONDARY AIR COMBINATION VALVE NOTE:
LH CONNECTOR. In this case, repair
1) Turn the ignition switch to OFF. the following item:
2) Remove the secondary air combination • Open circuit in
valve relay 2 from the relay box. harness between
3) Measure the resistance of the harness secondary air com-
between the secondary air combination valve bination valve re-
relay 2 and secondary air combination valve LH lay 2 connector
connector. and secondary air
Connector & terminal combination valve
(F9) No. 8 — (E40) No. 2: LH connector
• Poor contact of
coupling connector
Terminals
No. 7 — No. 8:

Step Check Yes No

chassis ground.
nector
• Poor contact of
coupling connector
14 CHECK HARNESS BETWEEN SECONDARY Is the resistance less than 1 Ω? Go to step 15. Repair the harness
AIR COMBINATION VALVE RELAY 1 AND and connector.
SECONDARY AIR COMBINATION VALVE NOTE:
LH CONNECTOR. In this case, repair
1) Turn the ignition switch to OFF. the following item:
2) Remove the secondary air combination • Open circuit in
valve relay 1 from the relay box. harness between
3) Measure the resistance of the harness secondary air com-
between the secondary air combination valve bination valve re-
relay 1 and secondary air combination valve LH lay 1 connector
connector. and secondary air
Connector & terminal combination valve
(F9) No. 3 — (E40) No. 6: LH connector
• Poor contact of
coupling connector
Terminals
No. 3 — No. 4:

Step Check Yes No

chassis ground.
nector
• Poor contact of
coupling connector
FN:DTC P2443 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

NOTE:
For the diagnostic procedure, refer to DTC P2442. <Ref. to EN(H4DOTC)(diag)-451, DTC P2442 SECOND-
ARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK2), Diagnostic Procedure with

FO:DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON

TEM PUMP STUCK ON, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
System.>
FUSE
B220
B220
15A SBF-7
21 4 3
22
23
24
MAIN SBF
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E41 E40 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE RH
(WITH BUILT-IN E
AIR COMBINATION
VALVE LH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 10 14 18 22
20 21 22 23 24 25 26 27 3 4 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 11 12 15 16 19 20 23 24
28 29 30 31 32 33 34 35 5 6 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9
11 F37 B143 F11 E40 E41 B144

5
12 13
1 9 14 1 2 3 4 5 6 7 8 9
3 4 6 7 8 1 2 3 4 5 6 7 8 9 1 2 1 2 3 1 2 3 4
2 10 10 11 12 13 14 15 16 17 18 19 20 1 2
10 11 12 13 14 15 16 17 18 19 20 4 5 6 5 6 7 8 9
15 16
EN-08734

FUSE
B220
B220
15A SBF-7
21 4 3
22
MAIN SBF
23
24
E
F9
RELAY HOLDER
6
10A
5
15
60A
16
MAIN FUSE BOX
(M/B)
B143 F37 4
3 SECONDARY
AIR COMBINATION
B8 2 5 2
A: B134
B20 14 16
B27 12 18
B: B135 7
A19 10 20 SECONDARY
8
D: B137 10
A29 VALVE RELAY 2
9
ECM 4 14
14
B21 AIR PUMP
28
47
46
6
1
12 RELAY
E2 13
F11
3
2
1
6
4
1
2
E40 E41 2
SECONDARY
1
SECONDARY AIR PUMP
AIR COMBINATION
VALVE LH
(WITH BUILT-IN
E
AIR COMBINATION
VALVE RH
A: B134 B: B135 B220 B21
1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 9 13 17 21 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
3 4 10 14 18 22 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
11 12 15 16 19 20 23 24 23 24 25 26 27 28 29 30 31 32 33
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 5 6
7 8 25 29 33 37 34 35 36 37 38 39 40 41
D: B137 26 30 34 38 42 43 44 45 46 47
27 28 31 32 35 36 39 40 48 49 50 51 52 53 54
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
F9 F37 B143 F11 E41 E40 B144
1 2 3 4 5 6 7 8 9 1 2 3 4
11 1 2 3 4 5 6 7 8 9 1 2 1 2 3
5 10 11 12 13 14 15 16 17 18 19 20 1 2 5 6 7 8 9
12 13 10 11 12 13 14 15 16 17 18 19 20 4 5 6
1 9 14
3 4 6 7 8
2 10
15 16
EN-08735

Step Check Yes No

1 CHECK SECONDARY AIR PIPING PRES- Is the difference between «Sec. Go to step 2. Even if DTC is
SURE. Air Piping Pressure» and atmo- detected, the cir-
1) Turn the ignition switch to ON. spheric pressure 50 mmHg (6.7 cuit has returned to
2) Using the Subaru Select Monitor, read the kPa, 2.0 inHg, 0.97 psig) or a normal condition
value of «Sec. Air Piping Pressure», and com- more? at this time. Repro-
pare with the actual atmospheric pressure. duce the failure,
NOTE: and then perform
For detailed operation procedures, refer to the diagnosis
“READ CURRENT DATA FOR ENGINE”. <Ref. again.
to EN(H4DOTC)(diag)-39, Subaru Select Moni- NOTE:
tor.> In this case, tem-
porary poor con-
tact of connector,
temporary open or
ness may be the
cause.
2 CHECK SECONDARY AIR PUMP. Is the secondary air pump oper- Go to step 3. Replace the sec-
1) Start the engine and warm up engine until ating? ondary air combi-
coolant temperature is higher than 75°C nation valve RH
(167°F). (models without
2) Check whether the secondary air pump is SI-DRIVE) or LH
operating. (models with SI-
DRIVE). <Ref. to
EC(STI)-29, Sec-
ondary Air Combi-
nation Valve.>
<Ref. to EC(w/o
STI)-30, Second-
ary Air Combina-
tion Valve.>
SECONDARY AIR PUMP RELAY CONNEC- more? circuit to ground in
1) Turn the ignition switch to OFF. ECM and second-
2) Remove the secondary air pump relay from ary air pump relay
the relay box. connector.
ondary air pump relay connector and engine
ground terminals.
(F9) No. 13 — Engine ground:
4 CHECK SECONDARY AIR PUMP RELAY. Is the resistance 1 MΩ or Repair the short Replace the sec-
Measure the resistance between the secondary more? circuit to power in ondary air pump
air pump relay terminals. the harness relay. <Ref. to
Terminals between second- EN(H4DOTC)(diag)
No. 14 — No. 11: ary air pump relay -8, Electrical Com-
and secondary air ponent Location.>
pump connector.

FP:DTC P2610 ECM/PCM INTERNAL ENGINE OFF TIMER PERFORMANCE

• GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-286, DTC P2610 ECM/PCM INTERNAL ENGINE OFF
TIMER PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
Step Check Yes No
1 CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Replace the ECM.
“List of Diagnostic <Ref. to FU(STI)-
Trouble Code 59, Engine Control
(DTC)”. <Ref. to Module (ECM).>
EN(H4DOTC)(diag) <Ref. to FU(w/o
-87, List of Diagnos- STI)-57, Engine
tic Trouble Code Control Module
(DTC).> (ECM).>
NOTE:
The soak timer IC
is built into the
ECM.
FQ:DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION

NOTE:
For the diagnostic procedure, refer to LAN section. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
FR:DTC U0122 CAN (VDC) DATA NOT LOADED
NOTE:
FS:DTC U0140 CAN (BCU) DATA NOT LOADED
NOTE:
FT:DTC U0416 CAN (VDC) DATA ABNORMAL
NOTE:
FU:DTC U0422 CAN (BCU) DATA ABNORMAL
NOTE:
Diagnostic Procedure without Diagnostic Trouble Code (DTC)

21.Diagnostic Procedure without Diagnostic Trouble Code (DTC)

A: CHECK SI-DRIVE (SUBARU INTELLIGENT DRIVE) SYSTEM
DIAGNOSIS:
SI-DRIVE mode does not switch.
CAUTION:
Note that SI-DRIVE system operates the following controls when it switches the modes.
1. Switches to S (SPORT) when turning the engine ON after turning the engine OFF in S# (SPORT
sharp) mode.
2. Returns to the mode last selected when turning the engine ON after turning the engine OFF in S
(SPORT) or I (Intelligent) mode.
3. Switches to S (SPORT) when the malfunction indicator light illuminates while the engine is run-
ning. In this case, Cannot switch to S# (SPORT sharp) or I (Intelligent) mode.
4. Cannot switch to S# (SPORT sharp), when engine coolant temperature tells that overheating may
occur. Switches to S (SPORT) while driving in S# (SPORT sharp) mode.

1. SI-DRIVE MODE INDICATION DOES NOT CHANGE AND MODES DO NOT SWITCH AFTER
SWITCHING SI-DRIVE MODES
WIRING DIAGRAM:
Electrical System.>
COMBINATION METER
i10
35
33
21
22
i53
5
*
*
R98
i97
R33 *
5
E
I
S#

MULTI SELECT *
SWITCH
(SI-DRIVE)
i97 R33 i53 i10
1 2 3 4 1 2 3 4 5 6 7 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 5 6 7 8 9 10 8 9 10 11 12 13 14 15 16 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
EN-06527

Step Check Yes No

1 CHECK SI-DRIVE SELECTOR. Does the resistance change as Go to step 4. Go to step 2.
1) Turn the ignition switch to OFF. below?
2) Disconnect the connector from the combi- S#: 3.48 — 3.85 kΩ
nation meter. I: 0.95 — 1.05 kΩ
3) Measure the resistance between connec- S: less than 1 Ω
tors when the SI-DRIVE selector is operated.
(i10) No. 33 — (i10) No. 35:
2 CHECK HARNESS BETWEEN COMBINA- Is the resistance less than 1 Ω? Go to step 3. Repair the harness
TION METER AND MULTI-SELECT SWITCH and connector.
CONNECTOR. NOTE:
1) Disconnect the connector from multi-select In this case, repair
switch. the following item:
combination meter and multi-select switch con- harness between
nector. combination meter
Connector & terminal and multi-select
(i10) No. 33 — (R33) No. 8: switch connector
(i10) No. 35 — (R33) No. 5: • Poor contact of
coupling connector
3 CHECK HARNESS BETWEEN COMBINA- Is the resistance 1 MΩ or Repair the poor Repair the ground
TION METER AND MULTI-SELECT SWITCH more? contact of multi- short circuit in har-
CONNECTOR. select switch con- ness between
Measure the resistance between multi-select nector. Replace combination meter
switch connector and chassis ground. the multi-select and multi-select
Connector & terminal switch if defective. switch connector.
(R33) No. 8 — Chassis ground: <Ref. to FU(STI)-
(R33) No. 5 — Chassis ground: 58, SI-DRIVE
(SUBARU Intelli-
gent Drive) Selec-
tor.>
4 CHECK HARNESS BETWEEN COMBINA- Is the resistance less than 5 Ω? Go to step 5. Repair the harness
TION METER AND CHASSIS GROUND. and connector.
Measure the resistance of harness between NOTE:
combination meter and chassis ground. In this case, repair
Connector & terminal the following item:
(i10) No. 21 — Chassis ground: • Open circuit in
(i10) No. 22 — Chassis ground: harness between
combination meter
and chassis
ground
• Poor contact of
coupling connector
5 RECHECK FAULT. Is there any fault? Repair the poor The circuit has
1) Connect all connectors. contact of combi- returned to a nor-
2) Switch SI-DRIVE modes. nation meter con- mal condition at
nector. Replace this time. Repro-
the combination duce the failure,
meter if defective. and then perform
<Ref. to IDI-18, the diagnosis
Combination again.
Meter.> NOTE:
In this case, tem-
porary poor con-
tact of connector,
temporary open or
ness may be the
cause.

2. “S” BLINKS ON SI-DRIVE MODE DISPLAY IN THE COMBINATION METER APPROX. 5

SECONDS AFTER SWITCHING SI-DRIVE MODES
Step Check Yes No
1 CHECK DTC. Is DTC displayed? Check the appro- Go to step 2.
priate DTC using
the “List of Diag-
nostic Trouble
Code (DTC)” con-
cerning the
respective units.
2 CHECK COMBINATION METER AND Is there any abnormal indica- For the diagnostic Go to step 3.
CLOCK DISPLAY. tion other than “S” blinking? procedure, refer to
Check for abnormal indication other than “S” LAN section. <Ref.
blinking. to LAN(diag)-2,
Examples: Basic Diagnostic
• Malfunction indicator light illuminates. Procedure.>
• “Err” is displayed on fuel efficiency display
part.
• Engine coolant temperature gauge does not
move.
3 CHECK COMBINATION METER, ECM AND Are the part numbers of combi- Replace the com- Replace the com-
BODY INTEGRATED UNIT. nation meter, ECM and body bination meter. bination meter,
integrated unit correct? <Ref. to IDI-18, ECM or body inte-
Combination grated unit with
Meter.> parts of proper part
number. <Ref. to
IDI-18, Combina-
tion Meter.> <Ref.
to FU(STI)-59,
Engine Control
Module (ECM).> or
<Ref. to SL-48,
Body Integrated
Unit.>

3. “S#”, “I” OR “S” BLINKS ON SI-DRIVE MODE DISPLAY IN THE COMBINATION METER
AFTER SWITCHING SI-DRIVE MODES
NOTE:
In this case, there is a fault other than in SI-DRIVE system.
Step Check Yes No
1 CHECK MALFUNCTION INDICATOR LIGHT. Does the malfunction indicator Read the DTC Go to step 2.
1) Start the engine. light illuminate? using Subaru
2) Check if malfunction indicator light illumi- Select Monitor and
nates. check the indicated
DTC. <Ref. to
EN(H4DOTC)(diag)
tic Trouble Code
(DTC).>
2 CHECK ENGINE COOLANT TEMPERATURE Does it indicate overheating? Inspect for the Go to step 3.
GAUGE. cause of overheat-
1) Turn the ignition switch to ON. ing and repair.
2) Check the engine coolant temperature
gauge.
3 CHECK COMBINATION METER INDICA- Does “S#”, “I” or “S” of the SI- Replace the com- Perform test driv-
TION. DRIVE mode blink in combina- bination meter. ing to check the
1) Turn the ignition switch to ON. tion meter? <Ref. to IDI-18, malfunction indica-
2) Switch SI-DRIVE modes. Combination tor light and engine
3) Check the SI-DRIVE mode display in the Meter.> coolant tempera-
combination meter. ture gauge. Com-
plete the diagnosis
if they are normal.
General Diagnostic Table

22.General Diagnostic Table

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(STI)-105, Engine Trouble in Gen-
eral.> <Ref. to ME(w/o STI)-103, Engine Trouble in General.>
Symptoms Faulty parts
1) Electronic throttle control
2) Manifold absolute pressure sensor
3) Mass air flow and intake air temperature sensor
4) Ignition parts (*1)
1. Engine stalls during idling.
5) Engine coolant temperature sensor (*2)
6) Crankshaft position sensor (*3)
7) Camshaft position sensor (*3)
8) Fuel injection parts (*4)
2. Rough idling 6) Air intake system (*5)
10) Oxygen sensor
11) Fuel pump and fuel pump relay
2) Engine coolant temperature sensor
3. Engine does not return to idle. 3) Manifold absolute pressure sensor
5) Accelerator pedal position sensor
4. Poor acceleration
9) A/C switch and A/C relay
10) Engine torque control signal circuit
12) Accelerator pedal position sensor
5. Engine stalls, hesitates, or sputters at accelera-
tion.
6) Purge control solenoid valve


6. Surging
3) Engine coolant temperature sensor
7. Spark knock
4) Knock sensor
8. After burning in exhaust system 3) Engine coolant temperature sensor (*2)
*1: Check ignition coil and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect for air leak in air intake system.

GENERAL DESCRIPTION
GD(H4DOTC)
Page
1. List of Diagnostic Trouble Code (DTC) ......................................................2
2. Diagnostic Trouble Code (DTC) Detecting Criteria ..................................11
List of Diagnostic Trouble Code (DTC)

GENERAL DESCRIPTION
1. List of Diagnostic Trouble Code (DTC)

A: LIST
DTC Item Index
P0011 Intake Camshaft Position - Timing <Ref. to GD(H4DOTC)-11, DTC P0011 INTAKE CAMSHAFT POSITION -
Over-Advanced or System Perfor- TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1),
mance (Bank 1) Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0014 Exhaust AVCS System 1 (Range/ <Ref. to GD(H4DOTC)-13, DTC P0014 EXHAUST AVCS SYSTEM 1
Performance) (RANGE/PERFORMANCE), Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
P0016 Crankshaft Position - Camshaft <Ref. to GD(H4DOTC)-15, DTC P0016 CRANKSHAFT POSITION - CAM-
Position Correlation (Bank1) SHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code
P0017 Crank and Cam Timing B System <Ref. to GD(H4DOTC)-17, DTC P0017 CRANK AND CAM TIMING B SYS-
Failure (Bank 1) TEM FAILURE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
P0018 Crankshaft Position - Camshaft <Ref. to GD(H4DOTC)-18, DTC P0018 CRANKSHAFT POSITION - CAM-
Position Correlation (Bank2) SHAFT POSITION CORRELATION (BANK2), Diagnostic Trouble Code
P0019 Crank and Cam Timing B System <Ref. to GD(H4DOTC)-18, DTC P0019 CRANK AND CAM TIMING B SYS-
Failure (Bank 2) TEM FAILURE (BANK 2), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
P0021 Intake Camshaft Position - Timing <Ref. to GD(H4DOTC)-18, DTC P0021 INTAKE CAMSHAFT POSITION -
Over-Advanced or System Perfor- TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2),
mance (Bank 2) Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0024 Exhaust AVCS System 2 (Range/ <Ref. to GD(H4DOTC)-19, DTC P0024 EXHAUST AVCS SYSTEM 2
Performance) (RANGE/PERFORMANCE), Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
P0030 HO2S Heater Control Circuit (Bank <Ref. to GD(H4DOTC)-19, DTC P0030 HO2S HEATER CONTROL CIRCUIT
1 Sensor 1) (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0031 HO2S Heater Control Circuit Low <Ref. to GD(H4DOTC)-21, DTC P0031 HO2S HEATER CONTROL CIRCUIT
(Bank 1 Sensor 1) LOW (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
P0032 HO2S Heater Control Circuit High <Ref. to GD(H4DOTC)-23, DTC P0032 HO2S HEATER CONTROL CIRCUIT
(Bank 1 Sensor 1) HIGH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
P0037 HO2S Heater Control Circuit Low <Ref. to GD(H4DOTC)-25, DTC P0037 HO2S HEATER CONTROL CIRCUIT
(Bank 1 Sensor 2) LOW (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
P0038 HO2S Heater Control Circuit High <Ref. to GD(H4DOTC)-27, DTC P0038 HO2S HEATER CONTROL CIRCUIT
(Bank 1 Sensor 2) HIGH (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
P0068 MAP/MAF - Throttle Position Cor- <Ref. to GD(H4DOTC)-29, DTC P0068 MAP/MAF - THROTTLE POSITION
relation CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0101 Mass or Volume Air Flow Circuit <Ref. to GD(H4DOTC)-31, DTC P0101 MASS OR VOLUME AIR FLOW CIR-
Range/Performance CUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
Low Input CUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
High Input CUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0107 Manifold Absolute Pressure/Baro- <Ref. to GD(H4DOTC)-37, DTC P0107 MANIFOLD ABSOLUTE PRES-
metric Pressure Circuit Low Input SURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trou-
ble Code (DTC) Detecting Criteria.>
P0108 Manifold Absolute Pressure/Baro- <Ref. to GD(H4DOTC)-39, DTC P0108 MANIFOLD ABSOLUTE PRES-
metric Pressure Circuit High Input SURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trou-
GD(H4DOTC)-2

GENERAL DESCRIPTION
DTC Item Index

P0111 Intake Air Temperature Sensor <Ref. to GD(H4DOTC)-41, DTC P0111 INTAKE AIR TEMPERATURE SEN-
Range/Performance Problem SOR RANGE/PERFORMANCE PROBLEM, Diagnostic Trouble Code (DTC)
Detecting Criteria.>
P0112 Intake Air Temperature Sensor 1 <Ref. to GD(H4DOTC)-44, DTC P0112 INTAKE AIR TEMPERATURE SEN-
Circuit Low SOR 1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0113 Intake Air Temperature Sensor 1 <Ref. to GD(H4DOTC)-46, DTC P0113 INTAKE AIR TEMPERATURE SEN-
Circuit High SOR 1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0116 Engine Coolant Temperature Sen- <Ref. to GD(H4DOTC)-48, DTC P0116 ENGINE COOLANT TEMPERA-
sor 1 Circuit Range/Performance TURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble
Code (DTC) Detecting Criteria.>
P0117 Engine Coolant Temperature Cir- <Ref. to GD(H4DOTC)-50, DTC P0117 ENGINE COOLANT TEMPERA-
cuit Low TURE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0118 Engine Coolant Temperature Cir- <Ref. to GD(H4DOTC)-52, DTC P0118 ENGINE COOLANT TEMPERA-
cuit High TURE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0122 Throttle/Pedal Position Sensor/ <Ref. to GD(H4DOTC)-54, DTC P0122 THROTTLE/PEDAL POSITION
Switch “A” Circuit Low SENSOR/SWITCH “A” CIRCUIT LOW, Diagnostic Trouble Code (DTC)
Switch “A” Circuit High SENSOR/SWITCH “A” CIRCUIT HIGH, Diagnostic Trouble Code (DTC)
P0125 Insufficient Coolant Temperature <Ref. to GD(H4DOTC)-58, DTC P0125 INSUFFICIENT COOLANT TEM-
for Closed Loop Fuel Control PERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble
P0128 Coolant Thermostat (Engine Cool- <Ref. to GD(H4DOTC)-60, DTC P0128 COOLANT THERMOSTAT (ENGINE
ant Temperature Below Thermo- COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEM-
stat Regulating Temperature) PERATURE), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0131 O2 Sensor Circuit Low Voltage <Ref. to GD(H4DOTC)-64, DTC P0131 O2 SENSOR CIRCUIT LOW VOLT-
(Bank 1 Sensor 1) AGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
P0132 O2 Sensor Circuit High Voltage <Ref. to GD(H4DOTC)-66, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLT-
ria.>
P0134 O2 Sensor Circuit No Activity <Ref. to GD(H4DOTC)-68, DTC P0134 O2 SENSOR CIRCUIT NO ACTIV-
Detected (Bank 1 Sensor 1) ITY DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC)
P0137 O2 Sensor Circuit Low Voltage <Ref. to GD(H4DOTC)-70, DTC P0137 O2 SENSOR CIRCUIT LOW VOLT-
ria.>
P0138 O2 Sensor Circuit High Voltage <Ref. to GD(H4DOTC)-72, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLT-
ria.>
P013A O2 Sensor Slow Response - Rich <Ref. to GD(H4DOTC)-73, DTC P013A O2 SENSOR SLOW RESPONSE -
to Lean (Bank 1 Sensor 2) RICH TO LEAN (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC)
P013B O2 Sensor Slow Response - Lean <Ref. to GD(H4DOTC)-75, DTC P013B O2 SENSOR SLOW RESPONSE -
to Rich (Bank 1 Sensor 2) LEAN TO RICH (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC)
P013E O2 Sensor Delayed Response - <Ref. to GD(H4DOTC)-77, DTC P013E O2 SENSOR DELAYED
Rich to Lean (Bank 1 Sensor 2) RESPONSE - RICH TO LEAN (BANK 1 SENSOR 2), Diagnostic Trouble
P013F O2 Sensor Delayed Response - <Ref. to GD(H4DOTC)-79, DTC P013F O2 SENSOR DELAYED
Lean to Rich (Bank 1 Sensor 2) RESPONSE - LEAN TO RICH (BANK 1 SENSOR 2), Diagnostic Trouble
P0140 O2 Sensor Circuit No Activity <Ref. to GD(H4DOTC)-81, DTC P0140 O2 SENSOR CIRCUIT NO ACTIV-
Detected (Bank1 Sensor2) ITY DETECTED (BANK1 SENSOR2), Diagnostic Trouble Code (DTC)
GD(H4DOTC)-3

GENERAL DESCRIPTION
DTC Item Index

P0141 O2 Sensor Heater Circuit (Bank1 <Ref. to GD(H4DOTC)-83, DTC P0141 O2 SENSOR HEATER CIRCUIT
Sensor2) (BANK1 SENSOR2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P014C O2 Sensor Slow Response - Rich <Ref. to GD(H4DOTC)-85, DTC P014C O2 SENSOR SLOW RESPONSE -
to Lean (Bank 1 Sensor 1) RICH TO LEAN (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC)
P014D O2 Sensor Slow Response - Lean <Ref. to GD(H4DOTC)-87, DTC P014D O2 SENSOR SLOW RESPONSE -
to Rich (Bank 1 Sensor 1) LEAN TO RICH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC)
P015A O2 Sensor Delayed Response - <Ref. to GD(H4DOTC)-88, DTC P015A O2 SENSOR DELAYED
Rich to Lean (Bank 1 Sensor 1) RESPONSE - RICH TO LEAN (BANK 1 SENSOR 1), Diagnostic Trouble
P015B O2 Sensor Delayed Response - <Ref. to GD(H4DOTC)-94, DTC P015B O2 SENSOR DELAYED
Lean to Rich (Bank 1 Sensor 1) RESPONSE - LEAN TO RICH (BANK 1 SENSOR 1), Diagnostic Trouble
P0171 System Too Lean (Bank 1) <Ref. to GD(H4DOTC)-95, DTC P0171 SYSTEM TOO LEAN (BANK 1),
Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0172 System Too Rich (Bank 1) <Ref. to GD(H4DOTC)-97, DTC P0172 SYSTEM TOO RICH (BANK 1),
P0201 Injector #1 <Ref. to GD(H4DOTC)-99, DTC P0201 INJECTOR #1, Diagnostic Trouble
Switch “B” Circuit Low SENSOR/SWITCH “B” CIRCUIT LOW, Diagnostic Trouble Code (DTC)
Switch “B” Circuit High SENSOR/SWITCH “B” CIRCUIT HIGH, Diagnostic Trouble Code (DTC)
P0230 Fuel Pump Primary Circuit <Ref. to GD(H4DOTC)-105, DTC P0230 FUEL PUMP PRIMARY CIRCUIT,
P0244 Turbo/Super Charger Wastegate <Ref. to GD(H4DOTC)-107, DTC P0244 TURBO/SUPER CHARGER
Solenoid “A” Range/Performance 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.>
P0300 Random/Multiple Cylinder Misfire <Ref. to GD(H4DOTC)-112, DTC P0300 RANDOM/MULTIPLE CYLINDER
Detected MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0301 Cylinder 1 Misfire Detected <Ref. to GD(H4DOTC)-113, DTC P0301 CYLINDER 1 MISFIRE
DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0327 Knock Sensor 1 Circuit Low (Bank <Ref. to GD(H4DOTC)-123, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW
1 or Single Sensor) (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
GD(H4DOTC)-4

GENERAL DESCRIPTION
DTC Item Index

P0328 Knock Sensor 1 Circuit High (Bank <Ref. to GD(H4DOTC)-125, DTC P0328 KNOCK SENSOR 1 CIRCUIT
1 or Single Sensor) HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC)
P0335 Crankshaft Position Sensor “A” Cir- <Ref. to GD(H4DOTC)-127, DTC P0335 CRANKSHAFT POSITION SEN-
cuit SOR “A” CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0336 Crankshaft Position Sensor “A” Cir- <Ref. to GD(H4DOTC)-129, DTC P0336 CRANKSHAFT POSITION SEN-
cuit Range/Performance SOR “A” CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code
P0340 Camshaft Position Sensor “A” Cir- <Ref. to GD(H4DOTC)-131, DTC P0340 CAMSHAFT POSITION SENSOR
cuit (Bank 1 or Single Sensor) “A” CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code
P0341 Camshaft Position Sensor "A" Cir- <Ref. to GD(H4DOTC)-133, DTC P0341 CAMSHAFT POSITION SENSOR
cuit Range/Performance (Bank 1 or "A" CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR),
Single Sensor) Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0345 Camshaft Position Sensor “A” Cir- <Ref. to GD(H4DOTC)-134, DTC P0345 CAMSHAFT POSITION SENSOR
cuit (Bank 2) “A” CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0346 Camshaft Position Sensor "A" Cir- <Ref. to GD(H4DOTC)-134, DTC P0346 CAMSHAFT POSITION SENSOR
cuit Range/Performance (Bank 2) "A" CIRCUIT RANGE/PERFORMANCE (BANK 2), Diagnostic Trouble Code
P0351 Ignition Coil A Primary/Secondary <Ref. to GD(H4DOTC)-135, DTC P0351 IGNITION COIL A PRIMARY/SEC-
Circuit ONDARY CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0352 Ignition Coil B Primary/Secondary <Ref. to GD(H4DOTC)-135, DTC P0352 IGNITION COIL B PRIMARY/SEC-
P0353 Ignition Coil C Primary/Secondary <Ref. to GD(H4DOTC)-135, DTC P0353 IGNITION COIL C PRIMARY/SEC-
P0354 Ignition Coil D Primary/Secondary <Ref. to GD(H4DOTC)-135, DTC P0354 IGNITION COIL D PRIMARY/SEC-
P0365 Camshaft Position Sensor “B” Cir- <Ref. to GD(H4DOTC)-136, DTC P0365 CAMSHAFT POSITION SENSOR
cuit (Bank 1) “B” CIRCUIT (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0366 Camshaft Position Sensor B Circuit <Ref. to GD(H4DOTC)-137, DTC P0366 CAMSHAFT POSITION SENSOR
Range/Performance (Bank 1) B CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code
P0390 Camshaft Position Sensor “B” Cir- <Ref. to GD(H4DOTC)-137, DTC P0390 CAMSHAFT POSITION SENSOR
cuit (Bank 2) “B” CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0391 Camshaft Position Sensor B Circuit <Ref. to GD(H4DOTC)-137, DTC P0391 CAMSHAFT POSITION SENSOR
Range/Performance (Bank 2) B CIRCUIT RANGE/PERFORMANCE (BANK 2), Diagnostic Trouble Code
P0410 Secondary Air Injection System <Ref. to GD(H4DOTC)-138, DTC P0410 SECONDARY AIR INJECTION
SYSTEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
Incorrect Flow Detected 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
GD(H4DOTC)-5

GENERAL DESCRIPTION
DTC Item Index

P0420 Catalyst System Efficiency Below <Ref. to GD(H4DOTC)-148, DTC P0420 CATALYST SYSTEM EFFICIENCY
Threshold (Bank 1) BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0441 Evaporative Emission Cont. Sys. <Ref. to GD(H4DOTC)-151, DTC P0441 EVAPORATIVE EMISSION CONT.
Incorrect Purge Flow SYS. INCORRECT PURGE FLOW, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
P0451 Evaporative Emission System <Ref. to GD(H4DOTC)-154, DTC P0451 EVAPORATIVE EMISSION SYS-
Pressure Sensor/Switch Range/ TEM PRESSURE SENSOR/SWITCH RANGE/PERFORMANCE, Diagnostic
Performance Trouble Code (DTC) Detecting Criteria.>
Pressure Sensor/Switch Low TEM PRESSURE SENSOR/SWITCH LOW, Diagnostic Trouble Code (DTC)
Pressure Sensor/Switch High TEM PRESSURE SENSOR/SWITCH HIGH, Diagnostic Trouble Code (DTC)
Leak Detected (Large Leak) TEM LEAK DETECTED (LARGE LEAK), Diagnostic Trouble Code (DTC)
P0456 Evaporative Emission Control Sys- <Ref. to GD(H4DOTC)-165, DTC P0456 EVAPORATIVE EMISSION CON-
tem Leak Detected (Very Small TROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trou-
Leak) ble Code (DTC) Detecting Criteria.>
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 <Ref. to GD(H4DOTC)-170, DTC P0461 FUEL LEVEL SENSOR “A” CIR-
Range/Performance CUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0462 Fuel Level Sensor “A” Circuit Low <Ref. to GD(H4DOTC)-172, DTC P0462 FUEL LEVEL SENSOR “A” CIR-
P0463 Fuel Level Sensor “A” Circuit High <Ref. to GD(H4DOTC)-174, DTC P0463 FUEL LEVEL SENSOR “A” CIR-
P04AC Evap System Purge Control Valve <Ref. to GD(H4DOTC)-176, DTC P04AC EVAP SYSTEM PURGE CON-
"B" Circuit Low TROL VALVE "B" CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P04AD Evap System Purge Control Valve <Ref. to GD(H4DOTC)-177, DTC P04AD EVAP SYSTEM PURGE CON-
"B" Circuit High TROL VALVE "B" CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P04DB Crankcase Ventilation System Dis- <Ref. to GD(H4DOTC)-178, DTC P04DB CRANKCASE VENTILATION SYS-
connected TEM DISCONNECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0500 Vehicle Speed Sensor “A” <Ref. to GD(H4DOTC)-180, DTC P0500 VEHICLE SPEED SENSOR “A”,
P0506 Idle Air Control System RPM <Ref. to GD(H4DOTC)-181, DTC P0506 IDLE AIR CONTROL SYSTEM
Lower Than Expected RPM LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0507 Idle Air Control System RPM <Ref. to GD(H4DOTC)-182, DTC P0507 IDLE AIR CONTROL SYSTEM
Higher Than Expected RPM HIGHER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P050A Cold Start Idle Air Control System <Ref. to GD(H4DOTC)-183, DTC P050A COLD START IDLE AIR CONTROL
Performance SYSTEM PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
P050B Cold Start Ignition Timing Perfor- <Ref. to GD(H4DOTC)-186, DTC P050B COLD START IGNITION TIMING
mance PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-6

GENERAL DESCRIPTION
DTC Item Index

P0513 Incorrect Immobilizer Key <Ref. to GD(H4DOTC)-187, DTC P0513 INCORRECT IMMOBILIZER KEY,
P0560 System Voltage <Ref. to GD(H4DOTC)-188, DTC P0560 SYSTEM VOLTAGE, Diagnostic
Trouble Code (DTC) Detecting Criteria.>
P0604 Internal Control Module Random <Ref. to GD(H4DOTC)-189, DTC P0604 INTERNAL CONTROL MODULE
Access Memory (RAM) Error RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code
P0605 Internal Control Module Read Only <Ref. to GD(H4DOTC)-190, DTC P0605 INTERNAL CONTROL MODULE
Memory (ROM) Error READ ONLY MEMORY (ROM) ERROR, Diagnostic Trouble Code (DTC)
P0606 Control Module Processor <Ref. to GD(H4DOTC)-191, DTC P0606 CONTROL MODULE PROCES-
SOR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P060A Internal Control Module Monitor- <Ref. to GD(H4DOTC)-193, DTC P060A INTERNAL CONTROL MODULE
ing Processor Performance MONITORING PROCESSOR PERFORMANCE, Diagnostic Trouble Code
P060B Internal Control Module A/D Pro- <Ref. to GD(H4DOTC)-195, DTC P060B INTERNAL CONTROL MODULE
cessing Performance A/D PROCESSING PERFORMANCE, Diagnostic Trouble Code (DTC)
P0616 Starter Relay Circuit Low <Ref. to GD(H4DOTC)-197, DTC P0616 STARTER RELAY CIRCUIT LOW,
P0617 Starter Relay Circuit High <Ref. to GD(H4DOTC)-198, DTC P0617 STARTER RELAY CIRCUIT HIGH,
P062F Internal Control Module EEPROM <Ref. to GD(H4DOTC)-199, DTC P062F INTERNAL CONTROL MODULE
Error EEPROM ERROR , Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0851 Neutral Switch Input Circuit Low <Ref. to GD(H4DOTC)-200, DTC P0851 NEUTRAL SWITCH INPUT CIR-
(MT Model) CUIT LOW (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
P0852 Neutral Switch Input Circuit High <Ref. to GD(H4DOTC)-201, DTC P0852 NEUTRAL SWITCH INPUT CIR-
(MT Model) CUIT HIGH (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
P1160 Return Spring Failure <Ref. to GD(H4DOTC)-202, DTC P1160 RETURN SPRING FAILURE, Diag-
nostic Trouble Code (DTC) Detecting Criteria.>
P1400 Fuel Tank Pressure Control Sole- <Ref. to GD(H4DOTC)-204, DTC P1400 FUEL TANK PRESSURE CON-
noid Valve Circuit Low TROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC)
Switching Valve Stuck Open SYSTEM SWITCHING VALVE STUCK OPEN, Diagnostic Trouble Code
P1420 Fuel Tank Pressure Control Sol. <Ref. to GD(H4DOTC)-208, DTC P1420 FUEL TANK PRESSURE CON-
Valve Circuit High TROL SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
Air Filter Clog SYS. AIR FILTER CLOG, Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
SYS., Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1570 Antenna <Ref. to GD(H4DOTC)-213, DTC P1570 ANTENNA, Diagnostic Trouble
P1571 Reference Code Incompatibility <Ref. to GD(H4DOTC)-213, DTC P1571 REFERENCE CODE INCOMPATI-
BILITY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1572 IMM Circuit Failure (Except <Ref. to GD(H4DOTC)-213, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
Antenna Circuit) ANTENNA CIRCUIT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1574 Key Communication Failure <Ref. to GD(H4DOTC)-213, DTC P1574 KEY COMMUNICATION FAILURE,
P1576 EGI Control Module EEPROM <Ref. to GD(H4DOTC)-213, DTC P1576 EGI CONTROL MODULE
EEPROM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-7

GENERAL DESCRIPTION
DTC Item Index

P1577 IMM Control Module EEPROM <Ref. to GD(H4DOTC)-213, DTC P1577 IMM CONTROL MODULE
EEPROM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1578 Meter Failure <Ref. to GD(H4DOTC)-213, DTC P1578 METER FAILURE, Diagnostic Trou-
P2004 Intake Manifold Runner Control <Ref. to GD(H4DOTC)-214, DTC P2004 INTAKE MANIFOLD RUNNER
Stuck Open (Bank 1) CONTROL STUCK OPEN (BANK 1), Diagnostic Trouble Code (DTC)
Stuck Open (Bank 2) CONTROL STUCK OPEN (BANK 2), Diagnostic Trouble Code (DTC)
Stuck Closed (Bank 1) CONTROL STUCK CLOSED (BANK 1), Diagnostic Trouble Code (DTC)
Stuck Closed (Bank 2) 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)
P2016 Tumble Generated Valve Position <Ref. to GD(H4DOTC)-224, DTC P2016 TUMBLE GENERATED VALVE
Sensor 1 Circuit Low POSITION SENSOR 1 CIRCUIT LOW, Diagnostic Trouble Code (DTC)
P2017 Intake Manifold Runner Position <Ref. to GD(H4DOTC)-226, DTC P2017 TUMBLE GENERATED VALVE
Sensor / Switch Circuit High (Bank POSITION SENSOR 1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC)
1) Detecting Criteria.>
P2021 Tumble Generated Valve Position <Ref. to GD(H4DOTC)-228, DTC P2021 TUMBLE GENERATED VALVE
Sensor 2 Circuit Low POSITION SENSOR 2 CIRCUIT LOW, Diagnostic Trouble Code (DTC)
P2022 Intake Manifold Runner Position <Ref. to GD(H4DOTC)-230, DTC P2022 TUMBLE GENERATED VALVE
Sensor / Switch Circuit High (Bank POSITION SENSOR 2 CIRCUIT HIGH, Diagnostic Trouble Code (DTC)
2) Detecting Criteria.>
P2088 Intake Camshaft Position Actuator <Ref. to GD(H4DOTC)-232, DTC P2088 INTAKE CAMSHAFT POSITION
Control Circuit Low (Bank 1) ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code
Control Circuit High (Bank 1) ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code
P2090 Exhaust Camshaft Position Actua- <Ref. to GD(H4DOTC)-234, DTC P2090 EXHAUST CAMSHAFT POSITION
tor Control Circuit Low (Bank 1) ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code
tor Control Circuit High (Bank 1) ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code
Control Circuit Low (Bank 2) ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code
GD(H4DOTC)-8

GENERAL DESCRIPTION
DTC Item Index

Control Circuit High (Bank 2) ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code
tor Control Circuit Low (Bank 2) ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code
tor Control Circuit High (Bank 2) ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code
P2096 Post Catalyst Fuel Trim System <Ref. to GD(H4DOTC)-237, DTC P2096 POST CATALYST FUEL TRIM
Too Lean (Bank 1) SYSTEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P2097 Post Catalyst Fuel Trim System <Ref. to GD(H4DOTC)-239, DTC P2097 POST CATALYST FUEL TRIM
Too Rich (Bank 1) SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P2101 Throttle Actuator Control Motor Cir- <Ref. to GD(H4DOTC)-241, DTC P2101 THROTTLE ACTUATOR CON-
cuit Range/Performance 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.>
P2109 Throttle/Pedal Position Sensor “A” <Ref. to GD(H4DOTC)-247, DTC P2109 THROTTLE/PEDAL POSITION
Minimum Stop Performance SENSOR “A” MINIMUM STOP PERFORMANCE, Diagnostic Trouble Code
P2119 Throttle Actuator Control Throttle <Ref. to GD(H4DOTC)-249, DTC P2119 THROTTLE ACTUATOR CON-
Body Range/Performance TROL THROTTLE BODY RANGE/PERFORMANCE, Diagnostic Trouble
Switch “D” Circuit Low Input SENSOR/SWITCH “D” CIRCUIT LOW INPUT, Diagnostic Trouble Code
Switch “D” Circuit High Input SENSOR/SWITCH “D” CIRCUIT HIGH INPUT, Diagnostic Trouble Code
Switch “E” Circuit Low Input SENSOR/SWITCH “E” CIRCUIT LOW INPUT, Diagnostic Trouble Code
Switch “E” Circuit High Input SENSOR/SWITCH “E” CIRCUIT HIGH INPUT, Diagnostic Trouble Code
Switch “A”/“B” Voltage Correlation SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION, Diagnostic Trouble
Switch “D”/“E” Voltage Correlation SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION, Diagnostic Trouble
P2195 O2 Sensor Signal Biased/Stuck <Ref. to GD(H4DOTC)-264, DTC P2195 O2 SENSOR SIGNAL BIASED/
Lean (Bank 1 Sensor 1) STUCK LEAN (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC)
P2196 O2 Sensor Signal Biased/Stuck <Ref. to GD(H4DOTC)-266, DTC P2196 O2 SENSOR SIGNAL BIASED/
Rich (Bank 1 Sensor 1) STUCK RICH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
P219A Bank 1 Air-Fuel Ratio Imbalance <Ref. to GD(H4DOTC)-268, DTC P219A BANK 1 AIR-FUEL RATIO IMBAL-
ANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-9

GENERAL DESCRIPTION
DTC Item Index

P2257 Air System Control "A" Circuit Low <Ref. to GD(H4DOTC)-271, DTC P2257 AIR SYSTEM CONTROL "A" CIR-
P2258 Air System Control "A" Circuit High <Ref. to GD(H4DOTC)-272, DTC P2258 AIR SYSTEM CONTROL "A" CIR-
Leak Detection Pump Control Cir- TEM LEAK DETECTION PUMP CONTROL CIRCUIT LOW, Diagnostic Trou-
cuit Low ble Code (DTC) Detecting Criteria.>
Leak Detection Pump Control Cir- TEM LEAK DETECTION PUMP CONTROL CIRCUIT HIGH, Diagnostic
cuit High Trouble Code (DTC) Detecting Criteria.>
Leak Detection Pump Sense Cir- TEM LEAK DETECTION PUMP SENSE CIRCUIT RANGE/PERFOR-
cuit Range/Performance MANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
Switching Valve Control Circuit TEM SWITCHING VALVE CONTROL CIRCUIT LOW, Diagnostic Trouble
Low Code (DTC) Detecting Criteria.>
Switching Valve Control Circuit TEM SWITCHING VALVE CONTROL CIRCUIT HIGH, Diagnostic Trouble
High Code (DTC) Detecting Criteria.>
P2431 Secondary Air Injection System Air <Ref. to GD(H4DOTC)-281, DTC P2431 SECONDARY AIR INJECTION
Flow /Pressure Sensor Circuit SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/PERFOR-
Range/Performance MANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
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
Switching Valve Stuck Open SYSTEM SWITCHING VALVE STUCK OPEN (BANK1), Diagnostic Trouble
(Bank1) Code (DTC) Detecting Criteria.>
Switching Valve Stuck Closed SYSTEM SWITCHING VALVE STUCK CLOSED (BANK1), Diagnostic Trou-
(Bank1) ble Code (DTC) Detecting Criteria.>
Switching Valve Stuck Open SYSTEM SWITCHING VALVE STUCK OPEN (BANK2), Diagnostic Trouble
(Bank2) Code (DTC) Detecting Criteria.>
Switching Valve Stuck Closed SYSTEM SWITCHING VALVE STUCK CLOSED (BANK2), Diagnostic Trou-
(Bank2) ble Code (DTC) Detecting Criteria.>
Pump Stuck On SYSTEM PUMP STUCK ON, Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
P2610 ECM/PCM Internal Engine Off <Ref. to GD(H4DOTC)-286, DTC P2610 ECM/PCM INTERNAL ENGINE
Timer Performance OFF TIMER PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
U0073 CAN Failure, Bus ‘Off’ Detection <Ref. to GD(H4DOTC)-294, DTC U0073 CAN FAILURE, BUS ‘OFF’ DETEC-
TION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
U0122 CAN (VDC) Data Not Loaded <Ref. to GD(H4DOTC)-295, DTC U0122 CAN (VDC) DATA NOT LOADED,
U0140 CAN (BCU) Data Not Loaded <Ref. to GD(H4DOTC)-295, DTC U0140 CAN (BCU) DATA NOT LOADED,
U0416 CAN (VDC) Data Abnormal <Ref. to GD(H4DOTC)-296, DTC U0416 CAN (VDC) DATA ABNORMAL,
U0422 CAN (BCU) Data Abnormal <Ref. to GD(H4DOTC)-296, DTC U0422 CAN (BCU) DATA ABNORMAL,
GD(H4DOTC)-10
Diagnostic Trouble Code (DTC) Detecting Criteria

GENERAL DESCRIPTION
2. Diagnostic Trouble Code (DTC) Detecting Criteria

A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR
SYSTEM PERFORMANCE (BANK 1)
1. OUTLINE OF DIAGNOSIS
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.
2. COMPONENT DESCRIPTION
(3)
(1)
(5)
(2)
(4)
EN-01852
(1) AVCS timing controller (3) Engine control module (ECM) (5) Oil pressure
(2) Vane (4) Oil flow control solenoid valve
3. ENABLE CONDITIONS
Secondary Parameters Enable Conditions
Time of establishing all secondary ≥ 3000 ms
parameter conditions
Battery voltage ≥ 10.9 V
Engine speed ≥ 1300 rpm (models without SI-DRIVE)
≥ 1500 rpm (models with SI-DRIVE)
Engine coolant temperature ≥ 60 °C (140 °F)
AVCS control Operation
Target timing advance change amount < 1.07 °CA
(per 64 ms)
4. GENERAL DRIVING CYCLE

Perform the diagnosis continuously after warming up when the engine speed increases and AVCS operates.
GD(H4DOTC)-11

GENERAL DESCRIPTION
5. DIAGNOSTIC METHOD
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.
• Abnormality Judgment
Judge as NG when the following conditions are established within the predetermined time.
Judgment Value
Malfunction Criteria Threshold Value
Σ(Target position – Actual position) > 5300 °CA (Bank 1)
> 5300 °CA (Bank 2)
or
Σ(Target position – Actual position) < –5300 °CA (Bank 1)
< –5300 °CA (Bank 2)
Time Needed for Diagnosis: 20000 ms

> 8000 °CA (Bank 2)
or
< –8000 °CA (Bank 2)

Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cy-
cles.
• Normality Judgment
Judge as OK and clear the NG if the following conditions are established within the predetermined time.
Judgment Value
Σ(Target position – Actual position) ≤ 5300 °CA (Bank 1)
≤ 5300 °CA (Bank 2)
and
≥ –5300 °CA (Bank 1)
≥ –5300 °CA (Bank 2)

≤ 8000 °CA (Bank 2)
and
≥ –8000 °CA (Bank 1)
≥ –8000 °CA (Bank 2)
GD(H4DOTC)-12

GENERAL DESCRIPTION
B: DTC P0014 EXHAUST AVCS SYSTEM 1 (RANGE/PERFORMANCE)

Detect the exhaust AVCS system malfunction.
Judge NG when the amount of exhaust AVCS actual timing advance does not approach the amount of ex-
haust AVCS target timing advance.
(3)
(1)
(5)
(2)
(4)
EN-01852
(1) Exhaust AVCS timing controller (3) Engine control module (ECM) (5) Oil pressure
Time of establishing all secondary ≥ 3000 ms
parameter conditions
Engine speed ≥ 1500 rpm
Exhaust AVCS control Operation
Target timing advance change amount < 1.07 °CA
(per 64 ms)

Perform the diagnosis continuously after warming up when the engine speed increases and exhaust AVCS
operates.
GD(H4DOTC)-13

GENERAL DESCRIPTION
1) When the conditions during which the differences of exhaust AVCS target timing advance amount and ex-
haust AVCS actual 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 exhaust 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.
Judgment Value
> 8000 °CA (Bank 2)
or
< –8000 °CA (Bank 2)
Time Needed for Diagnosis:

30000 ms
cles.
Judge as OK and clear the NG if the following conditions are established within the predetermined time.
Judgment Value
≤ 8000 °CA (Bank 2)
and
≥ –8000 °CA (Bank 1)
≥ –8000 °CA (Bank 2)
GD(H4DOTC)-14

GENERAL DESCRIPTION
C: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELA-

TION (BANK1)
Detect the AVCS system malfunction.
Judge as NG when standard timing advance amount is far from learning angle.
(3)
(1)
(5)
(2)
(4)
EN-01852
(1) AVCS timing controller (3) Engine control module (ECM) (5) Oil pressure
Engine speed (models without SI-DRIVE) ≥ 600 rpm
and
< 1000 rpm
Engine speed (models with SI-DRIVE) ≥ 600 rpm
and
< 975 rpm
AVCS control Not in operation
Target timing advance 0°CA

Perform the diagnosis continuously after starting engine and while AVCS is not operating.
GD(H4DOTC)-15

GENERAL DESCRIPTION
Judge as NG when the absolute value of the difference between cam signal input position and learning value
is out of specification.
If the duration of time while the following conditions are met is longer than the time indicated, judge as NG.
Judgment Value
|Crankshaft position when camshaft position > 8.5 °CA
sensor signal is input – Learning value|

cles.
NOTE:
Initial standard learning value is the value of crank angle initially input at the production plant. And then it will
be updated every time normal judgment has been completed. Learning value will not be updated if NG judg-
ment occurs because timing belt or chain derails suddenly in process or because wrong assembly occurs
during servicing.
Judge as OK and clear the NG if the continuous time while the following conditions are established is more
than the predetermined time.
Judgment Value
|Crankshaft position when camshaft position ≤ 8.5 °CA
Time Needed for Diagnosis: Less than 1 second
GD(H4DOTC)-16

GENERAL DESCRIPTION
D: DTC P0017 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 1)

Detect the exhaust AVCS system malfunction.
Judge as NG when standard timing advance amount is far from learning angle.
(3)
(1)
(5)
(2)
(4)
EN-01852
(1) Exhaust AVCS timing controller (3) Engine control module (ECM) (5) Oil pressure
and
< 975 rpm
Exhaust AVCS control Not in operation
Target timing advance 0°CA

Perform the diagnosis continuously while the exhaust AVCS is not operating after warming up.
GD(H4DOTC)-17

GENERAL DESCRIPTION
Judge as NG when the absolute value of the difference between cam signal input position and learning value
is out of specification.
Judgment Value
|Crankshaft position when camshaft position > 8.5 °CA

cles.
NOTE:
Initial standard learning value is the value of crank angle initially input at the production plant. And then it will
be updated every time normal judgment has been completed. Learning value will not be updated if NG judg-
ment occurs because timing belt or chain derails suddenly in process or because wrong assembly occurs
during servicing.
Judgment Value
|Crankshaft position when camshaft position ≤ 8.5 °CA

E: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELA-
TION (BANK2)
NOTE:
For the detection standard, refer to DTC P0016. <Ref. to GD(H4DOTC)-15, DTC P0016 CRANKSHAFT PO-
SITION - CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
F: DTC P0019 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 2)
NOTE:
For the detection standard, refer to DTC P0017. <Ref. to GD(H4DOTC)-17, DTC P0017 CRANK AND CAM
TIMING B SYSTEM FAILURE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
G: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR
SYSTEM PERFORMANCE (BANK 2)
NOTE:
For the detection standard, refer to DTC P0011. <Ref. to GD(H4DOTC)-11, DTC P0011 INTAKE CAM-
SHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic
GD(H4DOTC)-18

GENERAL DESCRIPTION
H: DTC P0024 EXHAUST AVCS SYSTEM 2 (RANGE/PERFORMANCE)

NOTE:
For the detection standard, refer to DTC P0014. <Ref. to GD(H4DOTC)-13, DTC P0014 EXHAUST AVCS
SYSTEM 1 (RANGE/PERFORMANCE), Diagnostic Trouble Code (DTC) Detecting Criteria.>
I: 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.
(1) (2) (3)

(4)
EN-08982
(1) Element cover (outer) (3) Sensor element (4) Sensor housing
(2) Element cover (inner)
Condition established time ≥ 42000 ms
Heater current Permitted
A/F sensor heater final control Main energization status
After fuel cut ≥ 20000 ms

Perform the diagnosis continuously after 42000 ms or more have passed since the engine started.
GD(H4DOTC)-19

GENERAL DESCRIPTION
Judgment Value
Front oxygen (A/F) sensor impedance > 50 Ω

cles.
Judgment Value
Front oxygen (A/F) sensor impedance ≤ 50 Ω
GD(H4DOTC)-20

GENERAL DESCRIPTION
J: 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.
(A)
OFF
(B)
ON (D)
0V
(C)
EN-01792
(A) Battery voltage (B) Front oxygen (A/F) sensor heater (C) 128 ms
output voltage
(D) Low error

Always perform the diagnosis continuously.
Judgment Value
Output voltage level Low
Front oxygen (A/F) sensor heater control duty < 87.5 %
Time Needed for Diagnosis: 4 ms × 250 time(s)

Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H4DOTC)-21

GENERAL DESCRIPTION
Judgment Value
Output voltage level High
GD(H4DOTC)-22

GENERAL DESCRIPTION
K: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (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 High.
(A)
(D) OFF
(B)
ON
0V
(C)
EN-01793
(A) Battery voltage (B) Front oxygen (A/F) sensor heater (C) 128 ms
output voltage
(D) High error

Judgment Value
Front oxygen (A/F) sensor heater control duty ≥ 12.5 %

GD(H4DOTC)-23

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-24

GENERAL DESCRIPTION
L: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

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.
Judge as NG when the terminal voltage remains Low.
(A)
OFF
(B)
ON (D)
0V
(C)
EN-01792
(A) Battery voltage (B) Output voltage of the rear oxygen (C) 256 ms (cycles)
sensor heater
(D) Low error
Elapsed time after engine starting ≥ 1 second
Engine speed < 8000 rpm

After starting the engine, perform the diagnosis continuously when engine is low speed.
Judgment Value
Rear oxygen sensor heater control duty < 75 %

cles.
GD(H4DOTC)-25

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-26

GENERAL DESCRIPTION
M: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

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.
Judge as NG when the terminal voltage remains High.
(A)
(D) OFF
(B)
ON
0V
(C)
EN-01793
(A) Battery voltage (B) Output voltage of the rear oxygen (C) 256 ms (cycles)
sensor heater
(D) High error
Elapsed time after engine starting ≥ 1 second

After starting the engine, perform the diagnosis continuously when engine is low speed.
Judgment Value
Rear oxygen sensor heater control duty ≥ 25 %

cles.
GD(H4DOTC)-27

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-28

GENERAL DESCRIPTION
N: 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.
(1) (2)
(A)
(B)
(3)
EN-01765
(A) Output voltage (B) Absolute pressure
(1) Connector (2) Terminals (3) O-ring

Perform the diagnosis continuously after idling.
GD(H4DOTC)-29

GENERAL DESCRIPTION
Judge as NG when Low side or High side becomes NG.
Judgment Value
Low
Throttle position ≥ 10 °
Output voltage < 1 V (Models without SI-DRIVE)
< 0.764 V (Models with SI-DRIVE)
Engine load > 1.356 g/rev (0.05 oz/rev)
High
Engine speed 600 rpm — 900 rpm
Throttle position < 2.75 °
Output voltage ≥ 2.36 V (Models without SI-DRIVE)
≥ 2.126 V (Models with SI-DRIVE)
Engine load < 0.4 g/rev (0.01 oz/rev)

Low side: 5000 ms
High side: 5000 ms
cles.
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.
Judgment Value
Low
Throttle position ≥ 10 °
Output voltage ≥ 1 V (Models without SI-DRIVE)
≥ 0.764 V (Models with SI-DRIVE)
Engine load > 1.356 g/rev (0.05 oz/rev)
High
Throttle position < 2.75 °
Output voltage < 2.36 V (Models without SI-DRIVE)
< 2.126 V (Models with SI-DRIVE)
Engine load < 0.4 g/rev (0.01 oz/rev)

Low side: Less than 1 second
High side: Less than 1 second
GD(H4DOTC)-30

GENERAL DESCRIPTION
O: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFOR-

MANCE
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.
(1)
(3)
(2)
(A)
(4)
EN-01766
(A) Air
(1) Air flow sensor (3) Voltage (V) (4) Amount of intake air (kg (lb)/s)
(2) Intake air temperature sensor

Perform the diagnosis continuously after idling.
GD(H4DOTC)-31

GENERAL DESCRIPTION
Judge as NG when Low side or High side becomes NG.
Judgment Value
Low
Output voltage < 1.5 V
Throttle opening angle ≥ 15 °
Intake manifold pressure ≥ 53.3 kPa (400 mmHg, 15.7 inHg)
High (1)
Output voltage ≥ 1.95 V
Throttle opening angle < 4.1 °
Intake manifold pressure < 52.7 kPa (395 mmHg, 15.6 inHg)
High (2)
Fuel system diagnosis Rich side malfunction

Low: 5000 ms
High: 5000 ms
cles.
Judge as OK and clear the NG when both Low side and High side become OK.
Judgment Value
Low
Throttle opening angle ≥ 15 °
Intake manifold pressure ≥ 53.3 kPa (400 mmHg, 15.7 inHg)
High
Fuel system diagnosis Rich side normal

Low: Less than 1 second
High: Less than 1 second
GD(H4DOTC)-32

GENERAL DESCRIPTION
P: 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.
(1)
(3)
(2)
(A)
(4)
EN-01766
(A) Air
None

Judgment Value
Output voltage ≤ 0.22 V

GD(H4DOTC)-33

GENERAL DESCRIPTION
Judgment Value
Output voltage > 0.22 V
GD(H4DOTC)-34

GENERAL DESCRIPTION
Q: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

Detect open or short circuits of the air flow sensor.
(1)
(3)
(2)
(A)
(4)
EN-01766
(A) Air
None

Judgment Value

GD(H4DOTC)-35

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-36

GENERAL DESCRIPTION
R: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
Detect the open or short circuit of intake manifold pressure sensor.
(1) (2)
(A)
(B)
(3)
EN-01765
None

Judgment Value
Output voltage ≤ 0.822 V (Models without SI-DRIVE)
≤ 0.581 V (Models with SI-DRIVE)

GD(H4DOTC)-37

GENERAL DESCRIPTION
Judgment Value
Output voltage > 0.822 V (Models without SI-DRIVE)
> 0.581 V (Models with SI-DRIVE)
GD(H4DOTC)-38

GENERAL DESCRIPTION
S: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT
Detect the open or short circuit of intake manifold pressure sensor.
(1) (2)
(A)
(B)
(3)
EN-01765
None

Judgment Value
Output voltage ≥ 4.474 V (models without SI-DRIVE)
≥ 4.681 V (models with SI-DRIVE)

GD(H4DOTC)-39

GENERAL DESCRIPTION
Judgment Value
Output voltage < 4.474 V (models without SI-DRIVE)
< 4.681 V (models with SI-DRIVE)
GD(H4DOTC)-40

GENERAL DESCRIPTION
T: DTC P0111 INTAKE AIR TEMPERATURE SENSOR RANGE/PERFORMANCE

PROBLEM
Detect the malfunction of intake air temperature sensor output property.
Judge as NG when the intake air temperature is not varied whereas it seemed to be varied from the viewpoint
of engine condition.
(1) (3)
(2)
(A)
(4)
EN-01767
(A) Air
(1) Air flow sensor (3) Resistance value (Ω) (4) Intake air temperature °C (°F)
GD(H4DOTC)-41

GENERAL DESCRIPTION
Engine coolant temperature at engine starting < 200 °C (392 °F)
Continuous time when the vehicle speed is less ≥1s
than 200 km/h (124.3 MPH)
Intake air amount sum value ≥ Value of Map 1
Number of experiences under conditions below ≥ 3 time(s)

• Continuous time when vehicle speed is less ≥ Value from Map 2
than 4 km/h (2.5 MPH)
• Continuous time when vehicle speed is 40 km/h ≥ 15 s
(24.9 MPH) or more
and
Establishing time of 1, 2 ≥ 15 s
1. Intake air amount ≥ 15 g/s (0.53 oz/s)
2. Vehicle speed ≥ 4 km/h (2.5 MPH)
Map 1 (Models without SI-DRIVE)

Engine coolant temperature –20 –10 0 10 20
°C (°F) (–4) (14) (32) (50) (68)
Intake air amount sum value 76000 10192 9028 7864 5800
(g (oz)) (2680.52) (359.47) (318.42) (277.36) (204.57)
Map 1 (Models with SI-DRIVE)

Engine coolant temperature –20 –10 0 10 20
°C (°F) (–4) (14) (32) (50) (68)
Intake air amount sum value 76000 10192 9028 7864 6320
(g (oz)) (2680.52) (359.47) (318.42) (277.36) (222.91)
Map 2
Engine coolant temperature –20 –10 5 20
°C (°F) (–4) (14) (41) (68)
Continuous time (s) when
vehicle speed is less than 250 40 32 24
4 km/h (2.5 MPH)

Perform the diagnosis when the vehicle speed condition is met after warming up from a cold condition.
Judge as NG when the following conditions are established.
Judgment Value
Output voltage difference between Max. and Min. < 0.02 V(Equivalent to approximately
0.5°C (0.9°F) near 25°C)

cles.
GD(H4DOTC)-42

GENERAL DESCRIPTION
Judge as OK and clear the NG if the following conditions are established.
Judgment Value
Output voltage difference between Max. and Min. ≥ 0.02 V
GD(H4DOTC)-43

GENERAL DESCRIPTION
U: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

Detect open or short circuit of the intake air temperature sensor.
(1) (3)
(2)
(A)
(4)
EN-01767
(A) Air
None

Judgment Value

GD(H4DOTC)-44

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-45

GENERAL DESCRIPTION
V: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

Detect open or short circuit of the intake air temperature sensor.
(1) (3)
(2)
(A)
(4)
EN-01767
(A) Air
None

Judgment Value

GD(H4DOTC)-46

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-47

GENERAL DESCRIPTION
W: DTC P0116 ENGINE COOLANT TEMPERATURE SENSOR 1 CIRCUIT

RANGE/PERFORMANCE
Detect the malfunction of the engine coolant temperature sensor characteristics.
When the ignition is ON after the specified period of soaking time has elapsed, compare the engine coolant
temperature with intake air temperature. Judge as NG if the difference between two temperatures is larger
than the predetermined value and the engine coolant temperature becomes the specified value or more.
(1)
(A)
(B)
(2)
EN-02917
(A) Resistance value (kΩ) (B) Temperature °C (°F)
(1) Connector (2) Thermistor element
Soaking time ≥ 21600 s
Engine coolant temperature at the last ≥ Value from Map
engine stop
Map (Models without SI-DRIVE)

Estimate ambient temperature –7 8 10 25
°C (°F) (19.4) (46.4) (50) (77)
Engine coolant temperature at
75 75 75 75
the last engine stop
(167) (167) (167) (167)
°C (°F)
Map (Models with SI-DRIVE)

°C (°F) (19.4) (46.4) (50) (77)
Engine coolant temperature at
77.5 77.5 77.5 77.5
the last engine stop
(171.5) (171.5) (171.5) (171.5)
°C (°F)
GD(H4DOTC)-48

GENERAL DESCRIPTION

Perform the diagnosis only once after starting the engine.
Judgment Value
All of the following conditions are established.
Engine coolant temperature – intake air temperature > 15°C (27°F)
Engine coolant temperature > 45 °C (113 °F)

cles.
Judgment Value
When any one of the followings is established.
Engine coolant temperature – intake air temperature ≤ 15°C (27°F)
Engine coolant temperature ≤ 45 °C (113 °F)
GD(H4DOTC)-49

GENERAL DESCRIPTION
X: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

Detect the open or short circuit of the engine coolant temperature sensor.
(1)
(A)
(B)
(2)
EN-02917
None

Judgment Value

GD(H4DOTC)-50

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-51

GENERAL DESCRIPTION
Y: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

Detect the open or short circuit of the engine coolant temperature sensor.
(1)
(A)
(B)
(2)
EN-02917
None

Judgment Value

GD(H4DOTC)-52

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-53

GENERAL DESCRIPTION
Z: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT

LOW
Detect the open or short circuit of throttle position sensor 1.
(3)
(4)
(1)
(2)
EN-01859
(1) 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 ≥6V

Judgment Value
Sensor 1 input voltage ≤ 0.27 V

GD(H4DOTC)-54

GENERAL DESCRIPTION
Judgment Value
Sensor 1 input voltage > 0.27 V
GD(H4DOTC)-55

GENERAL DESCRIPTION
AA:DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT

HIGH
(3)
(4)
(1)
(2)
EN-01859
Ignition switch ON

Judgment Value
Sensor 1 input voltage ≥ 4.858 V

GD(H4DOTC)-56

GENERAL DESCRIPTION
Judgment Value
Sensor 1 input voltage < 4.858 V
GD(H4DOTC)-57

GENERAL DESCRIPTION
AB:DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP

FUEL CONTROL
Detect the malfunction of engine coolant temperature output property.
Judge as NG when the engine coolant temperature does not rise in driving conditions where it should.
(1)
(A)
(B)
(2)
EN-02917
Engine speed ≥ Value from Map
Map
Engine coolant temperature –40 –30 –20 –10 0 10 20 30
°C (°F) (–40) (–22) (–4) (14) (32) (50) (68) (86)
Engine speed
500 500 500 500 500 500 500 500
rpm
Engine coolant temperature 40 50 60 70 80 90 100 110

°C (°F) (104) (122) (140) (158) (176) (194) (212) (230)
Engine speed
500 500 500 500 500 500 500 500
rpm

Perform the diagnosis only once after engine start.
GD(H4DOTC)-58

GENERAL DESCRIPTION
Judge as NG if the criteria below are met.
Judgment Value
Engine coolant temperature < 20 °C (68 °F)
Timer for diagnosis after engine start ≥ Judgment value of timer after engine start
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 ms + TWCNT ms (when at 64 ms)
TWCNT is defined as follows,
TWCNT = 0 at idle switch ON,
TWCNT show on the following table at idle switch OFF.
Vehicle speed km/h (MPH)
0 (0) 8 (5) 16 (9.9) 24 (14.9) 32 (19.9) 40 (24.9) 48 (29.8) 56 (34.8)
–20 (–4) 0 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 ms 27.391 ms 54.782 ms 82.173 ms 99.65 ms 117.13 ms 135.96 ms 154.8 ms
Temperature
0 (32) 0 ms 17.646 ms 35.292 ms 52.938 ms 72.64 ms 92.341 ms 108.34 ms 124.33 ms
°C (°F)
Judgment value of timer after engine starting

t = 451056 ms – 25870 ms × Ti
Ti : The lowest coolant temperature after engine start
cles.
Judge as OK and clear the NG when the malfunction criteria below are met.
Judgment Value
GD(H4DOTC)-59

GENERAL DESCRIPTION
AC:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE

BELOW THERMOSTAT REGULATING TEMPERATURE)
Detect malfunctions of the thermostat function.
Judge as NG when any one of the following conditions is established.
• When the actual engine coolant temperature does not reach the maximum temperature necessary to per-
form other OBDII diagnosis and Σ (Estimated engine coolant temperature – actual engine coolant tempera-
ture) exceeded the predetermined value. (Judgment 1)
• When the actual engine coolant temperature does not reach the range within –11°C (–19.8°F) from the
regulated temperature and Σ (Estimated engine coolant temperature – actual engine coolant temperature)
exceeded the predetermined value. (Judgment 2)
• When the difference between the estimated coolant temperature and the actual engine coolant tempera-
ture exceeds the predetermined value, and Σ (Estimated engine coolant temperature – actual engine coolant
temperature) exceeded the predetermined value. (Judgment 3)
(8) (2)
(2)
(7)
(6) (5)
(4) (1)
(9)
(3)
EN-01692
(1) Valve (4) Piston (7) Stop ring

(2) Spring (5) Guide (8) Wax element
(3) Stopper (6) Rubber seal (9) Jiggle valve
GD(H4DOTC)-60

GENERAL DESCRIPTION
<Judgment 1>
Estimate ambient temperature ≥ –7 °C (19.4 °F)
Vehicle speed ≥ 30 km/h (18.6 MPH)
Estimated coolant temperature ≥ Value of Map 1
<Judgment 2>
Estimated coolant temperature ≥ Value from Map 2
<Judgment 3>
Estimated coolant temperature ≥ Value from Map 3
Map 1
Engine coolant temperature at engine starting –7 8 10 25
°C (°F) (19.4) (46.4) (50) (77)
Estimated coolant temperature 70 70 70 70
°C (°F) (158) (158) (158) (158)

°C (°F) (19.4) (46.4) (50) (77)
Estimated coolant temperature 75 75 75 75
°C (°F) (167) (167) (167) (167)

°C (°F) (19.4) (46.4) (50) (77)
Estimated coolant temperature 77.5 77.5 77.5 77.5
°C (°F) (171.5) (171.5) (171.5) (171.5)

°C (°F) (19.4) (50) (77) (80.6)
Estimated coolant temperature 58.1 66.6 74.2 75
°C (°F) (136.6) (151.9) (165.6) (167)

°C (°F) (19.4) (50) (77) (114.8)
Estimated coolant temperature 59.8 65.5 70.5 77.5
°C (°F) (139.6) (149.9) (158.9) (171.5)

Perform the diagnosis only once after starting the engine.
GD(H4DOTC)-61

GENERAL DESCRIPTION
Judgment Value
<Judgment 1>
Actual engine coolant temperature < Value of Map 4
and
Σ (Estimated engine coolant temperature > Value of Map 5
– actual engine coolant temperature)
<Judgment 2>
Actual engine coolant temperature < Regulated tempera-
ture – Value of Map 6
and
<Judgment 3>
Estimated engine coolant temperature – > Value of Map 8
actual engine coolant temperature
and
Map 4
°C (°F) (19.4) (46.4) (50) (77)
Threshold Value 70 70 70 70
°C (°F) (158) (158) (158) (158)
Map 5
Engine coolant temperature at engine starting –7 0 8 10 25 35
°C (°F) (19.4) (32) (46.4) (50) (77) (95)
Threshold Value 1731.6 1731.6 1731.6 1731.6 1731.6 1000
°C (°F) (3116.9) (3116.9) (3116.9) (3116.9) (3116.9) (1800)
Map 6
°C (°F) (19.4) (46.4) (50) (77)
Threshold Value 11.1 11.1 11.1 11.1
°C (°F) (20) (20) (20) (20)
Map 7
Engine coolant temperature at engine starting –7 0 8 10 25 30 35
°C (°F) (19.4) (32) (46.4) (50) (77) (86) (95)
Threshold Value 1731.6 1731.6 1731.6 1731.6 1731.6 1731.6 1200
°C (°F) (3116.9) (3116.9) (3116.9) (3116.9) (3116.9) (3116.9) (2160)
Map 8
°C (°F) (19.4) (46.4) (50) (77)
°C (°F) (20) (20) (20) (20)
GD(H4DOTC)-62

GENERAL DESCRIPTION
Map 9
°C (°F) (19.4) (46.4) (50) (77)
Threshold Value 1731.6 1731.6 1731.6 1731.6
°C (°F) (3116.9) (3116.9) (3116.9) (3116.9)
Time Needed for Diagnosis: 300 — 700 seconds

cles.
Judgment Value
<Judgment 1>
Actual engine coolant temperature ≥ Value of Map 4
and
Σ (Estimated engine coolant temperature ≤ Value of Map 5
<Judgment 2>
Actual engine coolant temperature ≥ Regulated temperature – Value of Map 6
and
<Judgment 3>
Estimated engine coolant temperature – ≤ Value of Map 8
actual engine coolant temperature
and
and
Actual engine coolant temperature ≥ Regulated temperature – Value of Map 10
Map 10
°C (°F) (19.4) (46.4) (50) (77)
°C (°F) (20) (20) (20) (20)
GD(H4DOTC)-63

GENERAL DESCRIPTION
AD: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.
(1) (1) (A)
(2) (C) (B) (D)
EN-09361
(A) Electromotive force (B) Air fuel ratio (C) Lean

(D) Rich
(1) Exhaust gas (2) ZrO2

Judgment Value
Input voltage (+) < 1.128 V
or
Input voltage (–) < 0.23 V
or
|Input voltage (+) – Input voltage (–)| < 0.644 V

Input voltage (+): 1000 ms
Input voltage (–): 1000 ms
|Input voltage (+) – Input voltage (–)|: 1000 ms
GD(H4DOTC)-64

GENERAL DESCRIPTION
Judgment Value
Input voltage (+) ≥ 1.128 V
Input voltage (–) ≥ 0.23 V
|Input voltage (+) – Input voltage (–)| ≥ 0.644 V
GD(H4DOTC)-65

GENERAL DESCRIPTION
AE:DTC P0132 O2 SENSOR CIRCUIT HIGH 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.
(1) (1) (A)
(2) (C) (B) (D)
EN-09361

(D) Rich

Judgment Value
Input voltage (+) > 3.589 V
or
Input voltage (–) > 3.541 V

Input voltage (+): 1000 ms
Input voltage (–): 1000 ms
GD(H4DOTC)-66

GENERAL DESCRIPTION
Judgment Value
Input voltage (+) ≤ 3.589 V
Input voltage (–) ≤ 3.541 V
GD(H4DOTC)-67

GENERAL DESCRIPTION
AF:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SEN-

SOR 1)
Detect open circuits of the sensor.
Judge as NG when the impedance of the element is large.
(1) (1) (A)
(2) (C) (B) (D)
EN-09361

(D) Rich
None

Judgment Value
Time of heater control duty at 70 % or more ≥ 36000 ms
Front oxygen (A/F) sensor impedance. > 500 Ω

GD(H4DOTC)-68

GENERAL DESCRIPTION
Judgment Value
Front oxygen (A/F) sensor impedance. ≤ 500 Ω
GD(H4DOTC)-69

GENERAL DESCRIPTION
AG: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.
(E)
(3)
V (1)
(A) (F)
(2) (2)
(C) (B) (D)
EN-01696
(A) Electromotive force (B) Air fuel ratio (C) Rich

(D) Lean (E) Theoretical air fuel ratio (F) Comparative voltage
(1) Atmosphere (2) Exhaust gas (3) Electromotive force
GD(H4DOTC)-70

GENERAL DESCRIPTION
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 < 65535 time(s)
Front oxygen (A/F) sensor compensation coefficient Not in limit value
Low (1)
Amount of intake air ≥ 10 g/s (0.35 oz/s)
Low (2)
Amount of intake air < 10 g/s (0.35 oz/s)
Current continuation time of the rear oxygen sensor heater ≥ 25000 ms
Low (3)
Amount of intake air < 10 g/s (0.35 oz/s)
Current continuation time of the rear oxygen sensor heater ≥ 25000 ms
Fuel cut Experienced
Used for normality judgment


After starting the engine, continuously perform the diagnosis with the same engine condition.
GD(H4DOTC)-71

GENERAL DESCRIPTION
Judgment Value
Malfunction Criteria Threshold Value DTC
High P0138
Sensor output voltage > 1.2 V
Low P0137
Sensor output voltage < 0.03 V

High: 2500 ms
Low (1): 20000 ms
Low (2): 150000 ms
Low (3): Value from Map
Map
Fuel cut time (s) 0 2000 10000
Time Needed for Diagnosis (s) 150000 150000 150000
cles.
Judgment Value
High P0138
Sensor output voltage ≤ 1.2 V
Low P0137
Sensor output voltage ≥ 0.03 V

High: Less than 1 second
Low (1): Less than 1 second
AH: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)-72

GENERAL DESCRIPTION
AI: DTC P013A O2 SENSOR SLOW RESPONSE - RICH TO LEAN (BANK 1 SEN-
SOR 2)
Detect the slow response of rich → lean for rear oxygen sensor output.
When the deceleration fuel cut has occurred, detect the trouble by calculating the time when the rear oxygen
sensor output passes through the predetermined range of voltages.
Judge as NG when the response time is larger than the threshold value.
(E)
(3)
V (1)
(A) (F)
(2) (2)
(C) (B) (D)
EN-01696

Battery voltage > 10.9 V
Rear oxygen sensor closed loop control Operation
Current calculation time of the rear oxygen ≥ 180000 ms
sensor heater after starting
Engine speed when fuel cut starts ≥ 1600 rpm (Models without SI-DRIVE)
≥ 1700 rpm (Models with SI-DRIVE)
Rear oxygen sensor voltage when fuel cut ≥ 0.55 V
starts
Fuel cut time ≥ 5000 ms
Engine coolant temperature when fuel cut ≥ 70 °C (158 °F)
starts
Estimated temperature of rear oxygen ≥ 450 °C (842 °F)
sensor element when fuel cut starts

Perform diagnosis once during deceleration fuel cut from a constant and high speed driving, when rear oxy-
gen sensor is warmed up sufficiently.
GD(H4DOTC)-73

GENERAL DESCRIPTION
Detect the trouble by calculating the response time of the rear oxygen sensor during fuel cut.
Rear oxygen sensor (V)
(F)
(A)
(B)
(C)
(D)
(G) (H)
(E)
Fuel cut on decele ration

EN-09344
(A) 0.55 V (B) 0.50 V (C) 0.20 V

(D) 0.15 V (E) 0V (F) Diagnostic parameter
(G) Normal (H) Malfunction
Judgment Value
Time when rear oxygen sensor voltage > 837 ms
changed from 0.5 V to 0.2 V.
Time Needed for Diagnosis: 10 seconds

cles.
Judgment Value
Time when rear oxygen sensor voltage ≤ 837 ms
GD(H4DOTC)-74

GENERAL DESCRIPTION
AJ:DTC P013B O2 SENSOR SLOW RESPONSE - LEAN TO RICH (BANK 1 SEN-

SOR 2)
Detect the slow response of lean → rich for rear oxygen sensor output.
After the deceleration fuel cut has occurred, detect the trouble by calculating the time when the rear oxygen
sensor output passes through the predetermined range of voltages.
(E)
(3)
V (1)
(A) (F)
(2) (2)
(C) (B) (D)
EN-01696


Perform diagnosis only once after recovering from a deceleration fuel cut continued for more than predeter-
mined time.
GD(H4DOTC)-75

GENERAL DESCRIPTION
Detect the trouble by calculating the response time of the rear oxygen sensor after fuel cut.
(G) (H)
(A)
(B)
(C)
(D)
(F)
(E)

EN-09345
(A) 0.55 V (B) 0.50 V (C) 0.30 V

(D) 0.25 V (E) 0V (F) Diagnostic parameter
(G) Normal (H) Malfunction
Judgment Value

cles.
Judgment Value
GD(H4DOTC)-76

GENERAL DESCRIPTION
AK:DTC P013E O2 SENSOR DELAYED RESPONSE - RICH TO LEAN (BANK 1

SENSOR 2)
Detect the delayed response of rear oxygen sensor output for rich → lean.
After the deceleration fuel cut has started, detect the trouble by calculating the time when the rear oxygen
sensor output decreases to the predetermined voltages.
(E)
(3)
V (1)
(A) (F)
(2) (2)
(C) (B) (D)
EN-01696

Engine speed when fuel cut starts ≥ 1600 rpm (Models without SI-DRIVE)
≥ 1700 rpm (Models with SI-DRIVE)
Rear oxygen sensor voltage when fuel ≥ 0.55 V
cut starts
Engine coolant temperature when fuel ≥ 70 °C (158 °F)
cut starts
Estimated temperature of rear oxygen ≥ 450 °C (842 °F)
sensor element when fuel cut starts

Perform diagnosis once during deceleration fuel cut from a constant and high speed driving, when rear oxy-
gen sensor is warmed up sufficiently.
GD(H4DOTC)-77

GENERAL DESCRIPTION
Detect the trouble by calculating the time from the beginning of the fuel cut to the beginning of the rear oxy-
gen sensor voltage starting to drop.
(C)
(A)
(D) (E)
(B)

EN-09346
(A) 0.5 V (B) 0V (C) Diagnostic parameter

(D) Normal (E) Malfunction
Judgment Value
changed to 0.5 V after the fuel cut started.

cles.
Judgment Value
changed to 0.5 V after the fuel cut started.
GD(H4DOTC)-78

GENERAL DESCRIPTION
AL:DTC P013F O2 SENSOR DELAYED RESPONSE - LEAN TO RICH (BANK 1

SENSOR 2)
Detect the delayed response of rear oxygen sensor output for lean → rich.
After the deceleration fuel cut has completed, detect the trouble by calculating the time when the rear oxygen
sensor output increases to the predetermined voltages.
(E)
(3)
V (1)
(A) (F)
(2) (2)
(C) (B) (D)
EN-01696

Rear oxygen sensor voltage when fuel cut has < 0.15 V
completed
Engine coolant temperature when fuel cut has ≥ 70 °C (158 °F)
completed
Estimated element temperature of rear oxygen ≥ 450 °C (842 °F)
sensor when fuel cut has completed

Perform diagnosis only once when recovering from the deceleration fuel cut continued for more than prede-
termined time with the rear oxygen sensor warmed up sufficiently.
GD(H4DOTC)-79

GENERAL DESCRIPTION
Detect the trouble by calculating the time from the completion of the fuel cut to the beginning of the rear ox-
ygen sensor voltage starting to rise.
Rear oxygen sensor (V) (C)
(D) (E)
(A)
(B)

EN-09347
(A) 0.3 V (B) 0V (C) Diagnostic parameter

(D) Normal (E) Malfunction
Judgment Value
The number of times that the rear oxygen sensor > 3750 time(s)
voltage changed to 0.3 V after the fuel cut has
completed (time counter)

cles.
Judgment Value
The number of times that the rear oxygen sensor ≤ 3750 time(s)
voltage changed to 0.3 V after the fuel cut has
completed (time counter)
GD(H4DOTC)-80

GENERAL DESCRIPTION
AM:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1

SENSOR2)
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.
(E)
(3)
V (1)
(A) (F)
(2) (2)
(C) (B) (D)
EN-01696

3. ENABLE CONDITION (USED ONLY FOR MALFUNCTION JUDGMENT)

Closed loop control at the rear oxygen sensor In operation
Target output voltage of rear oxygen sensor ≥ 0.55 V + 0.05 V
Front oxygen (A/F) sensor compensation Not in limit value
coefficient
Deceleration fuel cut of 5000 ms or more. Experienced

Perform the diagnosis once after starting the engine.
GD(H4DOTC)-81

GENERAL DESCRIPTION
Judgment Value
Minimum output voltage > 0.15 V
or
Maximum output voltage < 0.55 V

cles.
Judgment Value
Diagnosis of the rear oxygen sensor Incomplete
voltage low side
Minimum output voltage ≤ 0.15 V
Maximum output voltage ≥ 0.55 V
GD(H4DOTC)-82

GENERAL DESCRIPTION
AN:DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2)

Detect malfunction of the rear oxygen sensor heater.
Judge as NG if it is determined that the rear oxygen sensor impedance is large by observing the engine con-
ditions.
(5)
(1) (2) (3) (4)
EN-01683
(1) Element cover (outer) (3) Sensor element (5) Sensor housing
(2) Element cover (inner) (4) Ceramic heater
Elapsed time after starting the engine ≥ 1000 ms
A/F sensor element impedance ≤ 50 Ω
A/F sensor heater control duty ≤ 75 %
Rear oxygen sensor heater control duty < 30 %

Perform the diagnosis continuously after 1000 ms seconds or more have passed since the engine started.
Judgment Value
Output terminal for heater characteristics Low
failure detection

cles.
GD(H4DOTC)-83

GENERAL DESCRIPTION
Judgment Value
Output terminal for heater characteristics High
failure detection
GD(H4DOTC)-84

GENERAL DESCRIPTION
AO:DTC P014C O2 SENSOR SLOW RESPONSE - RICH TO LEAN (BANK 1 SEN-

SOR 1)
Detect the slow response of front oxygen (A/F) sensor.
For diagnosis, detect the trouble by processing the λ waveform in normal driving without forcibly changing
the target air fuel ratio.
(1) (1) (A)
(2) (C) (B) (D)
EN-09361

(D) Rich
Closed loop control with main feedback Operation
Front oxygen (A/F) sensor impedance ≥0Ω
and
< 50 Ω
Idle switch OFF

Perform diagnosis only once in a city driving including normal acceleration and deceleration.
GD(H4DOTC)-85

GENERAL DESCRIPTION
5. DIAGNOSTIC METHOD 1
Detect the malfunction by checking “Cumulative value of time when λ changes from lean → rich” in compar-
ison to “Time during which diagnosis is in progress”.
(Sensor output)
Lean
Rich
Accumulated time
(A)
(B)
time
EN-09340
(A) Time during which diagnosis is in (B) Cumulative value of time when λ
progress changes from lean → rich
Judgment Value
(Cumulative value of time when λ < 0.39 P014C
changes from lean → rich) / (Time during > 0.63 P014D
which diagnosis is in progress)

cles.
Judgment Value
(Cumulative value of time when λ ≥ 0.39 P014C
changes from lean → rich) / (Time during ≤ 0.63 P014D
which diagnosis is in progress)
GD(H4DOTC)-86

GENERAL DESCRIPTION
Detect the malfunction by the cumulative value obtained from the amount of variation in λ change.
(Sensor output)
n-2 n-1 n
EN-09341
Judgment Value
Cumulative value obtained from the amount of variation in λ < Value from Map P014C and P014D
change
Σ |(lambda(n) – lambda(n-1)) – (lambda(n-1) – lambda(n-2))|
Map (Models without SI-DRIVE)

Cumulative value obtained from the amount of variation in λ
0.00 4.00
Σ |lambda(n) – lambda(n-1)|
0.00 4.00
change
Map (Models with SI-DRIVE)

0.00 6.00
Σ |lambda(n) – lambda(n-1)|
0.00 6.50
change

cles.
Judgment Value
Cumulative value obtained from the amount of variation in λ ≥ Value from Map P014C and P014D
change
Σ |(lambda(n) – lambda(n-1)) – (lambda(n-1) – lambda(n-2))|

AP:DTC P014D O2 SENSOR SLOW RESPONSE - LEAN TO RICH (BANK 1 SEN-
SOR 1)
NOTE:
For the detection standard, refer to DTC P014C. <Ref. to GD(H4DOTC)-85, DTC P014C O2 SENSOR
SLOW RESPONSE - RICH TO LEAN (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
GD(H4DOTC)-87

GENERAL DESCRIPTION
AQ:DTC P015A O2 SENSOR DELAYED RESPONSE - RICH TO LEAN (BANK 1

SENSOR 1)
Detect the slow response of front oxygen (A/F) sensor.
For diagnosis, detect the trouble by processing the λ waveform in normal driving without forcibly changing
the target air fuel ratio.
(1) (1) (A)
(2) (C) (B) (D)
EN-09361

(D) Rich
Diagnostic method 1
and
< 50 Ω
Idle switch OFF
GD(H4DOTC)-88

GENERAL DESCRIPTION
Diagnostic method 2
and
< 50 Ω
Learning value of EVAP conc. during < 0.2
purge
Total time of operating canister purge ≥ 20 s
Engine load change < 0.02 g/rev (0 oz/rev)
Idle switch OFF
Diagnostic method 3
and
< 50 Ω
and
< 4000 rpm
and
< 40 g/s (1.41 oz/s)
Learning value of EVAP conc. during < 0.2
purge
Catalyst depletion diagnosis Not under diagnosis

Perform diagnosis only once in a city driving including normal acceleration and deceleration.
GD(H4DOTC)-89

GENERAL DESCRIPTION
Detect the malfunction depending on the average value of time necessary for λ to inverse the air fuel ratio
from “Lean → Rich → Lean” to “Rich → Lean → Rich”.
(Sensor output)
Lean
Rich
time
EN-09342
Judgment Value
Average value of time necessary for λ to inverse > 200 ms (Models without SI-DRIVE) P015A
the air fuel ratio to Lean → Rich → Lean. > 100 ms (Models with SI-DRIVE)
Average value of time necessary for λ to inverse > 150 ms (Models without SI-DRIVE) P015B
the air fuel ratio to Rich → Lean → Rich. > 200 ms (Models with SI-DRIVE)
Time Needed for Diagnosis: 50 times of inversion

cles.
Judgment Value
Average value of time necessary for λ to inverse ≤ 200 ms (Models without SI-DRIVE) P015A
the air fuel ratio to Lean → Rich → Lean. ≤ 100 ms (Models with SI-DRIVE)
Average value of time necessary for λ to inverse ≤ 150 ms (Models without SI-DRIVE) P015B
the air fuel ratio to Rich → Lean → Rich. ≤ 200 ms (Models with SI-DRIVE)
Time Needed for Diagnosis: 50 times of inversion
GD(H4DOTC)-90

GENERAL DESCRIPTION
Detect the malfunction by calculating the average amplitude of λ.
(Sensor output)
Lean
Amplitude
Rich
time
EN-09343
Judgment Value
Average value for λ amplitude > 0.1 P015A and P015B
Time Needed for Diagnosis: 11250 time(s) × 8 ms

cles.
Judgment Value
Average value for λ amplitude ≤ 0.1 P015A and P015B
Time Needed for Diagnosis: 11250 time(s) × 8 ms
GD(H4DOTC)-91

GENERAL DESCRIPTION
Change STFT (A/F compensation value) by interruption, and measure the reaction time of λ value. When A/F
sensor malfunctions, the reaction time takes longer than at normal condition. In this case, judge as abnormal.
STFT
Rich
Lean
Time
Sensor output
Lean
Rich
Time
Response time
EN-09890
GD(H4DOTC)-92

GENERAL DESCRIPTION
Measure reaction time (t1, t2, t3) and reaction time (t4, t5, t6). Use the average value of the reaction time to
obtain the diagnostic value.
STFT
Rich
Lean
Time
Sensor output
t1 t2 t3
Lean
Rich
t4 t5 t6 Time
EN-09891
Judgment Value
(t1 + t2 + t3)/3 > 420 ms (Models without SI-DRIVE) P015A and P015B
> 380 ms (Models with SI-DRIVE)
and
(t4 + t5 + t6)/3 > 420 ms (Models without SI-DRIVE)
> 380 ms (Models with SI-DRIVE)
Time Needed for Diagnosis: 1000 ms × [1 time(s)/2] + 1000 ms × 3 time(s) + 500 ms

cles.
Judgment Value
(t1 + t2 + t3)/3 ≤ 420 ms (Models without SI-DRIVE) P015A and P015B
≤ 380 ms (Models with SI-DRIVE)
or
(t4 + t5 + t6)/3 ≤ 420 ms (Models without SI-DRIVE)
≤ 380 ms (Models with SI-DRIVE)
Time Needed for Diagnosis: 1000 ms × [1 time(s)/2] + 1000 ms × 3 time(s) + 500 ms
GD(H4DOTC)-93

GENERAL DESCRIPTION
AR:DTC P015B O2 SENSOR DELAYED RESPONSE - LEAN TO RICH (BANK 1

SENSOR 1)
NOTE:
For the detection standard, refer to DTC P015A. <Ref. to GD(H4DOTC)-88, DTC P015A O2 SENSOR DE-
LAYED RESPONSE - RICH TO LEAN (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Cri-
teria.>
GD(H4DOTC)-94

GENERAL DESCRIPTION
AS: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.
A/F main learning system In operation
Engine load ≥ Value of Map 1
Map1 (models without SI-DRIVE)

Engine speed (rpm) Idling 800 1200 1600 2000 2400 2800 3200 3600 4000 4400
0.228 0.22 0.22 0.22 0.228 0.23 0.234 0.242 0.25 0.25
Measured value (g (oz)/rev) na
(0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01)
Map1 (models with SI-DRIVE)

0.225 0.245 0.239 0.224 0.233 0.259 0.257 0.254 0.256 0.274
(0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01)

Perform the diagnosis continuously at idling or at a constant speed after warming up the engine.
Compare the diagnostic value (fsobd) with the threshold value, and if a condition meeting the malfunction cri-
teria below continues for 10 s × 5 time(s) or more, judge that there is a fault in the fuel system.
Judgment Value
fsobd = (sglmd – tglmda) + faf + flaf ≥ Value from Map 2
In this case: sglmd = measured lambda
tglmda = target lambda
faf = main feedback compensation coefficient
(every 64 milliseconds)
flaf = main feedback learning compensation
coefficient
Map 2
2.34375 4.6875 7.03125 9.375 11.71875 14.0625
Amount of air (g (oz)/s) 0 (0)
(0.08) (0.17) (0.25) (0.33) (0.41) (0.5)
fsobdL1 (%) 1.4 1.4 1.368623 1.319185 1.26975 1.265 1.265
Time Needed for Diagnosis: 10 s × 5 time(s)

cles.
GD(H4DOTC)-95

GENERAL DESCRIPTION
Judgment Value
fsobd = (sglmd – tglmda) + faf + flaf < 1.15
Time Needed for Diagnosis: 10 s
GD(H4DOTC)-96

GENERAL DESCRIPTION
AT:DTC P0172 SYSTEM TOO RICH (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.
Engine load change ≤ 0.02 g/rev (0 oz/rev)
Learning value of EVAP conc. < 0.2
Cumulative time of canister purge after engine start ≥ 20 s
Continuous period after canister purge starting ≥ 5000 ms
Engine load ≥ Value of Map 1
Map1 (models without SI-DRIVE)

0.228 0.22 0.22 0.22 0.228 0.23 0.234 0.242 0.25 0.25
(0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01)
Map1 (models with SI-DRIVE)

0.225 0.245 0.239 0.224 0.233 0.259 0.257 0.254 0.256 0.274
(0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01)

Perform the diagnosis continuously at idling or at a constant speed after warming up the engine.
Compare the diagnostic value (fsobd) with the threshold value, and if a condition meeting the malfunction cri-
teria below continues for 10 s × 5 time(s) or more, judge that there is a fault in the fuel system.
Judgment Value
fsobd = (sglmd – tglmda) + faf + flaf < Value of Map 2
In this case: sglmd = measured lambda
tglmda = target lambda
faf = main feedback compensation coefficient
(every 64 milliseconds)
flaf = main feedback learning compensation
coefficient
Map 2
2.34375 4.6875 7.03125 9.375 11.7187 14.0625
Amount of air (g (oz)/s) 0 (0)
(0.08) (0.17) (0.25) (0.33) 5 (0.41) (0.5)
fsobdL1 (%) 0.6 0.6 0.63137 0.68082 0.71025 0.72525 0.73025

cles.
GD(H4DOTC)-97

GENERAL DESCRIPTION
Judge as OK if the status that the criteria below are met continues for 10 seconds.
Judgment Value
fsobd = (sglmd – tglmda) + faf + flaf ≥ 0.85
GD(H4DOTC)-98

GENERAL DESCRIPTION
AU:DTC P0201 INJECTOR #1

Based on the self-diagnostic result of the injector driving IC, judge the injector driving circuit as normal or ab-
normal.
Injector driving IC detects the status of “fuel remains injected” or “fuel is not injected” as a malfunction.
Elapsed time after starting the engine >1s
Engine speed > 500 rpm
Injection time ≥ 1000 µs
and
< 120000000/engine speed – 1000 µs
Injection status Not during fuel cut
and
Not during asynchronous injection controlled
by crankshaft position sensor

Judgment Value
Injector driving IC information Malfunction

Judgment Value
Injector driving IC information Normal
GD(H4DOTC)-99

GENERAL DESCRIPTION
AV:DTC P0202 INJECTOR #2

NOTE:
For the detection standard, refer to DTC P0201. <Ref. to GD(H4DOTC)-99, DTC P0201 INJECTOR #1, Di-
agnostic Trouble Code (DTC) Detecting Criteria.>
AW:DTC P0203 INJECTOR #3
NOTE:
AX:DTC P0204 INJECTOR #4
NOTE:
GD(H4DOTC)-100

GENERAL DESCRIPTION
AY:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT

LOW
(3)
(4)
(1)
(2)
EN-01859
Ignition switch ON

Judgment Value
Sensor 2 input voltage ≤ 1.15 V

GD(H4DOTC)-101

GENERAL DESCRIPTION
Judgment Value
Sensor 2 input voltage > 1.15 V
GD(H4DOTC)-102

GENERAL DESCRIPTION
AZ:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT

HIGH
(3)
(4)
(1)
(2)
EN-01859
Ignition switch ON

Judgment Value

GD(H4DOTC)-103

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-104

GENERAL DESCRIPTION
BA:DTC P0230 FUEL PUMP PRIMARY CIRCUIT

Detect the malfunction of fuel pump control unit.
Judge as NG when the NG signal is sent through a diagnostic line coming from the fuel pump control unit.
Fuel pump control unit detects the open or short circuit malfunction for each line, and then sends NG signals
if one of them is found NG.
+B
FPC FP+ (4)
(1) (2) (3)
DI FP-
EN-01771
(1) Engine control module (ECM) (3) Fuel pump (4) Battery
(2) Fuel pump control unit
None

Judgment Value
Fuel pump control ON
Fuel pump control unit output diagnosis signal Low
Fuel level ≥ 10 2 (2.64 US gal, 2.2 Imp gal)

cles.
GD(H4DOTC)-105

GENERAL DESCRIPTION
Judgment Value
Fuel pump control ON
Fuel pump control unit output diagnosis signal High
Fuel level ≥ 10 2 (2.64 US gal, 2.2 Imp gal)
GD(H4DOTC)-106

GENERAL DESCRIPTION
BB: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.
(1)
EN-01772
(1) Coil
None

GD(H4DOTC)-107

GENERAL DESCRIPTION
Judgment Value
Intake manifold pressure ≥ Value from Map
Map (models without SI-DRIVE)

Barometric pressure (kPa (mmHg, inHg))
58.7 77.3 89.3 96 98.6 101.3
(440, 17.3) (580, 22.8) (670, 26.4) (720, 28.3) (740, 29.1) (760, 29.9)
109.5 127.4 138.6 138.6 138.6 138.6
1000
(822, 32.3) (956, 37.6) (1040 , 40.9) (1040 , 40.9) (1040 , 40.9) (1040 , 40.9)
139.1 163.4 178.6 178.6 178.6 178.6
2000
(1044, 41.1) (1226, 48.3) (1340 , 52.8) (1340 , 52.8) (1340 , 52.8) (1340 , 52.8)
169.7 200.6 219.9 219.9 219.9 219.9
Engine 2400
(1273, 50.1) (1505, 59.3) (1650 , 65) (1650 , 65) (1650 , 65) (1650 , 65)
speed
(rpm) 169.7 200.6 219.9 219.9 219.9 219.9
4000
(1273, 50.1) (1505, 59.3) (1650 , 65) (1650 , 65) (1650 , 65) (1650 , 65)
144.1 173 193.9 200.7 217.9 217.9
5000
(1081, 42.6) (1298, 51.1) (1454 , 57.3) (1506 , 59.3) (1635 , 64.4) (1635 , 64.4)
138.6 166.6 187.2 194.6 213.3 213.3
6000
(1040, 40.9) (1250, 49.2) (1404 , 55.3) (1460 , 57.5) (1600 , 63) (1600 , 63)
kPa (mmHg, inHg)
Map (models with SI-DRIVE)

59.3 (445, 68.6 78 92 96 98.6
17.5) (515, 20.3) (585, 23) (690, 27.2) (720, 28.3) (740, 29.1)
124.4 135.3 135.3 135.3 135.3 135.3
1000
(934, 36.8) (1015, 40) (1015, 40) (1015, 40) (1015, 40) (1015 , 40)
169.4 185.3 185.3 185.3 185.3 185.3
2000
(1271, 50) (1390, 54.7) (1390, 54.7) (1390, 54.7) (1390, 54.7) (1390 , 54.7)
158.2 214.6 214.6 214.6 214.6 214.6
Engine 3000
(1187, 46.7) (1610, 63.4) (1610, 63.4) (1610, 63.4) (1610, 63.4) (1610 , 63.4)
speed
(rpm) 155.8 195.5 205.4 225.3 225.3 225.3
4000
(1169, 46) (1467, 57.7) (1541, 60.7) (1690, 66.5) (1690, 66.5) (1690 , 66.5)
145.8 169.7 185.6 215.3 225.3 225.3
5000
(1094, 43.1) (1273, 50.1) (1392, 54.8) (1616, 63.6) (1690, 66.5) (1690 , 66.5)
117.8 156.3 168.5 205 215.1 229.3
6000
(884, 34.8) (1173, 46.2) (1264, 49.8) (1538, 60.5) (1614, 63.5) (1720 , 67.7)
kPa (mmHg, inHg)

Judgment Value
Intake manifold pressure <Map Value of Map – 22.4 kPa (168 mmHg, 6.6 inHg) (models without SI-DRIVE)
<Map Value of Map – 20 kPa (150 mmHg, 5.9 inHg) (models with SI-DRIVE)
GD(H4DOTC)-108

GENERAL DESCRIPTION
BC: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.
(1)
EN-01772
(1) Coil
Elapsed time after starting the engine ≥ 1 second

Perform the diagnosis continuously after starting the engine.
Abnormality Judgment
Judgment Value
Terminal output voltage Low
Duty ratio of wastegate control < 75%

GD(H4DOTC)-109

GENERAL DESCRIPTION
Normality Judgment
Judgment Value
Terminal output voltage High
GD(H4DOTC)-110

GENERAL DESCRIPTION
BD: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.
(1)
EN-01772
(1) Coil

Judgment Value
Duty ratio of wastegate control ≥ 25%

GD(H4DOTC)-111

GENERAL DESCRIPTION
Normality Judgment
Judgment Value

BE:DTC P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED
NOTE:
For the detection standard, refer to DTC P0301. <Ref. to GD(H4DOTC)-113, DTC P0301 CYLINDER 1 MIS-
FIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-112

GENERAL DESCRIPTION
BF:DTC P0301 CYLINDER 1 MISFIRE DETECTED

Detect the presence of misfire occurrence. (Revolution fluctuation method)
Monitoring Misfire which influences exhaust deterioration (1.5 times of FTP) and catalyst damage is made
obligatory by the law. Misfire affecting these two has two patterns below. :
• Intermittent misfire (The same cylinder misfires in random, or different cylinders misfire in random.): FTP
1.5 times misfire
• Every time misfire (The same cylinder misfires every time.): FTP 1.5 times misfire, Catalyst damage mis-
fire
The following detecting methods are adopted for these detection.
1) Intermittent misfire: FTP 1.5 times misfire
• 180° Interval Difference Method
• 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
All secondary parameters enable conditions ≥ 1024 ms
Intake manifold pressure change at 180°CA < Value of Map 1
Throttle position change during 16 milliseconds < 14 °
Fuel shut-off function Not in operation
Fuel level ≥ 9.6 2 (2.54 US gal, 2.11 Imp gal)
Vehicle dynamic control or AT torque control Not in operation
Evaporative system leak check Not in operation
Intake manifold pressure ≥ Value from Map 2
Fuel parameter determination Not extremely low volatility
Engine speed change during 32 milliseconds < 1000 rpm

rpm 750 1000 1500 2000 2500 3000 3500 4000
13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3
kPa (mmHg, inHg)
(100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9)
rpm 4500 5000 5500 6000 6500 6700

13.3 13.3 13.3 13.3 13.3 13.3
kPa (mmHg, inHg)
(100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9)

rpm 700 1000 1500 2000 2500 3000 3500 4000
13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3
kPa (mmHg, inHg)
(100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9)
rpm 4500 5000 5500 6000 6500 6700

13.3 13.3 13.3 13.3 13.3 13.3
kPa (mmHg, inHg)
(100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9) (100, 3.9)
GD(H4DOTC)-113

GENERAL DESCRIPTION

• Normal ignition
66.7 76.6 80 84 86.6 92 100.2
(500.0 , 19.7) (575.0 , 22.6) (600.0 , 23.6) (630.0 , 24.8) (650.0 , 25.6) (690.0 , 27.2) (752.0 , 29.6)
23 23 23.7 25.4 26.7 26.5 27.9
700
(172.4 , 6.8) (172.4 , 6.8) (177.5 , 7) (190.2 , 7.5) (200.2 , 7.9) (198.6 , 7.8) (208.9 , 8.2)
20.4 20.4 20.8 22.7 23.2 23.9 25.1
1000
(152.8 , 6) (152.8 , 6) (156.0 , 6.1) (170.1 , 6.7) (174.4 , 6.9) (179.4 , 7.1) (188.4 , 7.4)
20.7 20.7 21.5 22.6 23.3 24.4 25.8
1500
(155.4 , 6.1) (155.4 , 6.1) (161.1 , 6.3) (169.4 , 6.7) (175.0 , 6.9) (183.2 , 7.2) (193.7 , 7.6)
20.1 20.1 20.9 22 22.8 23.6 24.8
2000
(150.9 , 5.9) (150.9 , 5.9) (156.7 , 6.2) (165.3 , 6.5) (170.8 , 6.7) (177.2 , 7) (186.1 , 7.3)
20.2 20.2 20.9 21.9 22.5 23.2 24.4
2500
(151.3 , 6) (151.3 , 6) (156.5 , 6.2) (164.4 , 6.5) (168.8 , 6.6) (174.3 , 6.9) (183.1 , 7.2)
21.4 21.4 20.7 21.9 22.6 23.6 24.3
3000
(160.9 , 6.3) (160.9 , 6.3) (155.6 , 6.1) (164.1 , 6.5) (169.2 , 6.7) (177.3 , 7) (182.2 , 7.2)
25.1 25.1 25.8 27.1 27.8 29.2 29.3
Engine 3500
(188.3 , 7.4) (188.3 , 7.4) (193.4 , 7.6) (203.5 , 8) (208.4 , 8.2) (218.8 , 8.6) (220.2 , 8.7)
speed
(rpm) 25.7 25.7 26.5 28 28.9 29.4 29.5
4000
(192.8 , 7.6) (192.8 , 7.6) (199.0 , 7.8) (210.2 , 8.3) (216.7 , 8.5) (220.6 , 8.7) (221.2 , 8.7)
25.8 25.8 26.3 27.5 28.7 29.1 29.2
4500
(193.3 , 7.6) (193.3 , 7.6) (197.1 , 7.8) (206.2 , 8.1) (215.3 , 8.5) (218.3 , 8.6) (219.3 , 8.6)
30 30 30.6 31.3 32.1 33 33.2
5000
(225.3 , 8.9) (225.3 , 8.9) (229.6 , 9) (234.5 , 9.2) (240.7 , 9.5) (247.4 , 9.7) (248.8 , 9.8)
33.8 33.8 34.2 35.5 36.2 37.2 37.2
5500
(253.2 , 10) (253.2 , 10) (256.8 , 10.1) (266.4 , 10.5) (271.9 , 10.7) (279.1 , 11) (278.9 , 11)
37.9 37.9 38.2 39.3 40.2 40.8 41.6
6000
(284.4 , 11.2) (284.4 , 11.2) (286.8 , 11.3) (294.5 , 11.6) (301.3 , 11.9) (306.3 , 12.1) (312.0 , 12.3)
42.6 42.6 43.4 44.5 45.5 47 47.2
6500
(319.8 , 12.6) (319.8 , 12.6) (325.4 , 12.8) (333.6 , 13.1) (341.2 , 13.4) (352.8 , 13.9) (354.0 , 13.9)
43.4 43.4 44.1 45.2 46.2 47.7 47.9
6700
(325.2 , 12.8) (325.2 , 12.8) (330.8 , 13) (339.0 , 13.3) (346.6 , 13.6) (358.2 , 14.1) (359.4 , 14.1)
kPa (mmHg, inHg)
GD(H4DOTC)-114

GENERAL DESCRIPTION
• Idling ignition
66.7 76.6 80 84 86.6 92 100.2
(500.0 , 19.7) (575.0 , 22.6) (600.0 , 23.6) (630.0 , 24.8) (650.0 , 25.6) (690.0 , 27.2) (752.0 , 29.6)
23 23 23.7 25.4 26.7 26.5 27.9
700
(172.4 , 6.8) (172.4 , 6.8) (177.5 , 7) (190.2 , 7.5) (200.2 , 7.9) (198.6 , 7.8) (208.9 , 8.2)
22.3 22.3 23 24.5 25.7 26.8 27
1000
(167.3 , 6.6) (167.3 , 6.6) (172.6 , 6.8) (184.2 , 7.3) (192.8 , 7.6) (201.0 , 7.9) (202.3 , 8)
22.3 22.3 24.2 24.8 26.2 26.7 28.2
1500
(167.6 , 6.6) (167.6 , 6.6) (181.9 , 7.2) (185.7 , 7.3) (196.7 , 7.7) (200.0 , 7.9) (211.8 , 8.3)
22 22 22.8 23.7 24.6 25.5 26.5
2000
(164.8 , 6.5) (164.8 , 6.5) (170.9 , 6.7) (177.8 , 7) (184.7 , 7.3) (191.6 , 7.5) (198.4 , 7.8)
21.2 21.2 21.9 22.9 23.6 25.5 25.4
2500
(158.9 , 6.3) (158.9 , 6.3) (164.3 , 6.5) (171.7 , 6.8) (177.2 , 7) (191.6 , 7.5) (190.3 , 7.5)
20.9 20.9 26.3 22.6 27.5 24.4 25.3
3000
(156.4 , 6.2) (156.4 , 6.2) (197.6 , 7.8) (169.7 , 6.7) (206.2 , 8.1) (183.1 , 7.2) (189.5 , 7.5)
30 30 30.9 32 32.8 33.7 33.8
Engine 3500
(225.3 , 8.9) (225.3 , 8.9) (231.8 , 9.1) (240.4 , 9.5) (246.0 , 9.7) (252.5 , 9.9) (253.7 , 10)
speed
(rpm) 30.7 30.7 31.1 32.3 33.9 34.7 33.9
4000
(230.0 , 9.1) (230.0 , 9.1) (233.6 , 9.2) (242.7 , 9.6) (254.5 , 10) (260.6 , 10.3) (254.4 , 10)
28.4 28.4 29 29.7 31.7 32.2 31.2
4500
(213.4 , 8.4) (213.4 , 8.4) (217.2 , 8.6) (222.9 , 8.8) (237.5 , 9.3) (241.8 , 9.5) (234.1 , 9.2)
34.4 34.4 34.4 34.9 35.7 36.4 37
5000
(257.9 , 10.2) (257.9 , 10.2) (257.7 , 10.1) (261.8 , 10.3) (268.1 , 10.6) (272.8 , 10.7) (277.6 , 10.9)
38.2 38.2 38.6 39.8 40.7 41.4 41.1
5500
(286.5 , 11.3) (286.5 , 11.3) (289.8 , 11.4) (298.3 , 11.7) (305.1 , 12) (310.8 , 12.2) (308.3 , 12.1)
40.7 40.7 41.1 42.2 44.2 44.3 44.2
6000
(305.0 , 12) (305.0 , 12) (308.6 , 12.2) (316.8 , 12.5) (331.3 , 13) (332.3 , 13.1) (331.3 , 13)
46.3 46.3 46.6 47.8 48.9 49.7 50.4
6500
(347.3 , 13.7) (347.3 , 13.7) (349.9 , 13.8) (358.4 , 14.1) (366.5 , 14.4) (372.9 , 14.7) (377.9 , 14.9)
47 47 47.4 48.5 49.6 50.4 51.1
6700
(352.7 , 13.9) (352.7 , 13.9) (355.3 , 14) (363.8 , 14.3) (371.9 , 14.6) (378.3 , 14.9) (383.3 , 15.1)
kPa (mmHg, inHg)
GD(H4DOTC)-115

GENERAL DESCRIPTION

• Normal ignition
66.7 76.6 80 84 86.6 92 100.2
(500, 19.7) (575, 22.6) (600, 23.6) (630, 24.8) (650, 25.6) (690, 27.2) (752, 29.6)
26.7 26.7 27.3 28.4 29.3 29.9 28.8
700
(200.0 , 7.9) (200.0 , 7.9) (205.0 , 8.1) (213.0 , 8.4) (220.0 , 8.7) (224.0 , 8.8) (216.0 , 8.5)
23.9 23.9 24.9 25.5 25.9 27.5 28.6
1000
(179.0 , 7) (179.0 , 7) (187.0 , 7.4) (191.0 , 7.5) (194.0 , 7.6) (206.0 , 8.1) (214.7 , 8.5)
22.4 22.4 23.3 24.1 24.7 24.8 24.9
1500
(168.0 , 6.6) (168.0 , 6.6) (175.0 , 6.9) (181.0 , 7.1) (185.0 , 7.3) (186.0 , 7.3) (186.9 , 7.4)
23.2 23.2 24 25.5 26.1 25.6 25.3
2000
(174.0 , 6.9) (174.0 , 6.9) (180.0 , 7.1) (191.0 , 7.5) (196.0 , 7.7) (192.0 , 7.6) (189.5 , 7.5)
23.9 23.9 24.5 25.5 26 25.5 25.1
2500
(179.0 , 7) (179.0 , 7) (184.0 , 7.2) (191.0 , 7.5) (195.0 , 7.7) (191.0 , 7.5) (188.6 , 7.4)
24.7 24.7 25.3 25.6 26.1 25.9 25.8
3000
(185.0 , 7.3) (185.0 , 7.3) (190.0 , 7.5) (192.0 , 7.6) (196.0 , 7.7) (194.0 , 7.6) (193.3 , 7.6)
29.1 29.1 29.8 29.9 31.3 31.5 29.5
3500
Engine (218.5 , 8.6) (218.5 , 8.6) (223.5 , 8.8) (224.5 , 8.8) (234.5 , 9.2) (236.0 , 9.3) (221.5 , 8.7)
speed 29.2 29.2 29.9 30.5 30.8 31.7 32.3
(rpm) 4000
(219.0 , 8.6) (219.0 , 8.6) (224.0 , 8.8) (229.0 , 9) (231.0 , 9.1) (238.0 , 9.4) (242.2 , 9.5)
29.3 29.3 30.3 30.9 31.4 32.1 32.6
4500
(219.5 , 8.6) (219.5 , 8.6) (227.5 , 9) (231.5 , 9.1) (235.5 , 9.3) (241.0 , 9.5) (244.2 , 9.6)
30.4 30.4 30.7 31.7 32.1 32.7 33.1
5000
(228.1 , 9) (228.1 , 9) (230.1 , 9.1) (238.1 , 9.4) (241.1 , 9.5) (245.0 , 9.6) (248.0 , 9.8)
33.4 33.4 34.2 34.9 35.1 35.7 36.1
5500
(250.6 , 9.9) (250.6 , 9.9) (256.6 , 10.1) (261.6 , 10.3) (263.6 , 10.4) (268.0 , 10.6) (271.0 , 10.7)
37.5 37.5 38 38.8 39.1 40.3 40.9
6000
(281.1 , 11.1) (281.1 , 11.1) (285.1 , 11.2) (291.1 , 11.5) (293.1 , 11.5) (302.0 , 11.9) (306.9 , 12.1)
42.6 42.6 43.3 43.9 43.8 44.9 45.6
6500
(319.6 , 12.6) (319.6 , 12.6) (324.6 , 12.8) (329.6 , 13) (328.6 , 12.9) (337.0 , 13.3) (341.7 , 13.5)
46.3
43.3 43.3 44 44.7 44.5 45.6
6700 (347.144274
(325, 12.8) (325, 12.8) (330, 13) (335, 13.2) (334, 13.1) (342, 13.5)
9, 13.7)
kPa (mmHg, inHg)
GD(H4DOTC)-116

GENERAL DESCRIPTION
• Idling ignition
66.7 76.6 80 84 86.6 92 100.2
(500, 19.7) (575 , 22.6) (600 , 23.6) (630 , 24.8) (650 , 25.6) (690 , 27.2) (752 , 29.6)
26.7 26.7 27.3 28.4 29.3 29.9 28.8
700
(200.0 , 7.9) (200.0 , 7.9) (205.0 , 8.1) (213.0 , 8.4) (220.0 , 8.7) (224.0 , 8.8) (216.0 , 8.5)
25.1 25.1 26 26.9 28 28.7 30.4
1000
(188.0 , 7.4) (188.0 , 7.4) (195.0 , 7.7) (202.0 , 8) (210.0 , 8.3) (215.0 , 8.5) (228.1 , 9)
22.9 22.9 23.3 23.9 24.7 24.9 26.7
1500
(172.0 , 6.8) (172.0 , 6.8) (175.0 , 6.9) (179.0 , 7) (185.0 , 7.3) (187.0 , 7.4) (200.6 , 7.9)
23.2 23.2 23.7 24.4 25.1 25.3 27.8
2000
(174.0 , 6.9) (174.0 , 6.9) (178.0 , 7) (183.0 , 7.2) (188.0 , 7.4) (190.0 , 7.5) (208.5 , 8.2)
23.2 23.2 23.7 24.5 24.8 25.3 26.6
2500
(174.0 , 6.9) (174.0 , 6.9) (178.0 , 7) (184.0 , 7.2) (186.0 , 7.3) (190.0 , 7.5) (199.7 , 7.9)
24.3 24.3 24.9 25.9 25.9 26.1 26.6
3000
(182.0 , 7.2) (182.0 , 7.2) (187.0 , 7.4) (194.0 , 7.6) (194.0 , 7.6) (196.0 , 7.7) (199.7 , 7.9)
31.7 31.7 31.4 32.6 33.1 34.6 35.2
3500
Engine (237.5 , 9.4) (237.5 , 9.4) (235.5 , 9.3) (244.5 , 9.6) (248.5 , 9.8) (259.5 , 10.2) (264.0 , 10.4)
speed 32.1 32.1 32.3 33.2 33.7 34.9 36
(rpm) 4000
(241.0 , 9.5) (241.0 , 9.5) (242.0 , 9.5) (249.0 , 9.8) (253.0 , 10) (262.0 , 10.3) (270.0 , 10.6)
32.1 32.1 32.1 33 33.9 35.5 35.3
4500
(240.5 , 9.5) (240.5 , 9.5) (240.5 , 9.5) (247.5 , 9.7) (254.5 , 10) (266.5 , 10.5) (265.1 , 10.4)
35.5 35.5 34.4 35.3 35.7 37.3 37.2
5000
(266.1 , 10.5) (266.1 , 10.5) (258.1 , 10.2) (265.1 , 10.4) (268.1 , 10.6) (280.1 , 11) (279.2 , 11)
38.1 38.1 37.5 38.5 39.5 40.3 40.7
5500
(285.6 , 11.2) (285.6 , 11.2) (281.6 , 11.1) (288.6 , 11.4) (296.6 , 11.7) (302.6 , 11.9) (305.2 , 12)
41.6 41.6 41.5 42.8 43.5 45.6 45.4
6000
(312.1 , 12.3) (312.1 , 12.3) (311.1 , 12.2) (321.1 , 12.6) (326.1 , 12.8) (342.1 , 13.5) (340.3 , 13.4)
48.6 48.6 49.3 48.6 49.4 49.4 53.4
6500
(364.6 , 14.4) (364.6 , 14.4) (369.6 , 14.6) (364.6 , 14.4) (370.6 , 14.6) (370.6 , 14.6) (400.7 , 15.8)
54.1
49.3 49.3 50 49.3 50.1 50.1
6700 (406.151453
(370, 14.6) (370, 14.6) (375, 14.8) (370, 14.6) (376, 14.8) (376, 14.8)
6, 16)
kPa (mmHg, inHg)

• If conditions are met, it is possible to detect the misfires from idling to high engine speed. However, in case
any engine load or breakage occurs, perform with the engine at idle.
• Perform the diagnosis continuously.
GD(H4DOTC)-117

GENERAL DESCRIPTION
When a misfire occurs, the engine speed will decrease 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. Count
the number of misfires, if the misfire ratio is higher during 1000 revs. or 200 revs., judge corresponding cyl-
inders as NG.
Diagnostic value calculation Misfire detection every single ignition NG judgment (Misfire occurrence judgment
(Calculate from angle speed) → (Compare diagnostic value with judgment required by the law) (Compare number of
value) → misfire with judgment value)
• 180° Interval Difference Method • FTP 1.5 times misfire NG judgment
• 360° Interval Difference Method • Catalyst damage misfire NG judgment
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.
(A) #3 #2 #4 #1 #3 #2 #4 #1 #3 #2
(B) omg7 omg6 omg5 omg4 omg3 omg2 omg1 omg0
EN-01774
(A) Ignition order (B) Crankshaft position speed
GD(H4DOTC)-118

GENERAL DESCRIPTION
180° Interval Difference Method

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
(Diagnostic value before 180° CA)
domg180
Threshold valve (positive number)
domg180
Threshold valve (negative number)
Judged as misfire.
EN-02877

Diagnostic value domg 360 = (omg 1 – omg 0) – (omg 3 – omg 2)
Misfire judgment domg 360 > Judgment value → Judge as misfire
domg360
Threshold valve
domg360
Judged as misfire.
EN-03273
GD(H4DOTC)-119

GENERAL DESCRIPTION

Diagnostic value domg 720 = (omg 1 – omg 0) – (omg 5 – omg 4)
Misfire judgment domg 720 > Judgment value → Judge as misfire
domg720
Threshold valve
domg720
Judged as misfire.
EN-03274
• FTP 1.5 times misfire (Misfire occurrence level which influences exhaust gas)
Judgment Value (Judge that malfunction occurs when the misfire ratio is high in 1000 engine revs.)
FTP emission diagnostic value ≥ 17 × 100/2000% in 1000 revs.
Time Needed for Diagnosis: 1000 engine revs.

cles.
Judgment Value
FTP emission diagnostic value < 17 × 100/2000% in 1000 revs.
GD(H4DOTC)-120

GENERAL DESCRIPTION
• Catalyst damage misfire (Misfire occurrence level damaging catalyst)

Judgment Value
Catalyst damage misfire diagnostic ≥ Value from Map 3
value

Intake air (g(oz)/rev)
0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
(0.01) (0.01) (0.02) (0.03) (0.04) (0.04) (0.05) (0.06) (0.06) (0.07)
700 100 100 100 100 100 90 90 90 90 90
1000 100 100 100 100 92 85 85 85 85 85
1500 100 100 100 90 85 85 85 72 72 72
2000 100 90 90 73 58 43 40 36 32 20
2500 100 87 57 45 39 36 34 32 30 20
3000 100 87 58 39 36 36 32 30 28 20
Engine 3500 98 74 43 27 23 22 20 20 20 20
speed
(rpm) 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

Intake air (g(oz)/rev)
0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
(0.01) (0.01) (0.02) (0.03) (0.04) (0.04) (0.05) (0.06) (0.06) (0.07)
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
Engine 3500 74 74 43 27 23 22 20 20 20 20
speed
(rpm) 4000 61 61 40 27 22 20 20 20 20 20
4500 55 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

GD(H4DOTC)-121

GENERAL DESCRIPTION
Judgment Value
Catalyst damage misfire diagnostic < Value of Map 3
value

BG:DTC P0302 CYLINDER 2 MISFIRE DETECTED
NOTE:
BH:DTC P0303 CYLINDER 3 MISFIRE DETECTED
NOTE:
BI: DTC P0304 CYLINDER 4 MISFIRE DETECTED
NOTE:
GD(H4DOTC)-122

GENERAL DESCRIPTION
BJ:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

Detect the open or short circuit of knock sensor.
(1) (4) (5)
(2)
(A)
(3)
EN-01707
(A) To knock sensor harness
(1) Case (3) Piezoelectric element (5) Resistance

(2) Weight (4) Nut
None

Judgment Value

GD(H4DOTC)-123

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-124

GENERAL DESCRIPTION
BK:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

Detect the open or short circuit of knock sensor.
(1) (4) (5)
(2)
(A)
(3)
EN-01707
(A) To knock sensor harness
(1) Case (3) Piezoelectric element (5) Resistance

(2) Weight (4) Nut
None

Judgment Value

GD(H4DOTC)-125

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-126

GENERAL DESCRIPTION
BL: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.
50 CA 50 CA 50 CA
(A)
50 CA 50 CA 50 CA
(B)
#1BTDC10 CA #3BTDC10 CA #2BTDC10 CA #4BTDC10 CA #1BTDC10 CA
(C)
10 30 30
EN-06283
(A) Camshaft signal (RH) (B) Camshaft signal (LH) (C) Crankshaft signal
(1)
(3)
(2)
EN-05539
(1) Crankshaft position sensor (2) Crank sprocket (3) Crankshaft half-turn
None

GD(H4DOTC)-127

GENERAL DESCRIPTION
Judgment Value
Starter switch ON
Crankshaft position sensor signal Not detected

Judgment Value
Crankshaft position sensor signal Input exists
GD(H4DOTC)-128

GENERAL DESCRIPTION
BM:DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PER-

FORMANCE
Detect for faults in crankshaft position sensor output properties.
Judge as NG when there is a problem in the number of crankshaft signals for every revolution.
50 CA 50 CA 50 CA
(A)
50 CA 50 CA 50 CA
(B)
(C)
10 30 30 (D)
EN-06384
(D) Number of crankshaft signals = 30
is normal
(1)
(3)
(2)
EN-05539
(1) Crankshaft position sensor (2) Crank sprocket (3) Crankshaft half-turn
GD(H4DOTC)-129

GENERAL DESCRIPTION

Perform the diagnosis continuously under 3000 rpm engine speed.
Judgment Value
Cylinder number identification Completed
Amount of crank sensor signal during 1 rev. Not = 30

cles.
Judgment Value
Cylinder number identification Completed
Amount of crank sensor signal during 1 rev. = 30
GD(H4DOTC)-130

GENERAL DESCRIPTION
BN:DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SIN-

GLE SENSOR)
Detect the open or short circuit of the camshaft position sensor.
When there is no camshaft position signal input continuously, judge as NG.
(D)
50 CA 50 CA 50 CA
(A)
50 CA 50 CA 50 CA
(B)
(C)
10 30 30
EN-06382
(D) Camshaft position signal: When
normal, there will be 3 camshaft
position signals for every 2 crank-
shaft revolutions.
Diagnosis 1
Diagnosis 2
Starter ON

GD(H4DOTC)-131

GENERAL DESCRIPTION
Diagnosis 1
Judge as NG when no input of camshaft position sensor signal in TDC remains for 14 time(s).
Judgment Value
No camshaft position sensor signal input ≥ 14 time(s)
in TDC
Time Needed for Diagnosis: TDC × 14 time(s)

Diagnosis 2
Judgment Value
Camshaft position sensor signal No input

Diagnosis 1
Judgment Value
No camshaft position sensor signal input = 0 time(s)
in TDC

Diagnosis 2
Judgment Value
Camshaft position sensor signal Input exists
GD(H4DOTC)-132

GENERAL DESCRIPTION
BO:DTC P0341 CAMSHAFT POSITION SENSOR "A" CIRCUIT RANGE/PERFOR-

MANCE (BANK 1 OR SINGLE SENSOR)
Detect the malfunction of camshaft position sensor property.
Judge as NG when the number of camshaft signals remains abnormal.
(D)
50 CA 50 CA 50 CA
(A)
50 CA 50 CA 50 CA
(B)
(C)
10 30 30
EN-06382
(D) Camshaft position signal: When
normal, there will be 3 camshaft
position signals for every 2 crank-
shaft revolutions.

Judge as NG when the status where the number of camshaft position sensor signal in two crankshaft revo-
lutions is other than 3 time(s).
Judgment Value
Amount of camshaft sensor signal during ≠ 3 time(s)
2 revs of crankshaft.
Time Needed for Diagnosis: Two engine revs. × 4 time(s)

GD(H4DOTC)-133

GENERAL DESCRIPTION
Judgment Value
Camshaft position sensor signal = 3 time(s)
Time Needed for Diagnosis: Two engine revs.

BP:DTC P0345 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 2)
NOTE:
For the detection standard, refer to DTC P0340. <Ref. to GD(H4DOTC)-131, DTC P0340 CAMSHAFT PO-
SITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
BQ:DTC P0346 CAMSHAFT POSITION SENSOR "A" CIRCUIT RANGE/PERFOR-
MANCE (BANK 2)
NOTE:
SITION SENSOR "A" CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR), Diagnostic
GD(H4DOTC)-134

GENERAL DESCRIPTION
BR:DTC P0351 IGNITION COIL A PRIMARY/SECONDARY CIRCUIT

Based on the self-diagnostic result of the ignition coil driving IC, judge the ignition coil driving circuit as normal
or abnormal.
The ignition coil driving IC detects “no ignition” status as a malfunction.
Elapsed time after starting the engine >1s
Ignition energization time > 2000 µs
Ignition status Not during ignition cut

Judgment Value
Ignition driving IC information Malfunction

Judgment Value
Ignition driving IC information Normal

BS:DTC P0352 IGNITION COIL B PRIMARY/SECONDARY CIRCUIT
NOTE:
For the detection standard, refer to DTC P0351. <Ref. to GD(H4DOTC)-135, DTC P0351 IGNITION COIL A
PRIMARY/SECONDARY CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
BT:DTC P0353 IGNITION COIL C PRIMARY/SECONDARY CIRCUIT
NOTE:
BU:DTC P0354 IGNITION COIL D PRIMARY/SECONDARY CIRCUIT
NOTE:
GD(H4DOTC)-135

GENERAL DESCRIPTION
BV:DTC P0365 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 1)

Detect the open or short circuit of the camshaft position sensor.
When there is no camshaft position signal input continuously, judge as NG.

Judge as NG when no input of camshaft position sensor signal in TDC remains for 15 time(s).
Judgment Value
No camshaft position sensor signal input ≥ 15 time(s)
in TDC

Judgment Value
No camshaft position sensor signal input = 0 time(s)
in TDC
GD(H4DOTC)-136

GENERAL DESCRIPTION
BW:DTC P0366 CAMSHAFT POSITION SENSOR B CIRCUIT RANGE/PERFOR-

MANCE (BANK 1)
Detect the malfunction of camshaft position sensor property.
Judge as NG when the number of camshaft signals remains abnormal.

Judge as NG when the status where the number of camshaft position sensor signal in two crankshaft revo-
lutions is other than 2 time(s).
Judgment Value
Amount of camshaft sensor signal during ≠ 2 time(s)
2 revs of crankshaft.
Time Needed for Diagnosis: Two engine revs. × 4 time(s)

Judgment Value
Camshaft position sensor signal = 2 time(s)

BX:DTC P0390 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 2)
NOTE:
SITION SENSOR “B” CIRCUIT (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
BY:DTC P0391 CAMSHAFT POSITION SENSOR B CIRCUIT RANGE/PERFOR-
MANCE (BANK 2)
NOTE:
SITION SENSOR B CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detect-
ing Criteria.>
GD(H4DOTC)-137

GENERAL DESCRIPTION
BZ: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.
Pump supply pressure check
Estimate ambient temperature ≥ 4.4 °C
Atmospheric pressure ≥ 75 kPa (563 mmHg, 22.2 inHg)
Engine In operation
Secondary air pump Operating
Combination valve Bank open (Except with both
banks closed)
Combination valve both closed pulse
diagnosis
Engine In operation
Engine load ≥ 0.2 g/rev (0.01 oz/rev)
Combination valve changeover pres-
sure diagnosis
Engine In operation
Amount of intake air > 2 g/s (0.07 oz/s)
and
< 25 g/s (0.88 oz/s)
Overflow diagnosis
Engine In operation

Perform diagnosis during secondary air pump operation
GD(H4DOTC)-138

GENERAL DESCRIPTION
Measure secondary air delivery pipe pressure, pulse of secondary air delivery pipe pressure and secondary
air pipe airflow amount.
ON
(1)
OFF
(2)
ON
(3)
OFF
OPEN
(4)
CLOSE
OPEN
(5)
CLOSE
(12)
(11) (13)
(6)
(10)
(7)
(8)
(9)
EN-05591
(1) IG (6) Secondary air delivery pipe pres- (10) Barometric pressure (Pas) mea-
sure (psi) surement before secondary air
control
(2) Ne (7) Diagnosis enable condition (11) Right bank all closed pressure
(P0R) measurement
(3) Secondary air pump operating (8) Pump supply pressure check (12) Both banks all closed pressure
status (judgment) (P0RL) measurement
(4) E-COMB valve (right hand) status (9) Flow amount check (judgment) (13) Left bank all closed pressure
(P0L) measurement
(5) E-COMB valve (left hand) status
GD(H4DOTC)-139

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.
Judgment Value
Secondary air supply pipe pressure (after < 0.9 kPa (7 mmHg, 0.3 inHg) P0410
barometric pressure compensation)
Time Needed for Diagnosis: 2000 ms + 2800 ms

cles.
Judgment Value
Secondary air supply pipe pressure (after ≥ 0.9 kPa (7 mmHg, 0.3 inHg) P0410
barometric pressure compensation)
Time Needed for Diagnosis: 2000 ms + 2800 ms

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 delivery pipe pressure when both combination valves are closed. The
calculation 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
Pulse calculation value when both > Value of Map 3 P2440
combination valves are closed
Air flow amount when the right bank is ≥ Air flow amount when the left bank is
closed (value from Map 4) closed (value from Map 5)
Pulse calculation value when both > Value of Map 3 P2442
combination valves are closed
Air flow amount when the left bank is > Air flow amount when the right bank is
closed (value from Map 5) closed (value from Map 4)
Time Needed for Diagnosis: 4000 ms + 992 ms + 992 ms + 992 ms

cles.
GD(H4DOTC)-140

GENERAL DESCRIPTION
Judgment Value
Pulse calculation value when both com- ≤ Value of Map 3 P2440, P2442
bination valves are closed

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.
Judgment Value
Pressure variation value when the RH < Value of Map 6 P2441
combination valve is switched

cles.
Judgment Value
Pressure variation value when the RH ≥ Value of Map 6 P2441

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.
Judgment Value
Pressure variation value when the LH < Value of Map 7 P2443

cles.
GD(H4DOTC)-141

GENERAL DESCRIPTION
Judgment Value
Pressure variation value when the LH combination valve is ≥ Value of Map 7 P2443
switched

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
Air flow amount when the right bank is closed (value from Map 4) > Value of Map 8 P0411
or
Air flow amount when the left bank is closed (value from Map 5) > Value of Map 9
Voltage at P0RL measurement – Voltage at P0R measurement ≤4V

Voltage at P0RL measurement – Voltage at P0L measurement ≤4V
P0RL: Both banks all closed pressure

P0R: Right bank all closed pressure
P0L: Left bank all closed pressure
cles.
Judgment Value
Air flow amount when the right bank is closed (value from Map 4) ≤ Value of Map 8 P0411
or
Air flow amount when the left bank is closed (value from Map 5) ≤ Value of Map 9
Voltage at P0RL measurement – Voltage at P0R measurement ≤4V

Voltage at P0RL measurement – Voltage at P0L measurement ≤4V
P0RL: Both banks all closed pressure

P0R: Right bank all closed pressure
P0L: Left bank all closed pressure
0.1 0.25 0.3 1
Intake air (g (oz)/rev)
(0) (0.01) (0.01) (0.04)
Threshold value (V) 13 13 3.25 3.25
GD(H4DOTC)-142

GENERAL DESCRIPTION

0.1 0.25 0.3 1
Intake air (g (oz)/rev)
(0) (0.01) (0.01) (0.04)
Threshold value (V) 100 100 4.5 4.5
Map 4
Secondary air
pressure in
the pipe when
both comb.
valve is clos-
ing kPa
69.3 74.6 80 85.3 90.6 96 101.3 106.6 112 117.3 122.6 128 133.3 138.6 144 149.3
(mmHg, inHg)
(520, (560, (600, (640, (680, (720, (760, (800, (840, (880, (920, (960, (1000, (1040, (1080, (1120,
Secondary air
20.5) 22) 23.6) 25.2) 26.8) 28.3) 29.9) 31.5) 33.1) 34.6) 36.2) 37.8) 39.4) 40.9) 42.5) 44.1)
pressure in
the pipe when
LH comb.
valve is clos-
ing kPa
(mmHg, inHg)
69.3
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400 2400 2400
(520, 20.5)
74.6
–200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400 2400
(560, 22)
80
–400 –200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400
(600, 23.6)
85.3
–600 –400 –200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400
(640, 25.2)
90.6
–800 –600 –400 –200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
(680, 26.8)
96
–1000 –800 –600 –400 –200 0 200 400 600 800 1000 1200 1400 1600 1800 2000
(720, 28.3)
101.3
–1200 –1000 –800 –600 –400 –200 0 200 400 600 800 1000 1200 1400 1600 1800
(760, 29.9)
106.6
–1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600 800 1000 1200 1400 1600
(800, 31.5)
112
–1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600 800 1000 1200 1400
(840, 33.1)
117.3
–1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600 800 1000 1200
(880, 34.6)
122.6
–2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600 800 1000
(920, 36.2)
128
–2200 –2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600 800
(960, 37.8)
133.3
–2400 –2200 –2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600
(1000, 39.4)
138.6
–2400 –2400 –2200 –2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400
(1040, 40.9)
144
–2400 –2400 –2400 –2200 –2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200
(1080, 42.5)
149.3
–2400 –2400 –2400 –2400 –2200 –2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0
(1120, 44.1)
(L/min)
GD(H4DOTC)-143

GENERAL DESCRIPTION
Map 5
Secondary air
pressure in
the pipe when
both comb.
valve is clos-
ing kPa
69.3 74.6 80 85.3 90.6 96 101.3 106.6 112 117.3 122.6 128 133.3 138.6 144 149.3
(mmHg, inHg)
(520, (560, (600, (640, (680, (720, (760, (800, (840, (880, (920, (960, (1000, (1040, (1080, (1120,
Secondary air
20.5) 22) 23.6) 25.2) 26.8) 28.3) 29.9) 31.5) 33.1) 34.6) 36.2) 37.8) 39.4) 40.9) 42.5) 44.1)
pressure in
the pipe when
RH comb.
valve is clos-
ing kPa
(mmHg, inHg)
69.3
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400 2400 2400
(520, 20.5)
74.6
–200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400 2400
(560, 22)
80
–400 –200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2400
(600, 23.6)
85.3
–600 –400 –200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400
(640, 25.2)
90.6
–800 –600 –400 –200 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
(680, 26.8)
96
–1000 –800 –600 –400 –200 0 200 400 600 800 1000 1200 1400 1600 1800 2000
(720, 28.3)
101.3
–1200 –1000 –800 –600 –400 –200 0 200 400 600 800 1000 1200 1400 1600 1800
(760, 29.9)
106.6
–1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600 800 1000 1200 1400 1600
(800, 31.5)
112
–1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600 800 1000 1200 1400
(840, 33.1)
117.3
–1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600 800 1000 1200
(880, 34.6)
122.6
–2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600 800 1000
(920, 36.2)
128
–2200 –2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600 800
(960, 37.8)
133.3
–2400 –2200 –2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400 600
(1000, 39.4)
138.6
–2400 –2400 –2200 –2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200 400
(1040, 40.9)
144
–2400 –2400 –2400 –2200 –2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0 200
(1080, 42.5)
149.3
–2400 –2400 –2400 –2400 –2200 –2000 –1800 –1600 –1400 –1200 –1000 –800 –600 –400 –200 0
(1120, 44.1)
(L/min)
GD(H4DOTC)-144

GENERAL DESCRIPTION
Map 6
Amount of intake air when RH comb. valve
switches (g (oz)/s) 10 15 20 25 26
Battery voltage when RH comb. valve (0.35) (0.53) (0.71) (0.88) (0.92)
switches (V)
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 7
Amount of intake air when LH comb. valve
switches (g (oz)/s) 10 15 20 25 26
Battery voltage when LH comb. valve (0.35) (0.53) (0.71) (0.88) (0.92)
switches (V)
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 8
Amount of intake air when P0R is measuring
2 25
(g (oz)/s)
(0.07) (0.88)
Battery voltage when P0R measuring (V)
11.5 345 345
12.5 345 345
13.5 345 345
14.5 390 390
15.5 420 420
(L/min)
Map 9
Amount of intake air when P0L is measuring
2 25
(g (oz)/s)
(0.07) (0.88)
Battery voltage when P0L measuring (V)
11.5 345 345
12.5 345 345
13.5 345 345
14.5 390 390
15.5 420 420
(L/min)
CA:DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW DE-

TECTED
NOTE:
For the detection standard, refer to DTC P0410. <Ref. to GD(H4DOTC)-138, DTC P0410 SECONDARY AIR
INJECTION SYSTEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-145

GENERAL DESCRIPTION
CB:DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE “A”

CIRCUIT OPEN
Judge as NG when the ECM output level differs from the actual terminal level.
None

Judgment Value
Ignition ON
Terminal output voltage when ECM outputs LOW
OFF signal

Judgment Value
Ignition ON
Terminal output voltage when ECM outputs HIGH
OFF signal
GD(H4DOTC)-146

GENERAL DESCRIPTION
CC:DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE “A”

CIRCUIT SHORTED
None

Judgment Value
Ignition ON
ON signal

Judgment Value
Ignition ON
ON signal

CD: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.>
CE: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)-147

GENERAL DESCRIPTION
CF: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) (2)
(A) (3)
(B) (3)
(C) (D)
EN-01713
(A) Normal (B) Deterioration (C) Output waveform from the front
oxygen (A/F) sensor
(D) Output waveform from the front
oxygen sensor
(1) Front oxygen (A/F) sensor (2) Front oxygen sensor (3) Catalytic converter
GD(H4DOTC)-148

GENERAL DESCRIPTION
Engine coolant temperature ≥ 68.5 °C (155.3 °F) (models without SI-DRIVE)
≥ 70 °C (158 °F) (models with SI-DRIVE)
Estimated catalyst temperature ≥ 460 °C (860 °F) (models without SI-DRIVE)
≥ 490 °C (914 °F) (models with SI-DRIVE)
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 ≥ 1000 ms
lambda and target lambda
Vehicle speed > 60 km/h (37.3 MPH)
and
< 50 g/s (1.76 oz/s)
Engine load change every 0.5 engine revs. < 0.02 g/rev (0 oz/rev)
Rear oxygen output change from 660 mV or Experienced after fuel cut
less to 660 mV or more
Elapsed time after starting the engine ≥ Value from Map
Purge execution calculated time ≥5s
Map (models without SI-DRIVE)

Engine coolant temperature –30 –20 –10 0 10 20
°C (°F) (–22) (–4) (14) (32) (50) (68)
Elapsed time after starting the engine
470 430 390 350 310 213
s
Map (models with SI-DRIVE)

Engine coolant temperature –30 –20 –10 0 10 20
°C (°F) (–22) (–4) (14) (32) (50) (68)
Elapsed time after starting the engine
470 430 390 350 310 230
s

Perform the diagnosis only once at a constant speed of 60 km/h (37.3 MPH) or higher.
GD(H4DOTC)-149

GENERAL DESCRIPTION
After the enable conditions have been established, calculate the front oxygen (A/F) sensor lambda value de-
viation sum value (Σ |(sglmdn – sglmdn–1)|), and rear oxygen sensor output voltage deviation sum value (Σ
|(ro2sadn – ro2sadn–1)|) in every 32 ms × 4 times. If the front oxygen (A/F) sensor lambda value deviation
sum value (Σ |(sglmdn – sglmdn–1)|) is the predetermined value or more, calculate the diagnostic value.
If the duration of time while the following conditions are met is within the time indicated, judge as NG.
Judgment Value
Σ |(ro2sadn – ro2sadn–1)| / Σ |(sglmdn – sglmdn–1)| > 7.94 (Models without SI-DRIVE)
> 8 (Models with SI-DRIVE)

cles.
Judge as OK and clear the NG if the continuous time while the following conditions are established is within
the predetermined time.
Judgment Value
Σ |(ro2sadn – ro2sadn–1)| / Σ |(sglmdn – sglmdn–1)| ≤ 7.94 (Models without SI-DRIVE)
≤ 8 (Models with SI-DRIVE)
GD(H4DOTC)-150

GENERAL DESCRIPTION
CG:DTC P0441 EVAPORATIVE EMISSION CONT. SYS. INCORRECT PURGE

FLOW
Detect the malfunction of purge flow by the change of ELCM pressure sensor output value before/after purge
introduction.
<Common conditions>
Atmospheric pressure > 75 kPa (563 mmHg, 22.2 inHg)
<First diagnosis>
Learning value of EVAP conc. during purge < 0.2
Total time of canister purge operation ≥ 120 s
<Second diagnosis>
Time after cancel of second diagnosis ≥ 60000 ms
Total time of canister purge operation ≥ 120 s
Intake manifold pressure (absolute pressure) > 13.3 kPa (100 mmHg, 3.9 inHg)
Intake manifold pressure (relative pressure) < 13.3 kPa (100 mmHg, 3.9 inHg)
Closed air/fuel ratio control In operation
Air fuel ratio > 0.76
and
< 1.25
Main feedback compensation coefficient > 0.9
Learning value of EVAP conc. during purge < 0.2

Perform the diagnosis only once after engine start.
GD(H4DOTC)-151

GENERAL DESCRIPTION
First diagnosis
Pressure decreases when the purge is introduced compared with when the purge is not performed. By using
this, judge if the purge is correctly performed. If there is no pressure decrease, go to the second diagnosis.
purge duty
Malfunction
Evap. Pressure
(1)
cpfokt measuring time OK
OK
(2)
cpfokt (timer)
Malfunction
EN-08947
(1) 0.0045 V (2) 2000 ms
Judgment Value
ELCM pressure sensor output voltage > 0.0045 V
when purge is not performed – ELCM
pressure sensor output voltage when
purge is performed
The accumulated time while the above < 2000 ms
conditions are met: cpfokt

Judgment Value
ELCM pressure sensor output voltage > 0.0045 V
when purge is not performed – ELCM
purge is performed
The accumulated time while the above ≥ 2000 ms
conditions are met: cpfokt
GD(H4DOTC)-152

GENERAL DESCRIPTION
Second diagnosis
Close the ELCM switching valve, and close the fuel tank completely, and perform the forced purging. If pres-
sure change amount is 0.7 kPa (5 mmHg, 0.2 inHg) or less, judge as malfunction of purge flow.
monitoring
purge duty
ON (Close)
Switching Valve Malfunction
Evap. Pressure
OK
(1)
EN-08948
(1) 0.7 kPa (5 mmHg, 0.2 inHg)
Judgment Value
ELCM pressure sensor output voltage < 0.7 kPa (5 mmHg,
when purge is not performed – ELCM 0.2 inHg)
purge is performed
Time of negative pressure introduction ≥ 30000 ms

cles.
Judgment Value
ELCM pressure sensor output voltage ≥ 0.7 kPa (5 mmHg,
when purge is not performed – ELCM 0.2 inHg)
purge is performed
GD(H4DOTC)-153

GENERAL DESCRIPTION
CH:DTC P0451 EVAPORATIVE EMISSION SYSTEM PRESSURE SENSOR/

SWITCH RANGE/PERFORMANCE
Detect the malfunction of ELCM pressure sensor output properties.
Judge as NG when the ELCM pressure sensor output value is largely different from the intake manifold pres-
sure when the ignition switch is ON.
(1) (2)
(7) (8)
(3) (10)
M (9)
(4) (5) (6)
EN-08957
(1) ELCM (5) Vacuum pump (9) Fuel tank

(2) Switching valve (6) Drain filter (10) Canister
(3) Reference orifice (0.02 inch ori- (7) Purge control solenoid valve
fice)
(4) Pressure sensor (8) Intake manifold
Ignition switch ON
Vehicle speed < 1 km/h (0.621 MPH)
Soaking time ≥ 60 s
Variation value of intake manifold pressure < 1.332 kPa (9.99 mmHg, 0.39 inHg)
(absolute pressure) since ignition switch is
turned to ON
ELCM vacuum pump Not in operation
ELCM switching valve Open
Purge control Not in operation

Perform the diagnosis once at ignition ON.
GD(H4DOTC)-154

GENERAL DESCRIPTION
Judgment Value
|ELCM pressure sensor output value – intake > 4.226 kPa (31.7 mmHg, 1.25 inHg)
manifold pressure (absolute pressure) when
ignition switch is ON|

cles.
Judgment Value
|ELCM pressure sensor output value – intake ≤ 4.226 kPa (31.7 mmHg, 1.25 inHg)
manifold pressure (absolute pressure) when
ignition switch is ON|
GD(H4DOTC)-155

GENERAL DESCRIPTION
CI: DTC P0452 EVAPORATIVE EMISSION SYSTEM PRESSURE SENSOR/

SWITCH LOW
Detect the open or short circuit of the ELCM pressure sensor.
(1) (2)
(7) (8)
(3) (10)
M (9)
(4) (5) (6)
EN-08957

fice)
None

Judgment Value

GD(H4DOTC)-156

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-157

GENERAL DESCRIPTION
CJ:DTC P0453 EVAPORATIVE EMISSION SYSTEM PRESSURE SENSOR/

SWITCH HIGH
Detect the open or short circuit of the ELCM pressure sensor.
(1) (2)
(7) (8)
(3) (10)
M (9)
(4) (5) (6)
EN-08957

fice)
None

Judgment Value

GD(H4DOTC)-158

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-159

GENERAL DESCRIPTION
CK:DTC P0455 EVAPORATIVE EMISSION SYSTEM LEAK DETECTED (LARGE

LEAK)
This diagnosis judges whether the ELCM operation is normal or not, and whether the evaporative emission
system has leak and clogging or not.
To purge the canister, after driving, perform the five hours soaking after ignition switch OFF in order to sta-
bilize the evaporative gas status. * After 5, 7 or 9.5 hours passed, ECM is activated by soaking timer, and the
leak check is started.
Judges whether the ELCM operation is normal or not, by measuring the reference pressure status via refer-
ence orifice (0.02 inch orifice). Judge as malfunction if the reference pressure is out of specified range. Then,
judge whether there is a leak or not, by comparing the pressure (leak pressure) when the reference pressure
and the evaporative emission system are in negative pressure condition. Judge as system leak in the evap-
orative emission system if the leak pressure is higher than reference pressure. Judge as clogging of pipe if
the leak pressure becomes lower than the reference pressure within the specified amount of time.
0.02 inch leak and 0.04 inch leak can be distinguished by measuring the leak pressure.
The diagnosis results are stored inside ECM until the engine is started again.
*: When the test conditions are not met in 5 hours, perform diagnosis at elapsed time of 7 hours. When the
test conditions are not met in 7 hours, perform diagnosis at elapsed time of 9.5 hours.
Diagnostic item
ELCM system (ELCM body) Vacuum pump stuck
Switching valve stuck to open
Switching valve stuck to close
Reference orifice flow large
Reference orifice flow small
Leak check Large leak
• 0.04 inch leak
• Fuel cap loose
• Fuel cap off
• System malfunction
Very small leak
• 0.02 inch leak
Clogging of pipe —
OUTLINE OF DIAGNOSIS
5 hours after ignition switch turned off.
ON
OFF
ECM
ON
OFF
Vacuum Pump
ON:Evap. side
OFF:Orifice side
Switching Valve
Leak detection pump stuck Large leak
Pressure Sensor
Vent valve stuck close

Very small leak
Pref
Reference orifice high flow
Pipe clogging Pref

Reference orifice low flow Vent valve stuck open Pleak
EN-08949
GD(H4DOTC)-160

GENERAL DESCRIPTION
ELCM consists of the pressure sensor, the reference orifice (diameter of 0.02 inch), the vacuum pump which
introduces the negative pressure into evaporative emission system, and the switching valve which switches
the passage to introduce the negative pressure.
(1) (2)
(7) (8)
(3) (10)
M (9)
(4) (5) (6)
EN-08957

fice)
Activation of soaking timer Completed
Ignition switch OFF
Engine coolant temperature ≥ 4.4 °C (39.9 °F)
and
< 45 °C (113 °F)
and
< 110 kPa (825 mmHg, 32.5 inHg)
EVAP conc. learning during previous driving Done
cycle
Learning value of EVAP conc. during previ- ≤ 0.2
ous driving cycle
Accumulated purge amount during previous ≥ Value of Map 1
driving cycle
Map 1
Engine coolant temperature
0 (32) 30 (86) 45 (113)
°C (°F)
Accumulated purge amount during previous driving cycle 3000 3000 10000
g (oz) (105.81) (105.81) (352.7)
GD(H4DOTC)-161

GENERAL DESCRIPTION

Perform the diagnosis only once when 5, 7 or 9.5 hours has passed after ignition switch is OFF. For more de-
tail, refer to “OUTLINE OF DIAGNOSIS”. <Ref. to GD(H4DOTC)-160, OUTLINE OF DIAGNOSIS, DTC
P0455 EVAPORATIVE EMISSION SYSTEM LEAK DETECTED (LARGE LEAK), Diagnostic Trouble Code
Activated by soak timer
ON
OFF
ECM
ON
OFF
Vacuum Pump
ON:Evap. side
OFF:Orifice side
Switching Valve
Pressure Sensor
Judge the leak is occurred or

not by comparing the pressures.
Evap. System
target pressure calculation
Mode
A B C D E
EN-08950
Mode Explanation of Mode Diagnosis Period

A Vacuum pump operation confirmation and characteristics 7 s or less & 300 s
stability
B Measurement of reference pressure for setting the target 40 s or less
negative pressure
C Switching valve operation confirmation 12 s or less
D Clogging of pipe diagnosis and leak pressure measurement 900 s or less
E Reference pressure measurement for judgment 40 s or less
ENABLE satisfied Mode OK Mode OK Mode OK Mode OK Mode OK

CONDITION END
A B C D E
NG NG NG NG NG
not satisfied
EN-08956
GD(H4DOTC)-162

GENERAL DESCRIPTION
Mode A (Vacuum pump operation confirmation and characteristics stability)

Purpose: Detect the vacuum pump operation trouble.
Judge as OK if the following conditions are not established, and warm up for five minutes to stabilize the vac-
uum pump characteristics.
Judgment Value
Pressure sensor output value > –0.2 kPa (–1.68 mmHg, –0.1 inHg) P2404
Mode B (Measurement of reference pressure for setting the target negative pressure)
1. Purpose: Judge the reference pressure stability.
Judgment Value
|Pressure sensor maximum output value – Pressure > 0.3 kPa (2.355 mmHg, 0.1 inHg) P2404
sensor minimum output value|
2. Purpose: Judge whether the reference pressure is within the normal range, and detect the vacuum pump
and orifice malfunctions.
Judgment Value
Reference pressure for setting the target negative < Value of Map 2 P2404
pressure or
> Value of Map 3
Map 2
Atmospheric pressure
70 (525, 20.7) 80 (600, 23.6) 90 (675, 26.6) 100 (750, 29.5)
kPa (mmHg, inHg)
Reference pressure for setting the target
negative pressure –4 (–29.79, –1.2) –4.1 (–30.593, –1.2) –4.2 (–31.395, –1.2) –4.3 (–32.19, –1.3)
kPa (mmHg, inHg)
Map 3
70 (525, 20.7) 80 (600, 23.6) 90 (675, 26.6) 100 (750, 29.5)
kPa (mmHg, inHg)
Reference pressure for setting the target
negative pressure –0.9 (–7.065, –0.3) –1 (–7.86, –0.3) –1.2 (–8.663, –0.3) –1.3 (–9.465, –0.4)
kPa (mmHg, inHg)
Mode C (Switching valve operation confirmation)

Purpose: Measure the pressure increase when switching valve is changed from open to close, and detect the
stuck to open/close malfunctions of the switching valve.
Judgment Value
Pressure sensor output value – Reference pressure < 0.2 kPa (1.68 mmHg, 0.1 inHg) P2404
for setting the target negative pressure
GD(H4DOTC)-163

GENERAL DESCRIPTION
Mode D (Clogging of pipe diagnosis and leak pressure measurement)

1. Clogging of pipe
Purpose: Measure the time required for the evaporative emission system to reach the target negative
pressure by the vacuum pump, and detect the clogging of pipe trouble.
Judge as clogging of pipe malfunction if the evaporative emission system reaches to the target negative
pressure within the specified time.
Judgment Value
Time required to reach to the target negative pressure ≤ 30000 ms P1451
For target vacuum, use one of the followings.
•Reference pressure for target vacuum setting – value of Map 4
•–5 kPa (–37.298 mmHg, –1.5 inHg)
Map 4
Time of nega-
tive pressure
0 100000 200000 300000 400000 500000 600000 700000 800000 900000 1000000 1100000 1200000
introduction
ms
Reference
pressure for
setting the
target nega-
0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9
tive pressure
(7.058, (7.058, (7.058, (7.058, (7.058, (7.058, (7.058, (7.058, (7.058, (7.058, (7.058, (7.058, (7.058,
– Pressure
0.3) 0.3) 0.3) 0.3) 0.3) 0.3) 0.3) 0.3) 0.3) 0.3) 0.3) 0.3) 0.3)
sensor out-
put value
kPa (mmHg,
inHg)
2. Leak pressure measurement

Purpose: Measure the pressure (leak pressure) when the evaporative emission system becomes the neg-
ative pressure by the vacuum pump.
Store the pressure as a leak pressure while the following conditions are met.
Judgment Value
Conditions for storing the leak pressure Threshold Value
• Reference pressure for setting the target negative ≥ Value of Map 4
pressure – Pressure sensor output value
• Pressure sensor output value < –5 kPa (–37.298 mmHg, –1.5 inHg)
• Time of negative pressure introduction ≥ 900000 ms
Mode E (Measurement of reference pressure for judgment)

1. Purpose: Judge the reference pressure stability.
Judgment Value
|Pressure sensor maximum output value – > 0.3 kPa (2.355 mmHg, 0.1 inHg) P2404
Pressure sensor minimum output value|
GD(H4DOTC)-164

GENERAL DESCRIPTION
2. Purpose: Judge whether the reference pressure is within the normal range, and detect the vacuum pump
and orifice malfunctions. Judge the vacuum pump performance stability.
Judgment Value
Reference pressure for judgment < Value of Map 5 P2404
or
> Value of Map 6
Map 5
70 (525, 20.7) 80 (600, 23.6) 90 (675, 26.6) 100 (750, 29.5)
kPa (mmHg, inHg)
Reference pressure for judgment
–4.5 (–34.02, –1.3) –4.6 (–34.815, –1.4) –4.7 (–35.618, –1.4) –4.9 (–36.42, –1.4)
kPa (mmHg, inHg)
Map 6
70 (525, 20.7) 80 (600, 23.6) 90 (675, 26.6) 100 (750, 29.5)
kPa (mmHg, inHg)
Reference pressure for judgment
–0.8 (–6.18, –0.2) –0.9 (–6.983, –0.3) –1 (–7.785, –0.3) –1.1 (–8.58, –0.3)
kPa (mmHg, inHg)
3. Purpose: Judge the presence of evaporative emission system leak.

Judgment Value
<Large leak (0.04 inch)> P0455
Leak pressure ≥ lleakjdg (Pa)
lleakjdg = (Reference pressure for judgment) × 0.377 – (–45.5 Pa)

<Very small leak (0.02 inch)> P0456
Leak pressure < lleakjdg (Pa)
Time Needed for Diagnosis: Approx. 23 min

At next engine start, confirm whether the enable conditions are satisfied even though refueling has been
done during soaking, and determine the malfunction.
Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
At next engine start, confirm whether the enable conditions are satisfied even though refueling has been
done during soaking, then, if the following conditions are established, judge as OK and clear the NG.
Judgment Value
NG flag Not set P0455
P0456
P1451
P2404
CL:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECT-

ED (VERY SMALL LEAK)
NOTE:
For the detection standard, refer to DTC P0455. <Ref. to GD(H4DOTC)-160, DTC P0455 EVAPORATIVE
EMISSION SYSTEM LEAK DETECTED (LARGE LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-165

GENERAL DESCRIPTION
CM:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT LOW
Detect open or short circuit of the purge control solenoid valve.
(B) (A)
EN-02197
(A) To canister (B) To intake manifold

Always perform the diagnosis after starting the engine.
Judgment Value
Duty ratio of “ON” < 0.75

cles.
GD(H4DOTC)-166

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-167

GENERAL DESCRIPTION
CN:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT HIGH
Detect open or short circuit of the purge control solenoid valve.
(B) (A)
EN-02197
(A) To canister (B) To intake manifold

Judgment Value
Duty ratio of “ON” ≥ 0.25

cles.
GD(H4DOTC)-168

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-169

GENERAL DESCRIPTION
CO:DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE

Detect malfunctions of the fuel level sensor output property.
If the fuel level does not vary in a particular driving condition / engine condition where it should, judge as NG.
(A)
0 (B)
EN-01734
(A) Fuel level (B) Resistance
None

GD(H4DOTC)-170

GENERAL DESCRIPTION
Judgment Value
Accumulated amount of intake air ≥ 165375 g (5832.78 oz)
Max. – min. values of fuel level output < 2.6 2 (0.69 US gal, 0.57 Imp gal)

cles.
Judgment Value
Accumulated amount of intake air ≥ 165375 g (5832.78 oz)
Max. – min. values of fuel level output ≥ 2.6 2 (0.69 US gal, 0.57 Imp gal)
GD(H4DOTC)-171

GENERAL DESCRIPTION
CP: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.
(1) (5)
(4)
(2) (3)
EN-05371
(1) Engine control module (ECM) (3) Fuel sub level sensor (5) Body integrated unit
(2) Fuel level sensor (4) Detecting circuit
None

Judgment Value

cles.
GD(H4DOTC)-172

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-173

GENERAL DESCRIPTION
CQ:DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH

Detect the open or short circuit of fuel level sensor. Judge as NG if out of specification.
(1) (5)
(4)
(2) (3)
EN-05371
(1) Engine control module (ECM) (3) Fuel sub level sensor (5) Body integrated unit
(2) Fuel level sensor (4) Detecting circuit
None

Judgment Value

cles.
GD(H4DOTC)-174

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-175

GENERAL DESCRIPTION
CR:DTC P04AC EVAP SYSTEM PURGE CONTROL VALVE "B" CIRCUIT LOW
Detect open or short circuit of the purge control solenoid valve 2.
None

Judgment Value
Elapsed time after starting the engine ≥1s
Terminal output voltage when ECM outputs Low
OFF signal

cles.
Judgment Value
Terminal output voltage when ECM outputs High
OFF signal
GD(H4DOTC)-176

GENERAL DESCRIPTION
CS:DTC P04AD EVAP SYSTEM PURGE CONTROL VALVE "B" CIRCUIT HIGH
Detect open or short circuit of the purge control solenoid valve 2.
None

Judgment Value
ON signal

cles.
Judgment Value
ON signal
GD(H4DOTC)-177

GENERAL DESCRIPTION
CT:DTC P04DB CRANKCASE VENTILATION SYSTEM DISCONNECTED

Detect the blow-by hose disconnection abnormality.
Judge as NG when the diagnosis terminal voltage is high.
(1) (4)
(2)
(3)
EN-01790
(1) Engine control module (ECM) (3) PCV diagnosis connector (4) 5V
(2) Detecting circuit
None

Judgment Value
Engine condition After engine starting
Positive crankcase ventilation diagnosis High
voltage

GD(H4DOTC)-178

GENERAL DESCRIPTION
Judgment Value
Positive crankcase ventilation diagnosis Low
voltage
GD(H4DOTC)-179

GENERAL DESCRIPTION
CU:DTC P0500 VEHICLE SPEED SENSOR “A”

Judge as NG when outside of the judgment value.
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.
Elapsed time after engine starting ≥ 2000 ms

Always perform diagnosis more than 2000 ms after starting the engine.
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(H4DOTC)-180

GENERAL DESCRIPTION
CV: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.
Elapsed time after starting the engine ≥ 10.49 s
Feedback of ISC In operation
Lambda value (left and right) ≥ 0.9
and
< 1.1
After switching air conditioner to ON/OFF ≥ 5.1 s
After intake manifold pressure changes by 4 kPa > 5.1 s
(30 mmHg, 1.2 inHg) or more.
Elapsed time after switching neutral position > 5.1 s
switch to ON/OFF
Vehicle speed 0 km/h (0 MPH)

Perform the diagnosis continuously at idling after warming up engine.
Judgment Value
Actual engine speed – Targeted engine < –100 rpm
speed
Feedback compensation for ISC Max.

cles.
Judgment Value
Actual engine speed – Targeted engine ≥ –100 rpm
speed
GD(H4DOTC)-181

GENERAL DESCRIPTION
CW:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER 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.
Elapsed time after starting the engine ≥ 10.49 s
Feedback of ISC In operation
Lambda value (left and right) ≥ 0.9
and
< 1.1
After switching air conditioner to ON/ ≥ 5.1 s
OFF
After intake manifold pressure changes > 5.1 s
by 4 kPa (30 mmHg, 1.2 inHg) or more.
Elapsed time after switching neutral > 5.1 s
position switch to ON/OFF
Vehicle speed 0 km/h (0 MPH)

Perform the diagnosis continuously at idling after warming up engine.
Judgment Value
Actual engine speed – Targeted engine ≥ 200 rpm
speed
Feedback compensation for ISC Min.

cles.
Judgment Value
Actual engine speed – Targeted engine < 200 rpm
speed
GD(H4DOTC)-182

GENERAL DESCRIPTION
CX:DTC P050A COLD START IDLE AIR CONTROL SYSTEM PERFORMANCE

• When cold, the abnormality in the control of target engine speed increase is detected. (P050A)
Judge as NG if the exhaust gas temperature diagnosis or idle speed diagnosis 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 at cold start.
• Detect malfunctions of the catalyst advanced idling retard angle control. (P050B)
Judge as NG when ECM is not controlling the angle properly during catalyst advanced idling retard angle
control.
• Final ignition timing diagnosis
Judge as NG when actual retard amount is under the specified value at cold start.
<Exhaust gas temperature diagnosis>
Engine condition In operation
Vehicle speed ≤ 2 km/h (1.2 MPH)
Elapsed time after gear position change ≥ 3000 ms
(P ←→ D or N ←→ D)
ISC feedback In operation
Fuel property Not extremely low volatility
Target retard amount ≥ 5 °CA
<Idle speed diagnosis>
Intake air amount sum value ≤ Value of Map 1
(P ←→ D or N ←→ D)
<Final ignition timing diagnosis>
Intake air amount sum value ≤ Value of Map 2
(P ←→ D or N ←→ D)
Target retard amount ≥ Value from Map 3
GD(H4DOTC)-183

GENERAL DESCRIPTION

Engine coolant temperature at engine starting –40 –30 –20 –10 0 10 20 30
°C (°F) (–40) (–22) (–4) (14) (32) (50) (68) (86)
Intake air amount sum value 1240 1170 1100 1040 980 570 280 265
g (oz) (43.73) (41.27) (38.8) (36.68) (34.56) (20.1) (9.88) (9.35)
Engine coolant temperature at engine starting 40 50 60 70 80 90 100 110

°C (°F) (104) (122) (140) (158) (176) (194) (212) (230)
g (oz) (8.82) (7.41) (7.41) (7.41) (7.41) (7.41) (7.41) (7.41)

°C (°F) (–40) (–22) (–4) (14) (32) (50) (68) (86)
g (oz) (33.51) (32.62) (31.74) (30.68) (29.63) (21.87) (14.81) (10.93)

°C (°F) (104) (122) (140) (158) (176) (194) (212) (230)
Intake air amount sum value 260 210
170 (6) 170 (6) 170 (6) 170 (6) 170 (6) 170 (6)
g (oz) (9.17) (7.41)

°C (°F) (–40) (–22) (–4) (14) (32) (50) (68) (86)
g (oz) (43.73) (41.27) (38.8) (36.68) (34.56) (20.1) (9.88) (9.35)

°C (°F) (104) (122) (140) (158) (176) (194) (212) (230)
g (oz) (8.82) (7.41) (7.41) (7.41) (7.41) (7.41) (7.41) (7.41)

°C (°F) (–40) (–22) (–4) (14) (32) (50) (68) (86)
g (oz) (33.51) (32.62) (31.74) (30.68) (29.63) (21.87) (14.81) (10.93)

°C (°F) (104) (122) (140) (158) (176) (194) (212) (230)
Intake air amount sum value 260 210
170 (6) 170 (6) 170 (6) 170 (6) 170 (6) 170 (6)
g (oz) (9.17) (7.41)
Map 3
Engine coolant –40 °C –30 °C –20 °C –10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C 60 °C
temperature (–40 °F) (–22 °F) (–4 °F) (14 °F) (32 °F) (50 °F) (68 °F) (86 °F) (104 °F) (122 °F) (140 °F)
Target retard
6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA
amount

Perform the diagnosis at cold start.
GD(H4DOTC)-184

GENERAL DESCRIPTION
• Exhaust gas temperature diagnosis
Calculate the estimated exhaust gas temperature when the diagnostic enable condition is established. Judge
as NG when the following conditions are established.
Judgment Value
Estimated exhaust gas temperature < Value of Map 4

Engine coolant
–40 °C –30 °C –20 °C –10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 45 °C
temperature at
(–40 °F) (–22 °F) (–4 °F) (14 °F) (32 °F) (50 °F) (68 °F) (86 °F) (104 °F) (113 °F)
engine starting
200 °C 200 °C 200 °C 200 °C 80 °C 83 °C 81 °C 75 °C 74 °C 71 °C
Threshold Value
(392 °F) (392 °F) (392 °F) (392 °F) (176 °F) (181.4 °F) (177.8 °F) (167 °F) (165.2 °F) (159.8 °F)

Engine coolant
–40 °C –30 °C –20 °C –10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 45 °C
temperature at
(–40 °F) (–22 °F) (–4 °F) (14 °F) (32 °F) (50 °F) (68 °F) (86 °F) (104 °F) (113 °F)
engine starting
200 °C 200 °C 200 °C 200 °C 80 °C 78 °C 79 °C 82 °C 79 °C 75 °C
Threshold Value
(392 °F) (392 °F) (392 °F) (392 °F) (176 °F) (172.4 °F) (174.2 °F) (179.6 °F) (174.2 °F) (167 °F)

cles.
Normality Judgment
Judgment Value
Estimated exhaust gas temperature ≥ Value of Map 4

• Idle speed diagnosis
Judgment Value
Actual engine speed – Target engine < – 125 rpm
speed

cles.
Normality Judgment
Judgment Value
Actual engine speed – Target engine ≥ – 125 rpm
speed
GD(H4DOTC)-185

GENERAL DESCRIPTION
• Final ignition timing diagnosis

Judgment Value
Final ignition timing – ignition timing dur- > Value of Map 5
ing CSERS*
*: Ignition timing during CSERS (Cold
Start Emission Reduction Strategy) =
Base ignition timing – retard amount
Map 5
Engine coolant –40 °C –30 °C –20 °C –10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C 60 °C
temperature (–40 °F) (–22 °F) (–4 °F) (14 °F) (32 °F) (50 °F) (68 °F) (86 °F) (104 °F) (122 °F) (140 °F)
Threshold
6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA 6 °CA
Value

cles.
Normality Judgment
Judgment Value
Final ignition timing – ignition timing during CSERS* ≤ Value of Map 5
*: Ignition timing during CSERS (Cold Start Emission
Reduction Strategy) = Base ignition timing – retard amount

CY:DTC P050B COLD START IGNITION TIMING PERFORMANCE
NOTE:
For the detection standard, refer to DTC P050A. <Ref. to GD(H4DOTC)-183, DTC P050A COLD START
IDLE AIR CONTROL SYSTEM PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-186

GENERAL DESCRIPTION
CZ:DTC P0513 INCORRECT IMMOBILIZER KEY

DTC Item OUTLINE OF DIAGNOSIS
P0513 Incorrect Immobilizer Key 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 Communication failure between body integrated unit and ECM
Antenna Circuit)
P1574 Key Communication Failure 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 combination meter and
body integrated unit
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.
GD(H4DOTC)-187

GENERAL DESCRIPTION
DA:DTC P0560 SYSTEM VOLTAGE

Detect the open/short circuit of back-up power supply circuit.
Judge as NG when the backup power voltage is low.
None

Judgment Value
Voltage of back-up power supply Low

Judgment Value
Voltage of back-up power supply High
GD(H4DOTC)-188

GENERAL DESCRIPTION
DB: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.
None
Diagnosis with the initial routine.

Perform the diagnosis as soon as the ignition switch is turned to ON.
Judgment Value
Write the specified value into the RAM. The written value cannot
be read.

Judgment Value
Write the specified value into the RAM. The written value can be
read.
GD(H4DOTC)-189

GENERAL DESCRIPTION
DC:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)

ERROR
Judge as NG when SUM value of ROM is outside the standard value.
Ignition switch ON

Judge as NG if the criteria below are met.
Judgment Value
SUM value of ROM Standard
Time Needed for Diagnosis: Undetermined

GD(H4DOTC)-190

GENERAL DESCRIPTION
DD:DTC P0606 CONTROL MODULE PROCESSOR

Judge as NG when any one of the followings is established.
(1) If the CPU operation is abnormal (instruction/flow check).
(2) If the output IC operation is abnormal (output driver malfunction).
(9) (1)
(2)
(8) (7)
(12) (10)
(3)
(7)
(4)
(5)
(7)
(13) (11)
(6)
(7)
EN-08016
(1) Throttle position sensor (6) Accelerator pedal position sensor 2 (10) CPU
(2) Throttle position sensor 1 (7) I/F circuit (11) Monitoring IC
(3) Throttle position sensor 2 (8) Amplifier circuit (12) EEPROM
(4) Accelerator pedal position sensor (9) Engine control module (ECM) (13) Output IC
(5) Accelerator pedal position sensor 1
(1) Ignition switch ON
(1) ETC control Permission
(2) Ignition switch ON
(2) Battery voltage ≥ 10.9 V

GD(H4DOTC)-191

GENERAL DESCRIPTION
Judgment Value
(1) Main CPU calculation result The result and expected
value match.
(2) Communication between output ICs Possible to communicate

(1): 192 ms
(2): 2500 ms
GD(H4DOTC)-192

GENERAL DESCRIPTION
DE:DTC P060A INTERNAL CONTROL MODULE MONITORING PROCESSOR

PERFORMANCE
Judge as NG when the monitoring IC operation is abnormal. (Monitoring IC malfunction)
(9) (1)
(2)
(8) (7)
(12) (10)
(3)
(7)
(4)
(5)
(7)
(13) (11)
(6)
(7)
EN-08016

GD(H4DOTC)-193

GENERAL DESCRIPTION
Judgment Value
Monitoring IC operation The result and
expected value match.

GD(H4DOTC)-194

GENERAL DESCRIPTION
DF:DTC P060B INTERNAL CONTROL MODULE A/D PROCESSING PERFOR-

MANCE
Judge as NG when any one of the followings is established.
(1) If the input amplifier circuit of throttle position sensor 1 is abnormal (quadruple amplification problem).
(2) If the A/D converter operation is abnormal (ADC malfunction).
(9) (1)
(2)
(8) (7)
(12) (10)
(3)
(7)
(4)
(5)
(7)
(13) (11)
(6)
(7)
EN-08016
Ignition switch ON

GD(H4DOTC)-195

GENERAL DESCRIPTION
Judgment Value
(1) |Throttle position sensor 1 opening angle <3°
– (Throttle position sensor 1 opening angle
after passing amplifier/4)|
(2) |Standard voltage – Readings of voltage < 0.078125 V
value|

(1): 24 ms
(2): 200 ms
GD(H4DOTC)-196

GENERAL DESCRIPTION
DG:DTC P0616 STARTER RELAY CIRCUIT LOW

Detect abnormal continuity in the starter SW.
Judge as OFF NG when the starter SW signal remains OFF.
None

Judge as OFF NG when the following conditions are established.
Judgment Value
Engine condition Change from pre-start
to post-start
Starter SW signal No ON experience

Judge as OFF OK and clear the NG if the following conditions are established.
Judgment Value
Engine condition Change from pre-start
to post-start
Starter SW signal ON Experience exists
GD(H4DOTC)-197

GENERAL DESCRIPTION
DH:DTC P0617 STARTER RELAY CIRCUIT HIGH

Detect abnormal continuity in the starter SW.
Judge as ON NG when the starter SW signal remains ON.
None

Judgment Value
Starter SW signal ON

Judgment Value
Starter SW signal OFF
GD(H4DOTC)-198

GENERAL DESCRIPTION
DI: DTC P062F INTERNAL CONTROL MODULE EEPROM ERROR

Judge as NG when the EEPROM operation is abnormal. (EEPROM malfunction)
(9) (1)
(2)
(8) (7)
(12) (10)
(3)
(7)
(4)
(5)
(7)
(13) (11)
(6)
(7)
EN-08016
Starter switch OFF
Battery voltage >6V

Judgment Value
EEPROM writing Writing completed

GD(H4DOTC)-199

GENERAL DESCRIPTION
DJ:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)

Detect the open or short circuit of neutral SW.
Judge as 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.)
Starter relay OFF

Perform the diagnosis continuously in 2 seconds after starting the engine.
Judge NG when the malfunction criteria below are completed determined times or more after the neutral SW
change.
Judgment Value
Neutral switch signal (while changing LOW (ON) continues.
from a to b below)
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 — 2550 rpm
& Vehicle speed ≥ 64 km/h (39.8 MPH)
Time Needed for Diagnosis: 3 time(s)

cles.
Judge as OK and clear NG when there is change in the neutral SW.
Judgment Value
Neutral switch signal (while changing Changes to HIGH
from a to b below) (OFF).
GD(H4DOTC)-200

GENERAL DESCRIPTION
DK:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)

Detect the open or short circuit of neutral SW.
Judge as 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.)
Starter relay OFF

Perform the diagnosis continuously in 2 seconds after starting the engine.
Judge NG when the malfunction criteria below are completed determined times or more after the neutral SW
change.
Judgment Value
Neutral switch signal (while changing HIGH (OFF) contin-
from a to b below) ues.
Time Needed for Diagnosis: 3 time(s)

cles.
Judge as OK and clear NG when there is change in the neutral SW.
Judgment Value
Neutral switch signal (while changing Changes to LOW
from a to b below) (ON).
GD(H4DOTC)-201

GENERAL DESCRIPTION
DL: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.
(1)
(3) (8)
(2)
S S
(7)
(6)
(4) (5)
EN-04463
(1) Opener spring (4) Full closed stopper (7) DC motor

(2) Return spring (5) Throttle valve (8) Main and sub throttle position sen-
sor
(3) Intermediate stopper (6) Gear
Throttle position sensor Normal

• Ignition switch ON → OFF
• Ignition switch OFF → ON (Only after clearing memory)
Judgment Value
Opening variation after continuity is set <2°
to OFF

GD(H4DOTC)-202

GENERAL DESCRIPTION
Judgment Value
Opening variation after continuity is set ≥2°
to OFF
GD(H4DOTC)-203

GENERAL DESCRIPTION
DM:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT

LOW
Detect the open/short circuit of pressure control solenoid valve.
Judge as NG when ECM output level is different from actual terminal level.
(1)
(A)
(2)
(3)
(4)
(B) (C)
(5)
EN-01759
(A) Atmospheric pressure (B) Shut-off valve (C) To fuel tank
(1) Filter (3) Connector terminal (5) Valve

(2) Coil (4) Diaphragm
None

Judgment Value
OFF signal

cles.
GD(H4DOTC)-204

GENERAL DESCRIPTION
Judgment Value
OFF signal
GD(H4DOTC)-205

GENERAL DESCRIPTION
DN:DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

STUCK OPEN
Always detect abnormality 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.
and
< 10000 rpm
After secondary air system stops ≥ 9000 ms
and
< 400 g/s (14.11 oz/s)
Engine load > 0 g/rev

Perform continuous diagnosis when air flow amount is large during the secondary air pump stop after engine
start.
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.
Judgment Value
Pipe inner pressure difference between > 0.05 V
Max. and Min.
Sum of the pipe inner pressure variation >5V
value every 4 milliseconds
Barometric pressure variation value < 26.7 kPa (200
mmHg, 7.9 inHg)

GD(H4DOTC)-206

GENERAL DESCRIPTION
Judge as OK and clear NG if neither exceeds the threshold value, or if either of the two exceeds the threshold
value.
Judgment Value
Pipe inner pressure difference between ≤ 0.05 V
Max. and Min.
Sum of the pipe inner pressure variation ≤5V
value every 4 milliseconds
GD(H4DOTC)-207

GENERAL DESCRIPTION
DO:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
Detect the open/short circuit of pressure control solenoid valve.
Judge as NG when ECM output level is different from actual terminal level.
(1)
(A)
(2)
(3)
(4)
(B) (C)
(5)
EN-01759
(A) Atmospheric pressure (B) Shut-off valve (C) To fuel tank
(1) Filter (3) Connector terminal (5) Valve

(2) Coil (4) Diaphragm
None

Judgment Value
ON signal

cles.
GD(H4DOTC)-208

GENERAL DESCRIPTION
Judgment Value
ON signal
GD(H4DOTC)-209

GENERAL DESCRIPTION
DP:DTC P1449 EVAPORATIVE EMISSION CONT. SYS. AIR FILTER CLOG

Detect the drain filter clogging by the pressure change during purge introduction.
Judge as drain filter clogging malfunction if the pressure in the evaporative emission system piping suddenly
decreases by the purging.
(1) (2)
(7) (8)
(3) (10)
M (9)
(4) (5) (6)
EN-08957

fice)
Continuous time of |Pressure sensor output ≥ 5120 ms + 13000 ms
value – Pressure sensor output value 64 ms
ago| ≤ 0.7 kPa (5 mmHg, 0.2 inHg)
Establishing time for following conditions ≥ 10000 ms
• ELCM vacuum pump Not in operation
• ELCM switching valve Open

Perform the diagnosis continuously when purging is performed after 20000 ms have passed since the engine
started.
GD(H4DOTC)-210

GENERAL DESCRIPTION
purge duty
5 seconds
Evap. Pressure
OK
monitoring value
Malfunction
EN-08951
Calculate the difference between the ELCM pressure sensor output value as of 5 seconds ago and the cur-
rent one, and if the value is greater than judgment value, detect and judge as filter clogging trouble.
Judgment Value
|Pressure sensor output value as of 5 > Value from Map
seconds ago – Current pressure sensor
output value|
Number of above conditions established > 2 time(s)
Map
Vehicle speed
0 (0) 20 (12.4) 40 (24.9) 60 (37.3) 80 (49.7) 100 (62.1) 120 (74.6) 300 (186.4)
km/h (MPH)
|Pressure sensor output value as of
0.8 0.8 0.9 1 1 1 1 1.6
5 seconds ago – Current pressure
(5.864 , (5.864 , (6.757 , (7.649 , (7.649 , (7.649 , (7.649 , (11.647 ,
sensor output value|
0.2) 0.2) 0.3) 0.3) 0.3) 0.3) 0.3) 0.5)
kPa (mmHg, inHg)
Time Needed for Diagnosis: Approx. 5 seconds

cles.
GD(H4DOTC)-211

GENERAL DESCRIPTION
Judgment Value
|Pressure sensor output value as of 5 ≤ Value from Map
seconds ago – Current pressure sensor
output value|
GD(H4DOTC)-212

GENERAL DESCRIPTION
DQ:DTC P1451 EVAPORATIVE EMISSION CONT. SYS.

NOTE:
EMISSION SYSTEM LEAK DETECTED (LARGE LEAK), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
DR:DTC P1570 ANTENNA
NOTE:
For the detection standard, refer to DTC P0513. <Ref. to GD(H4DOTC)-187, DTC P0513 INCORRECT IM-
MOBILIZER KEY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
DS:DTC P1571 REFERENCE CODE INCOMPATIBILITY
NOTE:
DT:DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)
NOTE:
DU:DTC P1574 KEY COMMUNICATION FAILURE
NOTE:
DV:DTC P1576 EGI CONTROL MODULE EEPROM
NOTE:
DW:DTC P1577 IMM CONTROL MODULE EEPROM
NOTE:
DX:DTC P1578 METER FAILURE
NOTE:
GD(H4DOTC)-213

GENERAL DESCRIPTION
DY: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.
Engine coolant temperature ≥ –30 °C (–22 °F)
Ambient air temperature ≥ –30 °C (–22 °F)

Judgment Value
Tumble generator valve opening ≥ 64.3 °
Tumble generator valve “close” signal ≥ 3200 ms
output

Judgment Value
Tumble generator valve opening < 64.3 °
output
GD(H4DOTC)-214

GENERAL DESCRIPTION
DZ: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.

Judgment Value
output

Judgment Value
output
GD(H4DOTC)-215

GENERAL DESCRIPTION
EA: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.

Judgment Value
Tumble generator valve “open” signal ≥ 4600 ms
output

Judgment Value
output
GD(H4DOTC)-216

GENERAL DESCRIPTION
EB: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.

Judgment Value
output

Judgment Value
output
GD(H4DOTC)-217

GENERAL DESCRIPTION
EC: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.
(1)
(3)
M (2)
E
EN-01789
(1) Engine control module (ECM) (2) Tumble generator valve (3) Battery

At the main IC, check the sent signal at each timing which occurs immediately after the tumble generator
valve output is set to ON → OFF, and judge open NG when the open NG signal is sent 96 ms × 20 time(s)
in a row.
Judgment Value
Open NG signal input Low

GD(H4DOTC)-218

GENERAL DESCRIPTION
Judge as OK and clear the NG when the OK signal is sent.
Judgment Value
Open NG signal input High
GD(H4DOTC)-219

GENERAL DESCRIPTION
ED: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.
(1)
(3)
M (2)
E
EN-01789

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 ms × 10 time(s) in a row.
Judgment Value
Overcurrent NG signal input Low

Judgment Value
Overcurrent NG signal input High
GD(H4DOTC)-220

GENERAL DESCRIPTION
EE: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.
(1)
(3)
M (2)
E
EN-01789

At the main IC, check the sent signal at each timing which occurs immediately after the tumble generator
valve output is set to ON → OFF, and judge open NG when the open NG signal is sent 96 ms × 20 time(s)
in a row.
Judgment Value
Open NG signal input Low

GD(H4DOTC)-221

GENERAL DESCRIPTION
Judgment Value
Open NG signal input High
GD(H4DOTC)-222

GENERAL DESCRIPTION
EF: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.
(1)
(3)
M (2)
E
EN-01789

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 ms × 10 time(s) in a row.
Judgment Value
Overcurrent NG signal input Low

Judgment Value
Overcurrent NG signal input High
GD(H4DOTC)-223

GENERAL DESCRIPTION
EG:DTC P2016 TUMBLE GENERATED VALVE POSITION SENSOR 1 CIRCUIT

LOW
Detect open or short circuit of tumble generator valve position sensor.
(3)
(4)
(1) (2)
EN-01768
(1) Rotor (3) Voltage (V) (4) Tumble generator valve opening
(°)
(2) Return spring
None

Judgment Value

GD(H4DOTC)-224

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-225

GENERAL DESCRIPTION
EH:DTC P2017 TUMBLE GENERATED VALVE POSITION SENSOR 1 CIRCUIT

HIGH
(3)
(4)
(1) (2)
EN-01768
(°)
(2) Return spring
None

Judgment Value

GD(H4DOTC)-226

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-227

GENERAL DESCRIPTION
EI: DTC P2021 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT

LOW
(3)
(4)
(1) (2)
EN-01768
(°)
(2) Return spring
None

Judgment Value

GD(H4DOTC)-228

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-229

GENERAL DESCRIPTION
EJ:DTC P2022 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT

HIGH
(3)
(4)
(1) (2)
EN-01768
(°)
(2) Return spring
None

Judgment Value

GD(H4DOTC)-230

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-231

GENERAL DESCRIPTION
EK: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.
None

Judgment Value
Oil flow control solenoid valve control duty ≥ 99.61 %
Oil control solenoid valve control present < 0.306 A
current

Judgment Value
Target current value of the oil flow control ≥ 0.14 A
solenoid valve
|Target current value of the oil flow control < 0.08 A
solenoid valve – oil flow control solenoid
valve control current value|
GD(H4DOTC)-232

GENERAL DESCRIPTION
EL: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.
None

Judgment Value
Oil flow control solenoid valve control duty < 0.39 %
Oil control solenoid valve control present ≥ 0.306 A
current

Judgment Value
GD(H4DOTC)-233

GENERAL DESCRIPTION
EM:DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-

CUIT 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.
None

Judgment Value
Oil flow control solenoid valve control duty ≥ 99.61 %
Oil control solenoid valve control present < 0.306 A
current

Judgment Value
Target current value of the oil flow control ≥ 0.14 A
solenoid valve
GD(H4DOTC)-234

GENERAL DESCRIPTION
EN:DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-

CUIT 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.
None

Judgment Value
Oil flow control solenoid valve control duty < 0.39 %
Oil control solenoid valve control present ≥ 0.306 A
current

Judgment Value
GD(H4DOTC)-235

GENERAL DESCRIPTION
EO: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.>
EP: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.>
EQ:DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-
CUIT LOW (BANK 2)
NOTE:
For the detection standard, refer to DTC P2090. <Ref. to GD(H4DOTC)-234, DTC P2090 EXHAUST CAM-
SHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) De-
tecting Criteria.>
ER:DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-
CUIT HIGH (BANK 2)
NOTE:
For the detection standard, refer to DTC P2091. <Ref. to GD(H4DOTC)-235, DTC P2091 EXHAUST CAM-
SHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) De-
tecting Criteria.>
GD(H4DOTC)-236

GENERAL DESCRIPTION
ES: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.
(E)
(3)
V (1)
(A) (F)
(2) (2)
(C) (B) (D)
EN-01696

Conditions for carrying out the sub feedback learning Completed
Continuous time when all conditions are established. ≥1s

Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km/h (50
MPH) or more.
Judgment Value
Sub feedback learning value < –0.024 (Models without SI-DRIVE)
< –0.037 (Models with SI-DRIVE)

cles.
GD(H4DOTC)-237

GENERAL DESCRIPTION
Judgment Value
Sub feedback learning value ≥ –0.024 + 0.004 (Models without SI-DRIVE)
≥ –0.037 + 0 (Models with SI-DRIVE)
GD(H4DOTC)-238

GENERAL DESCRIPTION
ET:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
Detect the malfunction of fuel system from the size of the sub feedback learning value.
Sub feedback learning is being performed. When the learning value goes to the rich side, judge as NG.
(E)
(3)
V (1)
(A) (F)
(2) (2)
(C) (B) (D)
EN-01696

Conditions for carrying out the sub feedback Completed
learning
Continuous time when all conditions are ≥1s
established.

Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km/h (50
MPH) or more.
Judgment Value
Sub feedback learning value ≥ 0.028 (Models without SI-DRIVE)
≥ 0.023 (Models with SI-DRIVE)

cles.
GD(H4DOTC)-239

GENERAL DESCRIPTION
Judgment Value
Sub feedback learning value < 0.028 + –0.01 (Models without SI-DRIVE)
< 0.023 + 0 (Models with SI-DRIVE)
GD(H4DOTC)-240

GENERAL DESCRIPTION
EU:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
Judge as NG when the motor current becomes large or drive circuit is heated.
12V 12V
(1)
(6)
(2) (3)
(4) (7)
(2) (5)
EN-01867
(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
CPU communication line sub → main normal Normal
judgment

GD(H4DOTC)-241

GENERAL DESCRIPTION
Judgment Value
Motor current >8A
or
Drive circuit inner temperature > 175°C (347°F)

Judgment Value
Motor current ≤8A
Drive circuit inner temperature ≤ 175°C (347°F)
GD(H4DOTC)-242

GENERAL DESCRIPTION
EV:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

Judge as NG when the electronic throttle control power is not supplied even when ECM sets the electric con-
trol throttle relay to ON.
12V 12V
(1)
(4)
(2)
(3) (5)
EN-01868
(1) Engine control module (ECM) (3) Drive circuit (5) Motor
(2) Voltage detection circuit (4) Electronic throttle control relay
Battery voltage ≥ 11 V
Electronic throttle control relay output ON

Judgment Value
Motor power voltage ≤5V

GD(H4DOTC)-243

GENERAL DESCRIPTION
Judgment Value
Motor power voltage >5V
GD(H4DOTC)-244

GENERAL DESCRIPTION
EW: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.
12V 12V
(1)
(4)
(2)
(3) (5)
EN-01868
(1) Engine control module (ECM) (3) Drive circuit (5) Motor
(2) Voltage detection circuit (4) Electronic throttle control relay
Electronic throttle control relay output OFF

• When ignition switch ON → OFF
• Ignition switch OFF → ON (Only after clearing memory)
Judgment Value
Motor power voltage ≥5V

GD(H4DOTC)-245

GENERAL DESCRIPTION
Judgment Value
Motor power voltage <5V
GD(H4DOTC)-246

GENERAL DESCRIPTION
EX: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.
(1) (3)
(2)
(4)
EN-01869
(1) Engine control module (ECM) (3) Motor (4) Throttle position sensor
(2) Drive circuit
Ignition switch ON → OFF
Ignition switch (only after clear memory) OFF → ON

Perform the diagnosis at full closed point learning.
Judgment Value
Throttle sensor opening angle at full close < 9.884 °
point learning or
> 20.116 °
or
Throttle opening angle when the ignition < 0.887 ° (models without SI-DRIVE)
switch is ON – Throttle minimum stop position < 1.637 ° (models with SI-DRIVE)
Time Needed for Diagnosis: 8 ms — 80 ms

GD(H4DOTC)-247

GENERAL DESCRIPTION
Judgment Value
Throttle sensor opening angle at full close ≥ 9.884 °
point learning and
≤ 20.116 °
Throttle opening angle when the ignition ≥ 0.887 ° (models without SI-DRIVE)
switch is ON – Throttle minimum stop position ≥ 1.637 ° (models with SI-DRIVE)
GD(H4DOTC)-248

GENERAL DESCRIPTION
EY:DTC P2119 THROTTLE ACTUATOR CONTROL THROTTLE BODY RANGE/

PERFORMANCE
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) (1)
(4)
(2)
EN-01863
(1) Motor (3) Engine control module (ECM) (4) Drive circuit
(2) Throttle position sensor
Ignition switch ON
Normal operation of electronic throttle ON
control

Always perform the diagnosis continuously when the electronic throttle control is operating.
Judgment Value
Difference between target opening angle Within OK range of
and actual opening angle Details of Judgment
value
Output duty to drive circuit < 95 %

• Difference between target opening angle and actual opening angle:
• NG judgment: See Details of Judgment time
• OK judgment: 2000 ms
• Output duty to drive circuit: 2000 ms
GD(H4DOTC)-249

GENERAL DESCRIPTION
Details of Judgment Value

(Y5)
Difference between
target opening angle
and
actual opening angle ( ) (NG area)
(Y4)
(Y3)
(Y1) (OK area)
(Y2)
0
0
(X1) (X2) (X3) (X4) (X5)
Target throttle opening angle ( )

EN-08017
(X1) 6.915 ° (X2) 11.565 ° (X3) 15.785 °

(X4) 21.285 ° (X5) 29.965 °
(Y1) 4.65 ° (Y2) 4.22 ° (Y3) 5.5 °

(Y4) 8.68 ° (Y5) 25 °
(Y4)
Difference between
target opening angle
and (NG area)
actual opening angle ( )
(Y3)
(Y2) (OK area)

(Y1)
0
0
(X1) (X2) (X3) (X4)
Target throttle opening angle ( )

EN-08055
(X1) 6.15 ° (X2) 9.65 ° (X3) 14.65 °

(X4) 26.65 °
(Y1) 3.5 ° (Y2) 5° (Y3) 12 °

(Y4) 25 °
GD(H4DOTC)-250

GENERAL DESCRIPTION
Details of Judgment time

(Y1)
Judgment time
(milliseconds)
(Y2)
(Y3)
(Y4)
0
0
(X1) (X2) (X3) (X4)
Throttle position sensor 1 opening angle (˚)

EN-08018
(X1) 8.049999237 ° (X2) 9.5 ° (X3) 14.5 °

(X4) 23.5 °
(Y1) 1000 ms (Y2) 400 ms (Y3) 304 ms

(Y4) 248 ms
(Y1)
Judgment time
(milliseconds)
(Y2)
(Y3)
(Y4)
0
0
(X1) (X2) (X3) (X4)
EN-08056
(X1) 5.5 ° (X2) 9° (X3) 13 °

(X4) 22 °
(Y1) 1000 ms (Y2) 400 ms (Y3) 300 ms

(Y4) 250 ms
NOTE:
Judgment time when actual opening angle ≤ target opening angle is always 1000 milliseconds.
GD(H4DOTC)-251

GENERAL DESCRIPTION
EZ:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT

LOW INPUT
Detect the open or short circuit of accelerator pedal position sensor 1.
(4)
(1)
(2)
(3)
EN-01861
(1) Engine control module (ECM) (3) Accelerator pedal position sensor (4) Accelerator pedal position sensor
2 signal
(2) Accelerator pedal position sensor
1 signal
Ignition switch ON

Judgment Value

GD(H4DOTC)-252

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-253

GENERAL DESCRIPTION
FA:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT

HIGH INPUT
(4)
(1)
(2)
(3)
EN-01861
2 signal
1 signal
Ignition switch ON

Judgment Value

GD(H4DOTC)-254

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-255

GENERAL DESCRIPTION
FB:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT

LOW INPUT
(4)
(1)
(2)
(3)
EN-01861
2 signal
1 signal
Ignition switch ON

Judgment Value

GD(H4DOTC)-256

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-257

GENERAL DESCRIPTION
FC:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT

HIGH INPUT
(4)
(1)
(2)
(3)
EN-01861
2 signal
1 signal
Ignition switch ON

Judgment Value

GD(H4DOTC)-258

GENERAL DESCRIPTION
Judgment Value
GD(H4DOTC)-259

GENERAL DESCRIPTION
FD:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLT-

AGE CORRELATION
Judge as NG when the signal level of throttle position sensor 1 is different from the throttle position sensor 2.
(3)
(4)
(1)
(2)
EN-01859
Ignition switch ON

Judgment Value
Signal difference between two sensors Within NG range of
Details of Judgment
value
GD(H4DOTC)-260

GENERAL DESCRIPTION
(Y5) (NG area)
(Y4)
Sensor output (Y3)

difference (˚)
(Y2)
(Y1) (OK area)
0
0
(X1) (X2) (X3) (X4)

EN-08032
(X1) 2.125 ° (X2) 4.25 ° (X3) 9°

(X4) 31.625 °
(Y1) 5.15 ° (Y2) 6.15 ° (Y3) 8.28 °

(Y4) 10.4 ° (Y5) 12.4 °

Judgment Value
Signal difference between two sensors Within OK range of
Details of Judgment
value
GD(H4DOTC)-261

GENERAL DESCRIPTION
FE:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLT-

AGE CORRELATION
Judge as NG when the signal level of accelerator pedal position sensor 1 is different from the accelerator
pedal position sensor 2.
(4)
(1)
(2)
(3)
EN-01861
2 signal
1 signal
Ignition switch ON

GD(H4DOTC)-262

GENERAL DESCRIPTION
Judgment Value
Signal difference between two sensors Within NG range of
Details of Judgment
value
(Y5)
(Y4) (NG area)
Sensor output
(Y3)
difference (˚)
(Y2)
(Y1)
(OK area)
0
0 (X1) (X2) (X3) (X4)
Accelerator pedal position sensor 1 opening angle (˚)
EN-08033
(X1) 0.6 ° (X2) 1.2 ° (X3) 2°

(X4) 4°
(Y1) 1.465 ° (Y2) 1.597 ° (Y3) 1.663 °

(Y4) 2.455 ° (Y5) 3.116 °

Judgment Value
Signal difference between two sensors Within OK range of
Details of Judgment
value
GD(H4DOTC)-263

GENERAL DESCRIPTION
FF:DTC P2195 O2 SENSOR SIGNAL BIASED/STUCK LEAN (BANK 1 SENSOR 1)

Detect that λ value remains low.
Judge as NG when lambda value is abnormal in accordance with λ 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.
λ value = Actual air fuel ratio/Theoretical air fuel ratio
λ > 1: Lean
λ < 1: Rich
(1) (1) (A)
(2) (C) (B) (D)
EN-09361

(D) Rich
GD(H4DOTC)-264

GENERAL DESCRIPTION
Time needed for all secondary parameters to be in enable ≥ 4096 ms
conditions
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.
Load change at 180°CA < 0.02 g/rev (0 oz/rev)
Front oxygen (A/F) sensor impedance 0 Ω — 50 Ω
Total time of operating canister purge ≥ 19.9 s
Targeted lambda value load compensation coefficient –1 — 1

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.
Judgment Value
λ value < 0.85

cles.
Judgment Value
λ value ≥ 0.85
GD(H4DOTC)-265

GENERAL DESCRIPTION
FG:DTC P2196 O2 SENSOR SIGNAL BIASED/STUCK RICH (BANK 1 SENSOR 1)

Detect that λ value remains high.
Judge as NG when lambda value is abnormal in accordance with λ 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.
λ value = Actual air fuel ratio/Theoretical air fuel ratio
λ > 1: Lean
λ < 1: Rich
(1) (1) (A)
(2) (C) (B) (D)
EN-09361

(D) Rich
GD(H4DOTC)-266

GENERAL DESCRIPTION
Time needed for all secondary parameters to be in enable ≥ 4096 ms
conditions
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.
Load change at 180°CA < 0.02 g/rev (0 oz/rev)
Front oxygen (A/F) sensor impedance 0 Ω — 50 Ω
Total time of operating canister purge ≥ 19.9 s
Targeted lambda value load compensation coefficient –1 — 1

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.
Judgment Value
λ value > 1.15

cles.
Judgment Value
λ value ≤ 1.15
GD(H4DOTC)-267

GENERAL DESCRIPTION
FH:DTC P219A BANK 1 AIR-FUEL RATIO IMBALANCE

Detect malfunction of air fuel ratio deviation between cylinders from main feedback learning value, sub feed-
back learning value and engine speed variation.
Atmospheric pressure > 75 kPa (563 mmHg, 22.2 inHg)
Engine coolant temperature > 70 °C (158 °F)
Intake air temperature < 70 °C (158 °F)
Engine load > Value of Map 1
Evaporative system leak check Not in operation
Cumulative time of canister purge after engine start ≥ 20 s
Learning value of EVAP conc. < 0.2
Vehicle dynamic control or AT torque control Not in operation
Intake manifold pressure change at 180°CA < Value of Map 2
Throttle position change during 16 milliseconds < 14 °
Fuel shut-off function Not in operation

0.228 0.22 0.22 0.22 0.228 0.23 0.234 0.242 0.25 0.25
(0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01)

0.225 0.245 0.239 0.224 0.233 0.259 0.257 0.254 0.256 0.274
(0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01) (0.01)

rpm 750 1000 1500 2000 2500 3000 3500 4000
13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100,
kPa (mmHg, inHg)
3.9) 3.9) 3.9) 3.9) 3.9) 3.9) 3.9) 3.9)
rpm 4500 5000 5500 6000 6500 6700

13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100,
kPa (mmHg, inHg)
3.9) 3.9) 3.9) 3.9) 3.9) 3.9)

rpm 700 1000 1500 2000 2500 3000 3500 4000
13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100,
kPa (mmHg, inHg)
3.9) 3.9) 3.9) 3.9) 3.9) 3.9) 3.9) 3.9)
rpm 4500 5000 5500 6000 6500 6700

13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100, 13.3 (100,
kPa (mmHg, inHg)
3.9) 3.9) 3.9) 3.9) 3.9) 3.9)
GD(H4DOTC)-268

GENERAL DESCRIPTION

Judgment Value
Rich
Main feedback learning value < –0.16
Sub feedback learning value < –0.0124
• Any one of the rich side misfire counters for each cylinder when in idling > 8 time(s)
• Total of the rich side misfire counters for each cylinder when in idling > 8 time(s)
• Any one of the rich side misfire counters for each cylinder when not in idling > 18 time(s)
• Total of the rich side misfire counters for each cylinder when not in idling > 18 time(s)
Lean
Main feedback learning value > 0.075
Sub feedback learning value <0
• Any one of the lean side misfire counters for each cylinder when in idling > 113 time(s)
• Total of the lean side misfire counters for each cylinder when in idling > 65535 time(s)
• Any one of the lean side misfire counters for each cylinder when not in idling > 127 time(s)
• Total of the lean side misfire counters for each cylinder when not in idling > 65535 time(s)

Rich
Main feedback learning value < –0.14
Sub feedback learning value < –0.017
• Any one of the rich side misfire counters for each cylinder when in idling > 9 time(s)
• Total of the rich side misfire counters for each cylinder when in idling > 9 time(s)
• Any one of the rich side misfire counters for each cylinder when not in idling > 20 time(s)
• Total of the rich side misfire counters for each cylinder when not in idling > 20 time(s)
Lean
Main feedback learning value >0
Sub feedback learning value < 100
• Any one of the lean side misfire counters for each cylinder when in idling > 177 time(s)
• Total of the lean side misfire counters for each cylinder when in idling > 65535 time(s)
• Any one of the lean side misfire counters for each cylinder when not in idling > 192 time(s)
• Total of the lean side misfire counters for each cylinder when not in idling > 65535 time(s)

cles.
GD(H4DOTC)-269

GENERAL DESCRIPTION
Judgment Value
Rich
Main feedback learning value ≥ –0.16
or
Sub feedback learning value ≥ –0.0124
or
• Any one of the rich side misfire counters for each cylinder when in idling ≤ 8 time(s)
• Total of the rich side misfire counters for each cylinder when in idling ≤ 8 time(s)
• Any one of the rich side misfire counters for each cylinder when not in idling ≤ 18 time(s)
• Total of the rich side misfire counters for each cylinder when not in idling ≤ 18 time(s)
Lean
Main feedback learning value ≤ 0.075
or
Sub feedback learning value ≥0
or
• Any one of the lean side misfire counters for each cylinder when in idling ≤ 113 time(s)
• Total of the lean side misfire counters for each cylinder when in idling ≤ 65535 time(s)
• Any one of the lean side misfire counters for each cylinder when not in idling ≤ 127 time(s)
• Total of the lean side misfire counters for each cylinder when not in idling ≤ 65535 time(s)

Rich
Main feedback learning value ≥ –0.14
or
Sub feedback learning value ≥ –0.017
or
• Any one of the rich side misfire counters for each cylinder when in idling ≤ 9 time(s)
• Total of the rich side misfire counters for each cylinder when in idling ≤ 9 time(s)
• Any one of the rich side misfire counters for each cylinder when not in idling ≤ 20 time(s)
• Total of the rich side misfire counters for each cylinder when not in idling ≤ 20 time(s)
Lean
Main feedback learning value ≤0
or
Sub feedback learning value ≥ 100
or
• Any one of the lean side misfire counters for each cylinder when in idling ≤ 177 time(s)
• Total of the lean side misfire counters for each cylinder when in idling ≤ 65535 time(s)
• Any one of the lean side misfire counters for each cylinder when not in idling ≤ 192 time(s)
• Total of the lean side misfire counters for each cylinder when not in idling ≤ 65535 time(s)
GD(H4DOTC)-270

GENERAL DESCRIPTION
FI: DTC P2257 AIR SYSTEM CONTROL "A" CIRCUIT LOW

None

Judgment Value
Ignition ON
Terminal output voltage when ECM out- LOW
puts OFF signal

Judgment Value
Ignition ON
Terminal output voltage when ECM out- HIGH
puts OFF signal
GD(H4DOTC)-271

GENERAL DESCRIPTION
FJ: DTC P2258 AIR SYSTEM CONTROL "A" CIRCUIT HIGH

None

Judgment Value
Ignition ON
ON signal

Judgment Value
Ignition ON
ON signal
GD(H4DOTC)-272

GENERAL DESCRIPTION
FK:DTC P2401 EVAPORATIVE EMISSION SYSTEM LEAK DETECTION PUMP

CONTROL CIRCUIT LOW
Detect the open or short circuit of the ELCM vacuum pump.
(1) (2)
(7) (8)
(3) (10)
M (9)
(4) (5) (6)
EN-08957

fice)
None

Judgment Value
Battery voltage ≥ 10.9
OFF signal

GD(H4DOTC)-273

GENERAL DESCRIPTION
Judgment Value
OFF signal
GD(H4DOTC)-274

GENERAL DESCRIPTION
FL:DTC P2402 EVAPORATIVE EMISSION SYSTEM LEAK DETECTION PUMP

CONTROL CIRCUIT HIGH
Detect the open or short circuit of the ELCM vacuum pump.
(1) (2)
(7) (8)
(3) (10)
M (9)
(4) (5) (6)
EN-08957

fice)
None

Judgment Value
ON signal

GD(H4DOTC)-275

GENERAL DESCRIPTION
Judgment Value
ON signal

FM:DTC P2404 EVAPORATIVE EMISSION SYSTEM LEAK DETECTION PUMP
SENSE CIRCUIT RANGE/PERFORMANCE
NOTE:
EMISSION SYSTEM LEAK DETECTED (LARGE LEAK), Diagnostic Trouble Code (DTC) Detecting Crite-
ria.>
GD(H4DOTC)-276

GENERAL DESCRIPTION
FN:DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CON-

TROL CIRCUIT LOW
Detect the open or short circuit of the ELCM switching valve.
(1) (2)
(7) (8)
(3) (10)
M (9)
(4) (5) (6)
EN-08957

fice)
None

Judgment Value
OFF signal

GD(H4DOTC)-277

GENERAL DESCRIPTION
Judgment Value
OFF signal
GD(H4DOTC)-278

GENERAL DESCRIPTION
FO:DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CON-

TROL CIRCUIT HIGH
Detect the open or short circuit of the ELCM switching valve.
(1) (2)
(7) (8)
(3) (10)
M (9)
(4) (5) (6)
EN-08957

fice)
None

Judgment Value
ON signal

GD(H4DOTC)-279

GENERAL DESCRIPTION
Judgment Value
ON signal
GD(H4DOTC)-280

GENERAL DESCRIPTION
FP: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.
After secondary air system stops ≥ 2976 ms

Perform the diagnosis with ignition switch ON.
Judgment Value
|Secondary air pipe pressure – Intake ≥ 26.7 kPa (200 mmHg, 7.9 inHg)
manifold pressure|
|Intake manifold pressure at engine start < 1.3 kPa (9.99 mmHg, 0.4 inHg)
– Intake manifold pressure|

cles.
Judgment Value
|Secondary air pipe pressure – Intake < 26.7 kPa (200 mmHg, 7.9 inHg)
manifold pressure|
GD(H4DOTC)-281

GENERAL DESCRIPTION
FQ:DTC P2432 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE

SENSOR CIRCUIT LOW
None

Judgment Value
Ignition switch ON

Judgment Value
Ignition switch ON
GD(H4DOTC)-282

GENERAL DESCRIPTION
FR:DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE

SENSOR CIRCUIT HIGH
None

Judgment Value
Ignition switch ON
Output voltage > 4.916 V

Judgment Value
Ignition switch ON
Output voltage ≤ 4.916 V
GD(H4DOTC)-283

GENERAL DESCRIPTION
FS:DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

STUCK OPEN (BANK1)
NOTE:
FT:DTC P2441 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
NOTE:
FU:DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
STUCK OPEN (BANK2)
NOTE:
FV:DTC P2443 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE
NOTE:
GD(H4DOTC)-284

GENERAL DESCRIPTION
FW: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.
Engine In operation

Judgment Value
Time since secondary air control com- ≥ 3000 ms
pletion and
≤ 8000 ms
Secondary air pipe pressure – Second- > 6.7 kPa (50 mmHg, 2 inHg)
ary air pipe pressure before operation

Judgment Value
Time since secondary air control com- ≥ 3000 ms
pletion and
≤ 8000 ms
Secondary air pipe pressure – Second- ≤ 6.7 kPa (50 mmHg, 2 inHg)
ary air pipe pressure before operation
GD(H4DOTC)-285

GENERAL DESCRIPTION
FX:DTC P2610 ECM/PCM INTERNAL ENGINE OFF TIMER PERFORMANCE

Detect malfunction of soaking timer IC by the five diagnoses below.
Monitor Number Explanation Time required for diagnosis
Monitor #1
Perform diagnosis of the soaking timer IC accuracy 196 ms
<Timer diagnosis>
Monitor #2 Perform diagnosis of the soaking timer IC counter
4000 ms
<Full count diagnosis> function
Monitor #3 Perform diagnosis of communication between ECM
196 ms
<Soaking timer IC setting diagnosis> and soaking timer IC
Monitor #4 Perform diagnosis of the soaking timer IC accuracy
3000 ms
<Timer diagnosis (during soaking)> during soaking
Monitor #5
Perform diagnosis of wake-up function 64 ms
<Wake-up diagnosis>
more than 10 min soak:more than 3 h
ignition swich
main relay
driving cycle
ECM counter
1h
Soak Timer IC counter
Monitoring #4
Monitoring #1 Monitoring #5
Monitoring #2 Monitoring #3
EN-09090
The soaking timer IC is built into the ECM.
GD(H4DOTC)-286

GENERAL DESCRIPTION
<Timer diagnosis>
Ignition switch OFF
Elapsed time after starting the engine > 600 s
< Full count diagnosis & soaking timer IC setting diagnosis>
Ignition switch OFF
<Timer diagnosis (during soaking)>
Ignition switch OFF
Number of wake-up = 1, 2, 3, 4, 6, 8 time(s)
<Wake-up diagnosis>
Ignition switch ON
Wake-up activation time setting Completed
Time in the soaking timer IC > 3600 s

Perform the diagnosis only once when the ignition switch is OFF and when the ignition switch is ON after the
soaking of one hour or more.
<Timer diagnosis>
Start the count up operation of counters in ECM and in soaking timer IC when the engine is started.
Judge as timer malfunction if the difference between the counter in ECM and counter in soaking timer IC ex-
ceeds the allowable limit when the ignition switch is OFF.
Timer Monitoring
ignition swich
main relay
driving cycle
ECM counter
Malfunction
OK
Malfunction
EN-08952
GD(H4DOTC)-287

GENERAL DESCRIPTION
Judgment Value
|osoaktimcpu – osoaktimic| / osoaktimcpu > 0.24
osoaktimcpu = Counter in ECM

osoaktimic = Counter in soaking timer IC
Judge as OK when the following conditions are established.
Judgment Value
|osoaktimcpu – osoaktimic| / osoaktimcpu ≤ 0.24
<Full count diagnosis>

Reset the counter in soaking timer IC and start the count up operation.
Judge as full count diagnosis malfunction if counter in soaking timer IC is not $3FF (1023 count) after 4 sec-
onds.
Counter Monitoring
ignition swich
main relay
driving cycle
4 sec
ECM counter
OK
Malfunction
EN-08953
Judgment Value
osoakfcntic ≠ $3FF (1023 count)
osoakfcntic = Counter in soaking timer IC
GD(H4DOTC)-288

GENERAL DESCRIPTION
Judgment Value
osoakfcntic = $3FF (1023 count)
<Soaking timer IC setting diagnosis>

When setting the activation setting time to soaking timer IC, compare the writing value to soaking timer IC
with read out value. Judge as malfunction if the values do not match 3 times in a row.
Soak Timer IC Monitoring
ignition swich
main relay
driving cycle
ECM counter
Malfunction
number of retrying
the Soak Timer
IC setting
OK
EN-09338
Judgment Value
Writing value and read out value when setting Unmatch
the soaking timer
Number of retrying the soaking timer setting ≥ 3 times
Judgment Value
Writing value and read out value when setting Match
the soaking timer
GD(H4DOTC)-289

GENERAL DESCRIPTION
<Timer diagnosis (during soaking)>

Wake-up at the predetermined interval until 5, 7 or 9.5 hours have passed after the ignition switch is OFF,
and compare the counter in soaking timer IC with the counter in ECM.
Judge as malfunction if the counter in soaking timer IC is counted up to maximum value (1023 count) when
the counter in ECM is 1637 ms, or if the counter in soaking timer IC is not counted up to maximum value
(1023 count) when the counter in ECM is 2455 ms.
“Wake up” period “Wake up” period

(3 sec) (10 30 min)
ignition switch
main relay
ECM counter
5 hours
Wake up
Soak Timer IC counter 1 hour
Evaporative leak diagnosis

Timer diagnostic during soak
Condition for monitoring

Malfunction $3FF (1023count)
OK
Malfunction
$000 (0count)
ECM counter
0 sec 1.637 sec 2.455 sec
EN-08981
GD(H4DOTC)-290

GENERAL DESCRIPTION
Judgment Value
• All of the following conditions are established.
Counter in ECM ≤ 1637 ms
Counter in soaking timer IC = $3FF (1023 count)
Counter in ECM ≥ 2455 ms
Counter in soaking timer IC ≠ $3FF (1023 count)
Judgment Value
Following conditions are established.
Counter in ECM ≤ 1637 ms
Counter in soaking timer IC ≠ $3FF (1023 count)
Counter in ECM ≥ 2455 ms
Counter in soaking timer IC = $3FF (1023 count)
GD(H4DOTC)-291

GENERAL DESCRIPTION
<Wake-up diagnosis>
Store the number of wake-up activation when the ECM wakes up by the soaking timer IC.
Next time when the ignition switch is ON, if the number of wake-up activation does not reach the predeter-
mined value even though the counter in soaking timer IC operates 1 hour or more, judge as wake-up mal-
function.
ignition swich
main relay
driving cycle
ECM counter
OK
number of
wake-up
Malfunction
EN-09339
Judgment Value
Number of wake-up < Wake-up indication count
Judgment Value
Number of wake-up ≥ Wake-up indication count
GD(H4DOTC)-292

GENERAL DESCRIPTION
Judgment Value
Ignition switch ON
Driving cycle Completed
• Timer diagnosis NG
• Full count diagnosis NG
• Soaking timer IC setting diagnosis NG
• Timer diagnosis (during soaking) NG
• Wake-up diagnosis NG
Time Needed for Diagnosis: Approx. 5 — 9.5 hours

cles.
Judgment Value
Ignition switch ON
Driving cycle Completed
• Timer diagnosis OK
• Full count diagnosis OK
• Soaking timer IC setting diagnosis OK
• Timer diagnosis (during soaking) OK
• Wake-up diagnosis OK
Time Needed for Diagnosis: Approx. 5 — 9.5 hours
GD(H4DOTC)-293

GENERAL DESCRIPTION
FY:DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION

Detect malfunction of CAN communication.
Judge as NG when CAN communication failure has occurred.
(Common Specifications)
CAN Protocol 2.0 B (Active)
Frame Format: 11 Bit ID Frame (Standard Frame)
Conforms to ISO11898
Communication Speed: 500 kbps
None

Judgment Value
Starter switch OFF
Engine run
bus off flag or error warning flag set (error)

Judgment Value
Engine run
bus off flag or error warning flag clear (No error)
GD(H4DOTC)-294

GENERAL DESCRIPTION
FZ:DTC U0122 CAN (VDC) DATA NOT LOADED

Judge as NG when CAN communication failure has occurred between VDC CM and body integrated unit.
None

Judgment Value
Starter switch OFF
Engine run
ID received from control module con- None during 500 milli-
nected to CAN seconds

Judgment Value
Engine run
ID received from control module con- Yes
nected to CAN

GA:DTC U0140 CAN (BCU) DATA NOT LOADED
NOTE:
For the detection standard, refer to DTC U0122. <Ref. to GD(H4DOTC)-295, DTC U0122 CAN (VDC) DATA
NOT LOADED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-295

GENERAL DESCRIPTION
GB:DTC U0416 CAN (VDC) DATA ABNORMAL

Judge as NG when data received from VDC CM and body integrated unit is not normal.
None

Judgment Value
Starter switch OFF
Engine run
Data updated from control module con- None during 2000 mil-
nected to CAN liseconds

Judgment Value
Engine run
Data updated from control module con- Yes
nected to CAN

GC:DTC U0422 CAN (BCU) DATA ABNORMAL
NOTE:
For the detection standard, refer to DTC U0416. <Ref. to GD(H4DOTC)-296, DTC U0416 CAN (VDC) DATA
ABNORMAL, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-296
2013 IMPREZA WRX STI SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
CONTROL SYSTEMS CS
MANUAL TRANSMISSION AND

5MT
DIFFERENTIAL

6MT
DIFFERENTIAL

6MT(diag)
DIFFERENTIAL (DIAGNOSTICS)
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data CLUTCH SYSTEM CL
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD. G1150BE5

CONTROL SYSTEMS
CS
Page
1. General Description ...................................................................................2
2. MT Gear Shift Lever ...................................................................................6
3. Reverse Check Cable ..............................................................................22
4. General Diagnostic Table .........................................................................27
General Description
CONTROL SYSTEMS
1. General Description
A: SPECIFICATION
Item Specifications
Swing torque of rod against lever N (kgf, lbf) 3.7 (0.38, 0.83) or less
CS-2
General Description
CONTROL SYSTEMS
B: COMPONENT
1. 6MT GEAR SHIFT LEVER
(33) T2
(6) (1)
(7)
(34) (12) T2 (8)
(13) (32) (9)

(12)
(13)
(35) (2)
(12) (11 )
(12) (13) (10)

(12)
(12)
T2
(4)
T1
(14)
(15)
(16)
(17)
(18)
(19) (4)
(3)
(20)
T3
(26) (21)
(27)
(30)
(25) (5)
(22)
(31) (28)
(29)
(23) T3
(24)
T4
CS-00925
(1) Gear shift knob (15) Snap ring (29) Snap pin
(2) Console box front (16) Bushing (30) Bracket
(3) Boot and insulator ASSY (17) O-ring (31) Cable plate
(4) Clamp (18) Spring pin (32) Rod
(5) Plate COMPL (19) Bushing (33) Spring pin
(6) Slider (20) O-ring (34) Joint
(7) Spring pin (21) Boot (35) Boss
(8) Spring (22) Cushion rubber
(9) Holder (23) Stay Tightening torque: N·m (kgf-m, ft-lb)
(10) Seat cushion (24) Bushing T1: 1.3 (0.1, 1.0)
(11) Lever (25) Reverse check cable T2: 12 (1.2, 8.9)
(12) Bushing (26) Band clip T3: 18 (1.8, 13.3)
(13) Spacer (27) Reverse check lever T4: 32 (3.3, 23.6)
(14) Lock wire (28) Washer
CS-3
General Description
CONTROL SYSTEMS
2. 5MT GEAR SHIFT LEVER
(1)
(2)
T1
(16)
(26)
(17) T1
(7)
(19) (7)
(24) T1 (3)
(19) (26)
(18) (26)
(6)
(7)
(7)
(7) (19)
(4)
(7)
(8)
(9)
T2 (3)
(12)
(10)
(11)
(13)
(14) (5)
(20)
(15)
(25)
(21) T2
T2
(22) (23)
(26) T2
CS-01074
(1) Gear shift knob (11) O-ring (21) Washer

(2) Console boot (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 COMPL (15) Boot (25) Bushing
(6) Lever (16) Spring pin (26) Self-locking nut
(7) Bushing (17) Joint
(8) Lock wire (18) Rod Tightening torque: N·m (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-4
General Description
CONTROL SYSTEMS
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.
• Use SUBARU genuine fluid, grease etc. or
equivalent. Do not mix fluid, grease, etc. of different
grades or manufacturers.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or rigid racks at the specified
points.
• Apply grease onto sliding or revolving surfaces
before installation.
• 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.
• Before disconnecting electrical connectors, be
sure to disconnect the negative terminal from bat-
tery.
CS-5
MT Gear Shift Lever

CONTROL SYSTEMS
2. MT Gear Shift Lever 8) Remove the plate COMPL from the body.
A: REMOVAL
1. STI MODEL
1) Disconnect the ground cable from battery.
2) Remove the gear shift knob.
3) Remove the console box. <Ref. to EI-51, RE-
MOVAL, Console Box.>
4) Remove the console side cover and console
front panel. <Ref. to EI-52, CONSOLE FRONT
CS-00735
PANEL, REMOVAL, Center Console.>
5) Remove the clamp. 9) Lift up the vehicle.
10) Remove the under cover.
11) Remove the center exhaust pipe. <Ref. to
EX(STI)-8, REMOVAL, Center Exhaust Pipe.>
12) Remove the heat shield cover.
CS-00926
6) Remove the boot and insulator assembly.
MT-01660
13) Remove the crossmember. <Ref. to 6MT-29,

REMOVAL, Transmission Mounting System.>
14) Remove the snap pin and washer, and remove
the reverse check cable from the reverse check le-
ver.
CS-00927
(A)
7) Remove the harness clamp from the plate COM-
PL.
(B)
(C)
CS-00220
(A) Snap pin

(B) Washer
(C) Reverse check cable
CS-00581
CS-6
MT Gear Shift Lever

CONTROL SYSTEMS
15) Move the transmission to the right side, and re- 2. EXCEPT FOR STI MODEL
move the joint COMPL, stay bolts and reverse 1) Disconnect the ground cable from battery.
check cable. 2) Remove the gear shift knob.
NOTE: 3) Remove the console box. <Ref. to EI-51, RE-
If the transmission is not moved aside, the joint MOVAL, Console Box.>
COMPL and stay bolts may contact the body and 4) Remove the console side cover and console
cause damage. front panel. <Ref. to EI-52, CONSOLE FRONT
PANEL, REMOVAL, Center Console.>
(C) 5) Remove the clamp.
(A)
(B)
CS-00221
(A) Joint COMPL bolt CS-00731

(B) Stay bolt
16) Remove the cushion rubber from the body.
CS-00732
7) Remove the harness clamp from the plate COM-

CS-00222 PL.
17) Lower the vehicle.
18) Remove the gear shift lever.
CS-00313
CS-7
MT Gear Shift Lever

CONTROL SYSTEMS
8) Remove the plate COMPL from the vehicle 13) Remove the rod from joint.
body.
(A)
(B)
CS-00051
CS-00869
(A) Stay
9) Lift up the vehicle.
(B) Rod
10) Remove the center exhaust pipe (rear). <Ref.
to EX(w/o STI)-2, General Description.> 14) Remove the cushion rubber from the vehicle
11) Remove the heat shield cover. body.
(A)
(B)
MT-01660
CS-00052
12) Remove the stay from transmission bracket.
(A) Stay
(B) Cushion rubber
15) Extract the spring pin and remove the joint.

(A)
(A)
(B)
MT-02037
(B)
(A) Stay
(B) Transmission bracket
CS-00053
(A) Joint
(B) Spring pin
CS-8
MT Gear Shift Lever

CONTROL SYSTEMS
17) Remove the gear shift lever. 6) Install the reverse check cable end, washer and
snap pin to the reverse check lever.
NOTE:
• Pay attention to the installing direction of the
snap ring.
• Before installing, adjust the reverse check cable.
<Ref. to CS-25, ADJUSTMENT, Reverse Check
Cable.>
CS-00870 (C)
B: INSTALLATION
(D)
1. STI MODEL
1) Insert the gear shift lever from the room side.
NOTE: (A)
(B)
After inserting the rod and stay, temporarily put CS-00224
them onto transmission mount.
2) Lift up the vehicle. (A) Reverse check cable
3) Mount the cushion rubber on the body. (B) Washer
Tightening torque: (C) Snap pin
18 N·m (1.8 kgf-m, 13.3 ft-lb) (D) Front side
7) Install the heat shield cover.
CS-00222
4) Move the transmission to the right side of the ve-

MT-01660
hicle, and install the joint COMPL and stay.
8) Install the center exhaust pipe. <Ref. to EX(w/o
Tightening torque: STI)-2, General Description.>
T1: 12 N·m (1.2 kgf-m, 8.9 ft-lb) 9) Install the under cover.
T2: 32 N·m (3.3 kgf-m, 23.6 ft-lb) 10) Install the plate COMPL.
(A) NOTE:
Be careful not to twist the inner boot when install-
T1 ing.
Tightening torque:
T2
18 N·m (1.8 kgf-m, 13.3 ft-lb)
(1) Set the plate COMPL to the vehicle.
(2) Temporarily tighten the bolt (A).
(3) Tighten the bolt (B).
CS-00223 (4) Tighten the bolt (A).
(A) Reverse check cable
5) Install the crossmember. <Ref. to 6MT-29, IN-

STALLATION, Transmission Mounting System.>
CS-9
MT Gear Shift Lever

CONTROL SYSTEMS
(5) Tighten the bolts (C) and (D). 2) Insert the gear shift lever from the room side.
NOTE:
(C) (B) Insert the rod and the stay, and then temporarily set
them onto the transmission mount.
(D) (A)
CS-00737
11) Install the harness clamp to the plate COMPL.

12) Install the boot and insulator assembly, and se-
cure with a clamp. CS-00870

4) Mount the cushion rubber on the vehicle body.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
(A)
CS-00927
13) Install the console side cover and console front

panel. <Ref. to EI-54, INSTALLATION, Center (B)
Console.>
14) Install the console box. <Ref. to EI-51, INSTAL-
CS-00052
LATION, Console Box.>
15) Install the gear shift knob. (A) Stay
16) Make sure the gears can be shifted accurately (B) Cushion rubber
into each gear.
2. EXCEPT FOR STI MODEL 5) Using new self-locking nuts, connect the rod to
the joint.
1) Install the joint to the transmission and secure
with a spring pin. Tightening torque:
12 N·m (1.2 kgf-m, 8.9 ft-lb)
(A)
(A)
(B)
(B)
CS-00053
CS-00051
(A) Joint
(B) Spring pin (A) Stay
(B) Rod
CS-10
MT Gear Shift Lever

CONTROL SYSTEMS
6) Using new self-locking nuts, connect the stay to 12) Install the console side cover and console front
the transmission bracket. panel. <Ref. to EI-54, INSTALLATION, Center
Console.>
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
14) Install the gear shift knob.
15) Make sure the gears can be shifted accurately
into each gear.
16) Connect the battery ground terminal.
(A)
C: DISASSEMBLY
1. STI MODEL
(B)
1) Remove the spring pin from the slider.
MT-02037
(B)
(A) Stay
(B) Transmission bracket
7) Install the heat shield cover. <Ref. to EI-74, IN-

STALLATION, Heat Shield Cover.> (A)
8) Install the center exhaust pipe (rear). <Ref. to
EX(w/o STI)-2, General Description.>
9) Install the plate COMPL to the body. CS-00225
Tightening torque:
(A) Slider
18 N·m (1.8 kgf-m, 13.3 ft-lb)
(B) Spring pin
(1) Set the plate COMPL to the vehicle.
(2) Temporarily tighten the bolt (A).
2) Remove the slider and spring.
(3) Tighten the bolt (B).
(4) Tighten the bolt (A).
(5) Tighten the bolts (C) and (D). (A)
(C) (B) (B)
(D) (A) CS-00226
(A) Slider
CS-00737 (B) Spring
10) Install the harness clamp to the plate.
11) Install the boot and insulator assembly, and se- 3) Cut off the band clip.
cure with a clamp.
CS-00227
CS-00732
CS-11
MT Gear Shift Lever

CONTROL SYSTEMS
4) Remove the reverse check cable from the cable 7) Disassemble the lock wire.
plate. NOTE:
Do not reuse the lock wire.
(B)
(A)
(A)
CS-00228
(A) Cable plate CS-00231
(B) Reverse check cable (A) Lock wire
5) Remove the reverse check cable from the gear 8) Remove the boss from the rod.
shift assembly.
(B)
(A)
CS-00232
CS-00229
6) Remove the holder and spring. (A) Rod

(B) Boss
(A)
9) Remove the rod from lever.
(B)
(A)
CS-00230
(A) Holder
(C)
CS-00233
(A) Rod
(B) Lever
(C) Stay
10) Separate the rod and inner boot.
CS-12
MT Gear Shift Lever

CONTROL SYSTEMS
11) Remove the snap ring from the stay. 14) Remove the spring pin, and then remove the
bushing and snap ring.
(B)
(A)
CS-00234 (A)
CS-00237
(A) Snap ring
(A) Bushing
12) Separate the gear shift lever and the stay. (B) Snap ring
15) Remove the bushing and spacer from the boss.
(A)
(B)
CS-00235
13) Remove the O-ring and bushing from the gear

(A) CS-00238
shift lever.
(A) Bushing
(B) Spacer
(A) (B) (A)
16) Remove the bushing and cushion rubber from

the stay.
(C)
(B)
CS-00236
(A) O-ring
(B) Bushing
(A)
CS-00239
(A) Bushing
(B) Stay
(C) Cushion rubber
CS-13
MT Gear Shift Lever

CONTROL SYSTEMS
2. EXCEPT FOR STI MODEL 5) Separate the gear shift lever and the stay.
1) Remove the lock wires.
(A)
CS-01413
CS-00316 6) Remove the O-ring and bushing from the gear

shift lever.
(A) Lock wire
2) Remove the rod from lever.

(A) (B) (A)
(B)
(A)
CS-01415
(A) O-ring
(C)
CS-00317 (B) Bushing
(A) Rod
7) Remove the spring pin, and then remove the
(B) Lever bushing and snap ring.
(C) Stay
(A)
3) Separate the rod and inner boot.
4) Remove the snap ring from the stay.
(B)
(C)
(A) CS-01414
(A) Spring pin

(B) Bushing
CS-00318 (C) Snap ring
(A) Snap ring
CS-14
MT Gear Shift Lever

CONTROL SYSTEMS
8) Remove the boss from the joint. D: ASSEMBLY

NOTE:
• Clean all the parts before assembly.
• Apply NIGTIGHT LYW No. 2 grease or equiva-
lent to each part. <Ref. to CS-3, 6MT GEAR SHIFT
LEVER, COMPONENT, General Description.>
1. STI MODEL
1) Mount the bushing and cushion rubber to the
stay.
CS-00322
(C)
9) Remove the bushing and spacer from the boss.
(B)
(A)
(B)
(A)
CS-00239
(A) Bushing
(A) CS-00238
(B) Stay
(A) Bushing (C) Cushion rubber
(B) Spacer
2) Install the bushing and spacer to boss.
10) Remove the bushing and cushion rubber from
(A)
the stay.
(A) (B)
(B)
(C)
(A) CS-00238
(A) Bushing
CS-00058
(B) Spacer
(A) Bushing
(B) Stay
(C) Cushion rubber
CS-15
MT Gear Shift Lever

CONTROL SYSTEMS
3) Install the snap ring to gear shift lever and install 6) Install the snap ring.
the bushing.
NOTE:
Apply grease to the bushing.
(A)
(B) CS-00234
(A) Snap ring

(A)
CS-00237 7) Insert the gear shift lever and rod into boot hole.
8) Install the rod.
(A) Bushing
(B) Snap ring Tightening torque:
12 N·m (1.2 kgf-m, 8.9 ft-lb)
4) Apply grease to the bushing and O-ring, and
then install to gear shift lever.
(B)
(A)
(A) (B) (A)
(C)
CS-00233
CS-00236 (A) Rod

(B) Lever
(A) O-ring (C) Stay
(B) Bushing
9) Install the boss to the rod.
5) Apply sufficient grease into boss, and then install
the gear shift lever to the stay. Tightening torque:
12 N·m (1.2 kgf-m, 8.9 ft-lb)
(B)
(A)
CS-00235
CS-00232
(A) Rod
(B) Boss
CS-16
MT Gear Shift Lever

CONTROL SYSTEMS
10) Install a new lock wire. 11) Install the holder.

Tightening torque:
1.3 N·m (0.1 kgf-m, 1.0 ft-lb)
(A)
(A)
CS-00231
(A) Lock wire

CS-00230
NOTE:
(A) Holder
• Install the lock wire to the stay groove.
• Bend the extra wire to the same direction of lock 12) Insert the reverse check cable into the boot
wire winding. hole.
(A) (A)
13) Insert the reverse check cable into the gear
shift assembly, and fix in place with a band clip.
B B
NOTE:
• Cut the excess band clip.
(B) • Make sure that the reverse check cable is insert-
(B)
ed into the gearshift lever with no gaps.
(C)
CS-00227
(B)
14) Install the seat cushion and spring.
B-B (A)
CS-00240
(A) Inner boot

(B) Lock wire (B)
(C) Stay
CS-00241
(A) Spring
(B) Seat cushion
CS-17
MT Gear Shift Lever

CONTROL SYSTEMS
15) Use the spring pin to secure the end of the slid- 2. EXCEPT FOR STI MODEL
er and reverse check cable.
NOTE:
NOTE: • Clean all the parts before assembly.
Apply grease to the moving part of slider. • Apply NIGTIGHT LYW No. 2 grease or equiva-
lent to each part. <Ref. to CS-4, 5MT GEAR SHIFT
LEVER, COMPONENT, General Description.>
(B)
1) Mount the bushing and cushion rubber to the
stay.
(A)
(A)
(B)
CS-00225
(A) Slider
(B) Spring pin
CS-00061
16) With the cable pulled (the slider is lowered), ad-
just the distance between the edge of cable plate (A) Bushing
and the reverse check cable to 84 mm (3.31 in), (B) Cushion rubber
and tighten the lock nut.
Tightening torque: 2) Install the bushing and spacer to boss.
6 N·m (0.6 kgf-m, 4.4 ft-lb)
(A)
(B)
(A)
(A) CS-00238
CS-00242
(A) Bushing
(A) 84 mm (3.31 in) (B) Spacer
17) Secure the reverse check cable to the stay clip. 3) Using new self-locking nuts, install the boss to
the joint.
NOTE:
Install the reverse check cable on top of the stay. Tightening torque:
12 N·m (1.2 kgf-m, 8.9 ft-lb)
(B)
(A)
CS-00243
CS-00322
(B) Clip
CS-18
MT Gear Shift Lever

CONTROL SYSTEMS
4) Install the snap ring to gear shift lever and install 7) Install the snap ring.
the bushing.
NOTE:
Apply grease to the bushing.
(A)
(A)
(B)
(C)
CS-00318
(A) Snap ring
CS-01414 8) Insert the gear shift lever and rod into boot hole.
9) Install the rod.
(A) Spring pin
(B) Bushing Tightening torque:
(C) Snap ring 12 N·m (1.2 kgf-m, 8.9 ft-lb)
5) Apply grease to the bushing and O-ring, and

then install to gear shift lever.
(B)
(A)
(A) (B) (A)
(C)
CS-00317
(A) Rod
CS-01415 (B) Lever
(C) Stay
(A) O-ring
(B) Bushing
6) Apply sufficient grease into boss, and then install

the gear shift lever to the stay.
CS-01413
CS-19
MT Gear Shift Lever

CONTROL SYSTEMS
10) Install a new lock wire. E: INSPECTION

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.
• STI model
(A)
CS-00316 (C)
(F)
(A) Lock wire
(A)
NOTE:
• Install the lock wire to the stay groove.
• Bend the extra wire to the same direction of lock (A) (C)
wire winding.
(A)
(A) (A) (C)
B B
(B)
(B) (D)
(B)
(E)
(C)
CS-00921
(A) Bushing
(B) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(B) (F) Rod
B-B
CS-00240
(A) Inner boot

(B) Lock wire
(C) Stay
CS-20
MT Gear Shift Lever

CONTROL SYSTEMS
• Except for STI model • Except for STI model
(C)
(F) (A)
(A) (B)
(A) (C)
(A)
CS-00116
(C)
(D)
(A) Pivot
(B) Swing torque
(B)
(E)
CS-01045
(A) Bushing
(B) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod
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
• STI model
(A)
(B)
CS-00116
(A) Pivot
(B) Swing torque
CS-21
Reverse Check Cable

CONTROL SYSTEMS
3. Reverse Check Cable 7) Remove the slider and spring.
A: REMOVAL
(A)
1) Remove the gear shift knob.
2) Remove the console box. <Ref. to EI-51, RE-
MOVAL, Console Box.> (B)
3) Remove the console side cover and console
front panel.
4) Remove the clamp.
CS-00226
(A) Slider
(B) Spring
8) Cut the band clip, and separate the reverse

check cable from the gear shift lever.
CS-00926
CS-00227

10) Remove the under cover.
CS-00927
6) Remove the spring pin from the slider. 12) Remove the heat shield cover.
(B)
(A)
CS-00225 MT-01660
(A) Slider 13) Remove the crossmember. <Ref. to 6MT-29,

(B) Spring pin
CS-22
Reverse Check Cable

CONTROL SYSTEMS
14) Remove the snap pin and washer, and sepa- 17) Pull out the reverse check cable from under-
rate the reverse check cable from the reverse side of the vehicle to remove it.
check lever. NOTE:
Be careful not to damage the inner boot.
18) Loosen the lock nut, and remove the reverse
(A) check cable from the cable plate.
(B) (B)
(C)
CS-00220
(A) Snap pin (A)
(B) Washer
CS-00228
(A) Cable plate
15) Move the transmission to the right side, and re-
(B) Reverse check cable
move the stay bolts and the reverse check cable.
NOTE: B: INSTALLATION
If the transmission is not moved aside, the stay 1) Insert the reverse check cable into the inner boot
bolts may contact the body and cause damage. hole from underside of the vehicle.
(A)
2) Insert the reverse check cable into the gear shift
lever assembly, and secure it with the band clip.
NOTE:
• Cut the excess band clip.
(B)
• Make sure that the reverse check cable is insert-
ed into the gearshift lever with no gaps.
CS-00245
(A) Stay
(B) Stay bolt
16) Lift up the stay clip, and separate the stay from
the reverse check cable.
CS-00247
(B)
(A)
CS-00243

(B) Clip
CS-23
Reverse Check Cable

CONTROL SYSTEMS
3) Use the spring pin to secure the end of the slider 6) Install the reverse check cable, washer and snap
and reverse check cable. pin to the reverse check lever.
NOTE: NOTE:
Apply grease to the moving part of slider. Make sure to point the snap pin in an appropriate
direction.
(B)
(C)
(D)
(A)
CS-00225 (B) (A)

CS-00224
(A) Slider
(B) Spring pin (A) Reverse check cable
(B) Washer
4) With the cable pulled (the slider is lowered), ad- (C) Snap pin
just the distance between the edge of cable plate (D) Front side
and the reverse check cable to 84 mm (3.31 in),
and tighten the lock nut. 7) Secure the reverse check cable to the stay clip.
Tightening torque: NOTE:
6 N·m (0.6 kgf-m, 4.4 ft-lb) Install the reverse check cable on top of the stay.
(B)
(A)
(A)
CS-00242 CS-00243
(A) 84 mm (3.31 in) (A) Reverse check cable

(B) Clip
5) Move the transmission to the right side, and in-
stall the stay. 8) Install the heat shield cover.
Tightening torque: Tightening torque:
T: 32 N·m (3.3 kgf-m, 23.6 ft-lb) 18 N·m (1.8 kgf-m, 13.3 ft-lb)
(A)
CS-00246 MT-01660
(A) Stay 9) Install the center exhaust pipe. <Ref. to EX(STI)-

9, INSTALLATION, Center Exhaust Pipe.>
CS-24
Reverse Check Cable

CONTROL SYSTEMS
10) Install the boot and insulator assembly, and se- 6) Remove the snap pin and washer, and separate
cure with a clamp. the reverse check cable from the reverse check le-
ver.
(A)
(B)
CS-00926 (C)
CS-00220
11) Install the console side cover and console front
panel. <Ref. to EI-54, INSTALLATION, Center (A) Snap pin
Console.>
(B) Washer
13) Install the gear shift knob.
7) Move the transmission to the right side, and re-
C: INSPECTION move the stay bolts and the reverse check cable.
1) Make sure the slider moves smoothly. If it does NOTE:
not move, adjust the reverse check cable, or check If the transmission is not moved aside, the stay
the slider for damage. <Ref. to CS-25, ADJUST- bolts may contact the body and cause damage.
MENT, Reverse Check Cable.>
2) Check if the gear shifts into reverse when pulling (A)
up the slider. If the gear cannot shift into reverse,
adjust the reverse check cable. <Ref. to CS-25,
ADJUSTMENT, Reverse Check Cable.>
(B)
3) Check that the gear does not shift into reverse
when the slider is not pulled up. If the gear shifts
into reverse, adjust or replace the reverse check
cable. <Ref. to CS-25, ADJUSTMENT, Reverse
Check Cable.>
CS-00245
D: ADJUSTMENT
(A) Stay
(B) Stay bolt
2) Remove the transmission under cover.
3) Remove the center exhaust pipe. <Ref. to 8) With the cable pulled (the slider is lowered), ad-
EX(STI)-8, REMOVAL, Center Exhaust Pipe.> just the distance between the edge of cable plate
4) Remove the heat shield cover. and the reverse check cable to 84 mm (3.31 in),
and tighten the lock nut.
Tightening torque:
6 N·m (0.6 kgf-m, 4.4 ft-lb)
MT-01660
(A)
5) Remove the crossmember. <Ref. to 6MT-29,
CS-00242
(A) 84 mm (3.31 in)
CS-25
Reverse Check Cable

CONTROL SYSTEMS
9) Move the transmission to the right side, and in- 13) Install the reverse check cable, washer and
stall the stay. snap pin to the reverse check lever.
T: 32 N·m (3.3 kgf-m, 23.6 ft-lb) Make sure to point the snap pin in an appropriate
direction.
(A)
(C)
T
(D)
CS-00246 (B) (A)

CS-00224
(A) Stay
10) Install the crossmember. <Ref. to 6MT-29, IN- (B) Washer
STALLATION, Transmission Mounting System.> (C) Snap pin
11) Install the heat shield cover. (D) Front side
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb) 14) Install the transmission under cover.
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
MT-01660
12) Install the center exhaust pipe. <Ref. to

EX(STI)-9, INSTALLATION, Center Exhaust
Pipe.>
CS-26

CONTROL SYSTEMS
4. General Diagnostic Table

A: INSPECTION
Symptoms Possible cause Corrective action
MT gear shift lever (6MT) Cannot shift into reverse. Adjust the reverse check cable.
Can shift into reverse when the slider is not pulled up. Adjust or replace the reverse check cable.
Slider cannot be pulled up or sticks in the pulled-up • Check the reverse check system of the
position. transmission.
• Adjust or replace the reverse check cable.
CS-27

DIFFERENTIAL
5MT
Page
2. Transmission Gear Oil .............................................................................21
3. Manual Transmission Assembly ..............................................................22
4. Transmission Mounting System ...............................................................28
5. Oil Seal .....................................................................................................30
6. Differential Side Retainer Oil Seal ............................................................31
7. Switches and Harness .............................................................................32
8. Preparation for Overhaul ..........................................................................33
9. Transfer Case and Extension Case Assembly .........................................34
10. Transfer Drive Gear .................................................................................40
11. Transfer Driven Gear ...............................................................................42
12. Center Differential ....................................................................................44
13. Reverse Check Sleeve .............................................................................45
14. Transmission Case ..................................................................................48
15. Main Shaft Assembly for Single-Range ...................................................52
16. Drive Pinion Shaft Assembly ....................................................................57
17. Front Differential Assembly ......................................................................68
18. Reverse Idler Gear ...................................................................................76
19. Shifter Fork and Rod ................................................................................78
General Description
MANUAL TRANSMISSION AND DIFFERENTIAL
A: SPECIFICATION
1. MANUAL TRANSMISSION AND DIFFERENTIAL
Model Turbo model
Type 5-forward speeds and 1-reverse (all stage with synchromesh)
1st 3.166
2nd 1.882
3rd 1.296
Transmission gear ratio
4th 0.972
5th 0.738
Reverse 3.333
Front reduction Type of gear Hypoid
Final
gear Gear ratio 3.900
Type of gear Helical
Transfer
Rear reduction Gear ratio 1.000
gear Type of gear Hypoid
Final
Gear ratio 3.900
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 3.5 L (3.7 US qt, 3.1 Imp qt)
2. TRANSMISSION GEAR OIL

Recommended oil:
GL-5 (75W-90) or equivalent
5MT-2
General Description
B: COMPONENT
1. TRANSMISSION CASE
(6)
(7)
(8)
(4)
(5)
(1)
(2)
(3)
MT-02724
(1) Transmission case ASSY (5) Harness clip Tightening torque: N·m (kgf-m, ft-lb)
(2) Gasket (6) Pitching stopper bracket T: 44 (4.5, 32.5) (Aluminum gasket,
silver)
(3) Drain plug (7) Oil level gauge 70 (7.1, 51.6) (Copper gasket,
brown)
(4) Harness bracket (8) Transmission radio ground cord 70 (7.1, 51.6) (Metal gasket,
black)
5MT-3
General Description
Transmission case tightening torque

Bolt size Tightening torque:
Bolt No.
(16)
mm N·m (kgf-m, ft-lb)
(9) (5) (7)
(5) — (15) 8 25 (2.5, 18.4)
(17)
(13) (11)
(1)
(3)
(15) (2) (1) — (4)
10 39 (4.0, 28.8)
(16), (17)
(4)
(14)
(10) (6) (8) (12)
MT-00003
5MT-4
General Description
2. DRIVE PINION ASSEMBLY
(4) (5)
(3)
(2)
(1)
(17)
(16)
(8) (15)
(14)
(7)
(13)
(12)
(11)
(10)
(9) (28)
(6) T1 (27) T3
(26)
T1
(25)
(24)
(23)
(22) T2
(34)
(21)
(33)
(20) (32)
(19) (31)
(18) (29)
(30)
(29)
MT-02938
(1) Drive pinion shaft (14) Outer baulk ring (27) Lock washer
(2) Roller bearing (15) 1st-2nd synchronizer hub (28) Lock nut
(3) Washer (16) Ball detent (29) Adjusting washer
(4) Thrust bearing (17) Reverse driven gear (30) Thrust bearing
(5) Needle bearing (18) Outer baulk ring (31) Differential bevel gear sleeve
(6) Driven shaft (19) Synchro cone (32) Washer
(7) Key (20) Inner baulk ring (33) Lock washer
(8) Woodruff key (21) 2nd driven gear (34) Lock nut
(9) Drive pinion collar (22) 2nd driven gear bushing
(10) Needle bearing (23) 3rd-4th driven gear Tightening torque: N·m (kgf-m, ft-lb)
(11) 1st driven gear (24) Driven pinion shim T1: 30 (3.1, 22.1)
(12) Inner baulk ring (25) Double taper roller bearing T2: 120 (12.2, 88.5)
(13) Synchro cone (26) 5th driven gear T3: 260 (26.5, 191.8)
5MT-5
General Description
3. MAIN SHAFT FOR SINGLE-RANGE
(3)
(17)
(2) (16)
(1) (15)
(14)
(13)
(11) (12)
(10)
(9)
(8)
(7)
(6)
(5)
(4)
(26)
(25)
(24)
(23)
(22) (31)
(21)
(30)
(20) (29)
(19) (28)
(18) (27)
MT-02939
(1) Oil seal (13) 4th drive gear (25) Lock washer
(2) Needle bearing (14) 4th needle bearing race (26) Lock nut
(3) Transmission main shaft (15) Needle bearing (27) Straight pin
(4) Needle bearing (16) 4th gear thrust washer (28) Reverse idler gear shaft
(5) 3rd drive gear (17) Double taper roller bearing (29) Washer
(6) Inner baulk ring (18) 5th needle bearing race (30) Reverse idler gear
(7) 3rd synchro cone (19) Needle bearing (31) Washer
(8) Outer baulk ring (20) Main shaft rear plate
(9) 3rd-4th coupling sleeve (21) 5th drive gear Tightening torque: N·m (kgf-m, ft-lb)
(10) 3rd-4th synchronizer hub (22) 5th baulk ring T: 120 (12.2, 88.5)
(11) 3rd-4th shifting insert key (23) Baulk lever
(12) 4th baulk ring (24) 5th hub & sleeve No. 2
5MT-6
General Description
4. SHIFTER FORK AND SHIFTER ROD
(1)
(2)
(8)
(7)
(4)
(6)
(5)
T
(3)
(12)
(18)
(9)
(10)
(10)
(6)
(7)
(5)
(17) T
(16)
(8)
(10)
(11)
(3)
(6)
(15) (5)
(14) T
(8)
(7)
(3) (13)
MT-01985
(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: N·m (kgf-m, ft-lb)
(7) Checking ball spring (14) Ball T: 20 (2.0, 14.8)
5MT-7
General Description
5. TRANSFER CASE AND EXTENSION

T3 (7)
(4) (5)
T2
T3 (40)
(6)
(3) (39)
(2) (8) T3
(1) (20)
(38) (21)
T1 T5
(23)
(22) T5
(39) (9)
(11)
(13)
(15)
(17)
(10) (19)
(12) (35)
T1
(14) (34)
(18) (36)
T3
(16) T6
(26) (27)
(25)
(24)
(31)
T6
(30)
(37) (33)
(29)
(32)
(28)
T4
MT-02940
5MT-8
General Description
(1) Oil guide (17) O-ring (33) Extension case

(2) Gasket (18) Adjusting select shim (34) Oil seal
(3) Transfer case (19) Reverse check sleeve (35) Dust cover
(4) Ball (20) Gasket (36) Shift bracket
(5) Reverse accent spring (21) Neutral position switch (37) Snap ring
(6) Gasket (22) Gasket (38) Precoat bolt
(7) Plug (23) Back-up light switch (39) Roller bearing
(8) Oil seal (24) Roller bearing (40) Transmission hanger
(9) Snap ring (inner) (25) Transfer driven gear
(10) Reverse check plate (26) Roller bearing Tightening torque: N·m (kgf-m, ft-lb)
(11) Reverse check spring (27) Thrust washer T1: 6.4 (0.7, 4.7)
(12) Reverse return spring (28) Ball bearing T2: 9.75 (1.0, 7.2)
(13) Reverse check cam (29) Center differential T3: 24.5 (2.5, 18.1)
(14) Reverse accent shaft (30) Thrust washer T4: 26 (2.7, 19.2)
(15) Return spring cap (31) Transfer drive gear T5: 32.3 (3.3, 23.8)
(16) Return spring (32) Ball bearing T6: 40 (4.1, 29.5)
5MT-9
General Description
6. FRONT DIFFERENTIAL
(7)
(5)
(6)
(1)
(6)
(5)
(8) (2)
(7)
(3)
(4)
T2
(8)
(11)
(10) (10)
(12)
(12)
(9)
(13)
T1 (13) (11) T1
MT-02932
(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: N·m (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, 45.7)
(6) Differential bevel gear (12) O-ring
5MT-10
General Description
7. TRANSMISSION MOUNTING
(4) (6)
(3)
T3 (5)
(2)
T2
T4
T1
(1) (11)
(8)
(3)
(10)
(2)
(7) (9)
T1
T4
T4
T5
MT-01808
(1) Pitching stopper (7) Upper cushion rubber Tightening torque: N·m (kgf-m, ft-lb)
(2) Spacer (8) Center crossmember T1: 35 (3.6, 25.8)
(3) Lower cushion rubber (9) Rear plate T2: 50 (5.1, 36.9)
(4) Front plate (10) Front crossmember T3: 58 (5.9, 42.8)
(5) Transmission cushion rubber (11) Rear cushion rubber T4: 70 (7.1, 51.6)
(6) Rear crossmember T5: 140 (14.3, 103.3)
5MT-11
General Description
C: CAUTION
• Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing
any work.
• Remove contamination including dirt and corrosion before removal, installation or disassembly.
• Keep the disassembled parts in order and protect them from dust and dirt.
• Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, in-
stallation, disassembly and replacement.
• When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry
apart with screwdrivers or other tools.
• Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
• Use SUBARU genuine gear oil, grease or equivalent. Do not mix gear oil, grease, etc. of different grades
or manufacturers.
• Be sure to tighten fasteners including bolts and nuts to the specified torque.
• Place shop jacks or rigid racks at the specified points.
• Apply gear oil onto sliding or revolving surfaces before installation.
• Replace deformed or damaged snap rings with new parts.
• Before installing O-rings or oil seals, apply sufficient amount of gear oil to avoid damage and deformation.
• Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts.
• Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth
between the part and the vise.
• Avoid damaging the mating surface of the case.
• Before applying liquid gasket, completely remove the old liquid gasket.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
399411700 ACCENT BALL Used for installing reverse shifter rail arm.
INSTALLER
ST-399411700
899524100 PULLER SET Used for removing and installing the front differ-
ential roller bearing.
1. PULLER
2. ADAPTER
ST-899524100
5MT-12
General Description

399780104 WEIGHT Used for measuring preload on the front differen-
tial roller bearing.
ST-399780104
498077000 REMOVER • Used for removing the roller bearing of the

drive pinion shaft.
• Used for removing the roller bearing of the
transfer driven gear.
ST-498077000
498077300 CENTER DIFFER- Used for removing the center differential cover
ENTIAL BEARING ball bearing.
REMOVER
ST-498077300
498147001 DEPTH GAUGE Used for adjusting the extension end play and
main shaft end play.
ST-498147001
498247001 MAGNET BASE • Used for measuring the backlash between

bevel pinion gear and hypoid gear.
• Used together with DIAL GAUGE
(498247100).
ST-498247001
5MT-13
General Description

498247100 DIAL GAUGE • Used for measuring the backlash between
bevel pinion gear and hypoid gear.
• Used together with MAGNET BASE
(498247001).
ST-498247100
498427100 STOPPER • Used for removing and installing the drive pin-
ion shaft assembly lock nut.
• Used for backlash measurement of the hypoid
gear and preload adjustment of the roller bear-
ing.
ST-498427100
498937000 TRANSMISSION Used for removing and installing the main shaft
HOLDER lock nut.
ST-498937000
499277100 BUSHING 1-2 • Used for installing the front differential roller
INSTALLER bearing inner race.
• Used for installing drive pinion shaft washer.
ST-499277100
499277200 INSTALLER • Used for installing the 2nd driven gear bush-
ing, 3rd-4th driven gear, roller bearing and 5th
driven gear.
• Used for installing drive pinion shaft washer.
ST-499277200
5MT-14
General Description

499757002 INSTALLER • Used for attaching the snap ring (outer 25).
• Used for removing the roller bearing and
driven gear of the drive pinion shaft.
ST-499757002
927640000 INSTALLER Used for installing the roller bearing (transfer

case side) of transfer driven gear.
ST-927640000
18630AA010 WRENCH COMPL • Used for removing and installing the differen-
RETAINER tial side retainer.
• Used for backlash measurement of the front
differential hypoid gear and preload adjustment
of the roller bearing.
• WRENCH ASSY (499787000) can also be
used.
ST18630AA010
499857000 5TH DRIVEN GEAR Used for removing the 5th driven gear.
REMOVER
ST-499857000
499877000 RACE 4-5 • Used for installing the 4th drive gear needle
INSTALLER bearing race, main shaft ball bearing and 5th
drive gear thrust washer.
• Used together with REMOVER (899714110).
ST-499877000
5MT-15
General Description

499917500 DRIVE PINION Used for adjusting the drive pinion shaft shim.
GAUGE ASSY
ST-499917500
499927100 HANDLE Used for backlash measurement of the front dif-

ferential hypoid gear and preload adjustment of
the roller bearing.
ST-499927100
499937100 TRANSMISSION Used for disassembling and assembling the

STAND transmission.
ST-499937100
499987003 SOCKET WRENCH Used for removing and installing the driven pin-
(35) ion lock nut and main shaft lock nut.
ST-499987003
499987300 SOCKET WRENCH Used for removing and installing the driven gear
(50) assembly lock nut.
ST-499987300
5MT-16
General Description

899714110 REMOVER Used for installing the transmission main shaft,
drive pinion shaft and rear drive shaft.
ST-899714110
899864100 REMOVER • Used for removing transmission main shaft

parts.
• Used for installing the roller bearing of the
transfer case.
• Used for installing the roller bearing of transfer
driven gear (extension case side).
driven gear (transfer case side).
ST-899864100
899884100 HOLDER • Used for removing and installing the drive pin-
ion shaft lock nut.
• Used for removing and installing the driven
shaft lock nut.
• Used for measuring the starting torque of the
drive pinion shaft.
ST-899884100
899904100 STRAIGHT PIN Used for removing and installing the straight pin.
REMOVER
ST-899904100
899988608 SOCKET WRENCH • Used for removing and installing the drive pin-
(27) ion shaft lock nut.
• Used for measuring the starting torque of the
drive pinion shaft.
ST-899988608
5MT-17
General Description

398497701 ADAPTER Used for installing the front differential roller
bearing.
ST-398497701
499587000 INSTALLER Used for installing the driven shaft parts.
ST-499587000
498057300 INSTALLER Used for installing the extension oil seal.
ST-498057300
498255400 PLATE Used for adjusting the extension end play.
ST-498255400
41099AC000 ENGINE SUPPORT Used for supporting engine.

ASSY
ST41099AC000
5MT-18
General Description

398527700 PULLER ASSY • Used for removing the extension oil seal.
• Used for removing the bearing outer race and
oil seal of front differential side retainer.
ST-398527700
398643600 GAUGE Used for adjusting the extension end play.
ST-398643600
398177700 INSTALLER Used for installing the ball bearing of the transfer
drive gear.
ST-398177700
498175500 INSTALLER Used for installing the roller bearing of transfer

ST-498175500
28399SA010 OIL SEAL PROTEC- Used for protecting the oil seal from damage
TOR when inserting the front drive shaft.
ST28399SA010
5MT-19
General Description

18675AA000 DIFFERENTIAL Used for installing the differential side retainer oil
SIDE OIL SEAL seal.
INSTALLER
ST18675AA000
398791700 STRAIGHT PIN Used for installing and removing the straight pin.
REMOVER 2
ST-398791700
498267200 CYLINDER HEAD Used for removing and installing the roller bear-
TABLE ing of the transfer case.
ST-498267200
498267300 CYLINDER HEAD Used for removing and installing the roller bear-
TABLE ing of the transfer case.
ST-498267300
2. GENERAL TOOL
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and current.
TORX® bit T70 Used for installing and removing the drain plug.
5MT-20
Transmission Gear Oil

2. Transmission Gear Oil B: REPLACEMENT

1) Pull out the oil level gauge.
A: INSPECTION 2) Lift up the vehicle.
1) Park the vehicle on a level surface. 3) Using the TORX® bit T70, remove the drain
2) Turn the ignition switch to OFF, and wait until the plug, and drain the transmission gear oil complete-
engine cools. ly.
3) Remove the oil level gauge and wipe it clean.
CAUTION:
4) Reinsert the oil level gauge all the way. Be sure
that the oil level gauge is correctly inserted in the • Immediately after the vehicle has been run-
proper direction. ning or after idling for a long time, the transmis-
5) Pull out the oil level gauge again, and check the sion gear oil will be hot. Be careful not to
oil level. If it is below the lower level, add oil through receive burns.
the oil level gauge hole to bring the level up to the • Be careful not to spill the transmission gear
upper level. oil on the exhaust pipe, to prevent emission of
smoke or causing a fire. If gear oil is spilled,
(A) wipe it off completely.
4) Tighten the drain plug using TORX® bit T70.
NOTE:
• Tighten the drain plug after draining the trans-
F
(B) mission gear oil.

(C) • Use a new gasket.
L
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gas-
PI-00564 ket silver)
70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket,
(A) Oil level gauge brown)
(B) Upper level 70 N·m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket,
(C) Lower level black)
MT-01548

6) Pour gear oil through the oil level gauge hole.
Recommended gear oil:
Gear oil capacity:
3.5 L (3.7 US qt, 3.1 Imp qt)
7) Measure the transmission gear oil amount, and
check that it is within the specification.
5MT-21
Manual Transmission Assembly

3. Manual Transmission As- 10) Remove the operating cylinder from the trans-
mission, and suspend on a wire.
sembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Open the front hood.
4) Drain transmission gear oil completely. <Ref. to
5MT-21, REPLACEMENT, Transmission Gear
Oil.>
5) Remove the intercooler. <Ref. to IN(w/o STI)-12,
REMOVAL, Intercooler.> CL-00253
6) Disconnect the following connector. 11) Remove the pitching stopper.
(A)
(B)
MT-01649 MT-00069
(A) Neutral position switch and back-up light switch 12) Set the ST.
connector ST 41099AC000 ENGINE SUPPORT ASSY
(B) Rear oxygen sensor connector
7) Disconnect the transmission radio ground termi-

nal.
ST
MT-01226

MT-01650 15) Remove the rear exhaust pipe and muffler.
8) Remove the engine hanger. <Ref. to EX(w/o STI)-2, General Description.>
CAUTION:
When removing the exhaust pipes, make sure
that each exhaust pipe does not drop off.
AT-04582
9) Remove the starter. <Ref. to SC(w/o STI)-2,

General Description.>
5MT-22

16) Remove the bolts which hold upper side of 20) Remove the gear shift rod and the stay from the
transmission to engine. transmission.
(1) Disconnect the stay from the transmission.
(2) Disconnect the gear shift rod from the trans-
mission.
(A)
(B)
(B)
MT-01524

MT-00075
(A) Stay
(B) Gear shift rod
21) Disconnect the stabilizer link from the front

arm.
MT-01660
18) Remove the hangar bracket from the transmis-

sion.
MT-01655
22) Remove the bolt securing the ball joint of the

front arm to the housing, then separate the front
arms and the housing.
MT-01653
19) Remove the propeller shaft. <Ref. to DS-11,

REMOVAL, Propeller Shaft.>
(B)
(A)
MT-01652
(A) Front arm

(B) Ball joint
5MT-23

23) Using a crowbar, remove the left and right front 26) Remove the front crossmember and rear cross-
drive shaft from the transmission. member from the vehicle.
(A)
MT-01017 MT-01851
(A) Crowbar
27) While lowering the transmission jack, tighten
the turnbuckle of the ST, and incline the engine unit
24) Remove the bolts and nuts which hold lower rearward.
side of transmission to engine. 28) Remove the transmission.
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-31, REPLACEMENT, Differential
Side Retainer Oil Seal.>
MT-00077
ST 18675AA000 DIFFERENTIAL SIDE OIL
25) Place the transmission jack under the transmis- SEAL INSTALLER
sion.
NOTE:
CAUTION: Be sure to replace the differential side retainer oil
Always support the transmission case with a seal after removing the front drive shaft.
transmission jack.
ST
MT-00103
MT-00078
2) Tap the transmission hanger in the rear side of
transmission with a rubber hammer to bend it until
it is in close contact with the transmission case.
CAUTION:
Do not apply excessive load or impact to the
transmission case.
3) Install the transmission cushion rubber to the
transmission, and tighten the bolt (A).
5MT-24

4) Install the transmission cushion rubber to the 9) Tighten the bolts and nuts which hold the lower
center crossmember, and tighten the nut (B). side of transmission to the engine.
Bolt (A) 50 N·m (5.1 kgf-m, 36.9 ft-lb)
35 N·m (3.6 kgf-m, 25.8 ft-lb)
Nut (B)
35 N·m (3.6 kgf-m, 25.8 ft-lb)
(A)
(A)
MT-00077
10) Connect the transmission to the engine.

(B) (1) Install the starter. <Ref. to SC(w/o STI)-2,
MT-01676 General Description.>
5) Install the transmission onto the engine. (2) Tighten the bolts which hold the upper side
(1) Lift up the transmission gradually using a of the transmission to the engine.
transmission jack. Tightening torque:
(2) Engage at the spline section. 50 N·m (5.1 kgf-m, 36.9 ft-lb)
NOTE:
Be careful not to hit the main shaft against the
clutch cover.
6) While raising the transmission jack, loosen the
turnbuckle of the ST, and set the engine unit to the
original position.
7) Install the front crossmember and rear cross-
member.
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb) MT-01524
T2: 140 N·m (14.3 kgf-m, 103.3 ft-lb) 11) Remove the ST.
T1
T1
T2 T2
ST
MT-01672
MT-01226
8) Take out the transmission jack.
5MT-25

12) Install the pitching stopper. 16) Attach the stabilizer link to the front arm.
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb) 30 N·m (3.1 kgf-m, 22.1 ft-lb)
T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)
T1
T2
MT-01655
MT-00085 17) Attach the gear shift rod and stay.
13) Lift up the vehicle. (1) Attach the gear shift rod to the transmission.
14) Install the front drive shaft into the transmis- Tightening torque:
sion.
12 N·m (1.2 kgf-m, 8.9 ft-lb)
ST 28399SA010 OIL SEAL PROTECTOR
(A)
(B)
ST CS-00051
MT-02693
15) Insert the front arm ball joint into the housing (A) Stay
lower part, and tighten the mounting bolt. (B) Gear shift rod
Tightening torque: (2) Install the stay to the transmission bracket.

50 N·m (5.1 kgf-m, 36.9 ft-lb)
Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
18) Install the propeller shaft. <Ref. to DS-12, IN-
STALLATION, Propeller Shaft.>
(B)
STALLATION, Heat Shield Cover.>
20) Install the hanger bracket to the transmission.
(A)
MT-01652
(A) Front arm

(B) Ball joint
MT-01653
5MT-26

21) Install the rear exhaust pipe and muffler. <Ref. 27) Connect the following connectors.
to EX(w/o STI)-2, General Description.>
(A)
STI)-2, General Description.>
23) Install the under cover. <Ref. to EI-28, INSTAL-
LATION, Front Under Cover.>
24) Install the operating cylinder.
Tightening torque:
37 N·m (3.8 kgf-m, 27.3 ft-lb)
(B)
MT-01649
(A) Neutral position switch and back-up light switch

connector
28) Install the intercooler. <Ref. to IN(w/o STI)-12,

INSTALLATION, Intercooler.>
CL-00253 30) Remove the lift arm from vehicle.
25) Install the transmission radio ground terminal.
Tightening torque:
13 N·m (1.3 kgf-m, 9.6 ft-lb)
MT-01650
26) Install the engine hanger.

Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)
AT-04582
5MT-27
Transmission Mounting System

4. Transmission Mounting Sys- 7) Remove the front crossmember and the rear
crossmember.
tem
A: REMOVAL
1. PITCHING STOPPER
REMOVAL, Intercooler.>
3) Remove the pitching stopper.
MT-01851
8) Remove the transmission cushion rubber.

B: INSTALLATION
1. PITCHING STOPPER
1) Install the pitching stopper.
Tightening torque:
MT-00069 T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)
2. CROSSMEMBER AND CUSHION RUB-
BER
3) Remove the center exhaust pipe. <Ref. to EX(w/o T1
T2
4) Remove the rear exhaust pipe and muffler.
<Ref. to EX(w/o STI)-2, General Description.>
MT-00085
2) Install the intercooler.

<Ref. to IN(w/o STI)-12, INSTALLATION, Inter-
cooler.>
MT-01660
6) Set the transmission jack under the transmission

case.
CAUTION:
Always support the transmission case with a
transmission jack.
5MT-28

2. CROSSMEMBER AND CUSHION RUB- C: INSPECTION

BER Check the following; repair or replace the faulty
1) Install the transmission cushion rubber to the parts.
transmission, and tighten the bolt (A).
2) Install the transmission cushion rubber to the 1. PITCHING STOPPER
center crossmember, and tighten the nut (B). Check the pitching stopper for bends or damage.
Check that the rubber is not stiff, cracked or other-
Tightening torque: wise damaged.
Bolt (A)
35 N·m (3.6 kgf-m, 25.8 ft-lb) 2. CROSSMEMBER AND CUSHION RUB-
Nut (B) BER
35 N·m (3.6 kgf-m, 25.8 ft-lb) Check the crossmember for bending or damage.
Check that the cushion rubber does not have hard-
ening, cracks or other damages.
(A)
(A)
(B)
MT-01676

member.
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb)
T2: 140 N·m (14.3 kgf-m, 103.3 ft-lb)
T1
T1
T2 T2
MT-01672
4) Remove the transmission jack.

STALLATION, Heat Shield Cover.>
7) Install the rear exhaust pipe and muffler. <Ref. to
5MT-29
Oil Seal
5. Oil Seal 7) Using the ST, remove the oil seal.

ST 398527700 PULLER ASSY
A: INSPECTION
Check for leakage of transmission gear oil from the (A) ST
oil seal. If there is oil leakage, replace the oil seal
with the new part and check the propeller shaft.
B: REPLACEMENT
1) Clean the transmission exterior.
2) Using the TORX® bit T70, remove the drain
plug, and drain the transmission gear oil complete-
ly.
3) Tighten the drain plug using TORX® bit T70.
MT-00098
NOTE: (A) Oil seal

Use a new gasket.
8) Using the ST, install the oil seal.
Tightening torque:
NOTE:
• When grease is not applied to the oil seal lips,
ket silver)
apply the transmission gear oil to the oil seal lips.
70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket
brown) • Use a new oil seal.
70 N·m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket ST 498057300 INSTALLER
black)
ST
MT-01299
MT-01548 9) Install the propeller shaft. <Ref. to DS-12, IN-

4) Remove the rear exhaust pipe and muffler. STALLATION, Propeller Shaft.>
<Ref. to EX(w/o STI)-2, General Description.> 10) Install the heat shield cover. <Ref. to EI-74, IN-
5) Remove the heat shield cover. STALLATION, Heat Shield Cover.>
11) Install the rear exhaust pipe and muffler. <Ref.
to EX(w/o STI)-2, General Description.>
12) Pour in transmission gear oil and check the oil
level. <Ref. to 5MT-21, Transmission Gear Oil.>
MT-01660
6) Remove the propeller shaft. <Ref. to DS-11, RE-

MOVAL, Propeller Shaft.>
5MT-30
Differential Side Retainer Oil Seal

6. Differential Side Retainer Oil 6) Remove the differential side retainer oil seal.
Seal NOTE:
• Be sure to replace the differential side retainer oil
A: INSPECTION seal whenever the front drive shaft is removed from
Check for leakage of gear oil from differential side the transmission.
retainer oil seal part. If there is oil leakage, replace • Use the ST 398527700 PULLER ASSY to re-
the oil seal with the new part and check the drive move the oil seal. If removing the oil seal with a flat
shaft. tip screwdriver, be careful not to scratch the differ-
ential side retainer.
B: REPLACEMENT 7) Using the ST, install the differential side retainer
1) Lift up the vehicle. oil seal by lightly tapping with a plastic hammer.
2) Remove the transmission gear oil drain plug us- ST 18675AA000 DIFFERENTIAL SIDE OIL
ing TORX® bit T70, and drain the transmission SEAL INSTALLER
gear oil completely. CAUTION:
Apply transmission gear oil to the oil seal lips,
and install the oil seal while being careful not to
deform the lip.
ST
MT-01548
3) Replace the gasket with a new part and tighten

the drain plug using the TORX® bit T70.
MT-00103
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gas- 8) Install the front drive shaft. <Ref. to DS-27, IN-
ket silver) STALLATION, Front Drive Shaft.>
70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket ST 28399SA010 OIL SEAL PROTECTOR
brown) 9) Install the center exhaust pipe. <Ref. to EX(w/o
70 N·m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket STI)-2, General Description.>
black) 10) Lower the vehicle.
11) Add the transmission gear oil through the oil
level gauge hole. <Ref. to 5MT-21, REPLACE-
MENT, Transmission Gear Oil.>
MT-01548
4) Remove the center exhaust pipe. <Ref. to EX(w/o

5) Separate the front drive shaft from the transmis-
sion. <Ref. to DS-27, REMOVAL, Front Drive
Shaft.>
5MT-31
Switches and Harness

7. Switches and Harness B: INSTALLATION

A: REMOVAL 1. BACK-UP LIGHT AND NEUTRAL POSI-
TION SWITCH
1. BACK-UP LIGHT AND NEUTRAL POSI-
1) Install the back-up light switch & neutral position
TION SWITCH switch with the harness.
2) Remove the intercooler. <Ref. to IN(w/o STI)-12, Tightening torque:
REMOVAL, Intercooler.> 32.3 N·m (3.3 kgf-m, 23.8 ft-lb)
3) Disconnect the connector back-up light switch &
neutral position switch. (A)
(A)
(B)
MT-02615
(A) Neutral position switch

MT-01659
(B) Back-up light switch
(A) Neutral position switch and back-up light switch
connector 2) Connect the connectors of back-up light switch &
neutral position switch.
4) Lift up the vehicle. 3) Install the intercooler. <Ref. to IN(w/o STI)-12,
5) Remove the back-up light switch & neutral posi- INSTALLATION, Intercooler.>
tion switch with the harness. 4) Connect the battery ground terminal.
C: INSPECTION
(A)
1. BACK-UP LIGHT SWITCH
Check the back-up light switch. <Ref. to LI-8, IN-
SPECTION, Back-up Light System.>
2. NEUTRAL POSITION SWITCH
1) Turn the ignition switch to OFF.
2) Disconnect the connector of neutral position
(B) switch.
MT-02615
3) Measure the resistance between neutral posi-
(A) Neutral position switch tion switch terminals.
(B) Back-up light switch
2 1
4 3
MT-00111
Gear shift position Terminal No. Specified resistance

Neutral position Less than 1 Ω
1 and 3
Other positions 1 MΩ or more
4) Replace faulty parts.
5MT-32
Preparation for Overhaul

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 transmis-
sion gear oil drain plug, and drain the transmission
gear oil completely.
3) Using the TORX® bit T70, tighten the transmis-
sion gear oil drain plug.
NOTE:
Use a new gasket.
Tightening torque:
ket silver)
70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket
brown)
70 N·m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket
black)
MT-01548
4) Attach the transmission to the ST.

ST 499937100 TRANSMISSION STAND
ST
MT-00115
5) Apply oil to rotating parts before assembly.

6) All disassembled parts, if to be reused, should
be reinstalled in the original positions and direc-
tions.
7) Gaskets, lock washers and lock nuts must be re-
placed with new ones.
8) Apply liquid gasket to the specified areas to pre-
vent leakage.
5MT-33
Transfer Case and Extension Case Assembly

9. Transfer Case and Extension 3) Remove the bearing outer race and thrust wash-
er from the extension case.
Case Assembly
A: REMOVAL (A)
1) Remove the manual transmission assembly

from the vehicle. <Ref. to 5MT-22, REMOVAL,
Manual Transmission Assembly.>
2) Remove the back-up light switch and the neutral
position switch. <Ref. to 5MT-32, REMOVAL,
Switches and Harness.>
3) Remove the transfer case together with the ex-
tension case assembly. MT-02301
(A) Bearing outer race
4) While pressing the bearing outer race horizontal-

ly, rotate the driven shaft for ten turns.
5) Measure the height “W” between transfer case
and taper roller bearing on the transfer driven gear.
MT-02614
4) Remove the shifter arm.

5) Remove the extension case assembly.
W
MT-00120
6) Measure depth “X” of bearing insertion part of

the extension case.
NOTE:
Measure with bearing outer race and thrust washer
removed.
MT-00117
B: INSTALLATION
1) Apply a coat of grease to the front roller bearing
and rear roller bearing of the transfer driven gear.
Grease:
NICHIMOLY N-130 or equivalent
2) Install the center differential and transfer driven X
gear into the transfer case.
MT-00121
MT-00118
5MT-34

7) Calculate the thrust washer thickness “t” using 10) Measure the depth “S” between transfer case
the following calculation. and center differential.
t = X – W + (0.15 — 0.20 mm (0.006 — 0.008 in)) ST 398643600 GAUGE
8) Select the washer with the nearest value in the
following table. ST
Preload of the taper roller bearing (amount of

standard protrusion):
0.15 — 0.20 mm (0.006 — 0.008 in) S
NOTE:
Be sure that it is always within the preload.
Thrust washer (61 × 50 × t)
Part No. Thickness mm (in) MT-00122
803050060 0.50 (0.0197) 11) Measure the height “T” between the extension
803050061 0.55 (0.0217) case and transfer drive gear.
803050062 0.60 (0.0236) ST 398643600 GAUGE
803050063 0.65 (0.0256)
803050064 0.70 (0.0276)
ST
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) T
803050070 1.00 (0.0394)

803050071 1.05 (0.0413)
MT-00123
803050072 1.10 (0.0433)
803050073 1.15 (0.0453) 12) Calculate the thrust washer thickness “U” using
803050074 1.20 (0.0472) the following calculation.
803050075 1.25 (0.0492)
U = S + T – 30 mm (1.18 in) – (0.15 — 0.35 mm
(0.0059 — 0.0138 in))
803050076 1.30 (0.0512)
S: Depth between transfer case and center differ-
803050077 1.35 (0.0531)
ential
803050078 1.40 (0.0551) T: Height between the extension case and transfer
803050079 1.45 (0.0571) drive gear
30 mm (1.18 in): Thickness of ST
9) Install the selected thrust washer and bearing 0.15 — 0.35 mm (0.0059 — 0.0138 in): Clearance
outer race (A) into the extension case. 13) Select a suitable washer in the following table.
Standard clearance:
(A)
0.15 — 0.35 mm (0.0059 — 0.0138 in)
Thrust washer
Part No. Thickness mm (in)
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
MT-02301
803036052 1.3 (0.051)
(A) Bearing outer race 803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
803036080 1.8 (0.071)
803036081 1.9 (0.075)
5MT-35

14) Fit the thrust washer onto the center differen- 19) Hang the shifter arm on 3rd-4th fork rod.
tial. (A)
15) Apply a proper amount of liquid gasket to the
transfer case mating surface.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or
equivalent
(B) MT-00127
(A) Shifter arm

(B) 3rd-4th fork rod
20) Install the extension case assembly along with

the transfer case to the transmission case.
MT-00124
Tightening torque:
16) Attach the extension assembly to the transfer 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
case.
Tightening torque:
40 N·m (4.1 kgf-m, 29.5 ft-lb)
MT-02614
C: DISASSEMBLY
MT-00117 1. TRANSFER CASE
17) Attach the shifter arm to transfer case. 1) Remove the reverse check sleeve assembly.
<Ref. to 5MT-45, REMOVAL, Reverse Check
Sleeve.>
2) Remove the oil guide.
MT-00126
18) Attach the gasket.

NOTE: MT-01563
Use a new gasket.
3) Remove the oil seal.
5MT-36

4) Set ST1, ST2 and transfer case to a press. 2. EXTENSION CASE

NOTE: 1) Remove the transfer drive gear assembly. <Ref.
• Set the ST2 under ST1. to 5MT-40, REMOVAL, Transfer Drive Gear.>
• Set the transfer case so that the hole for shifter 2) Remove the shift bracket.
arm is positioned vertically.
ST1 498267300 CYLINDER HEAD TABLE
ST1
MT-00130
3) Remove the oil seal from the extension case.

<Ref. to 5MT-30, Oil Seal.>
D: ASSEMBLY
ST2
1. EXTENSION CASE
ST1 1) Using the ST, install the oil seal to the extension
case. <Ref. to 5MT-30, Oil Seal.>
NOTE:
Use a new oil seal.
2) Install the shift bracket to extension case.
ST2
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
MT-02138
5) Using the round bar with diameter of 22 mm

(0.87 in) or 23 mm (0.91 in), remove the roller bear-
ing.
MT-00130
3) Install the transfer drive gear to the extension

case. <Ref. to 5MT-40, INSTALLATION, Transfer
Drive Gear.>
MT-02139
5MT-37

2. TRANSFER CASE 2) Press-fit the roller bearing using the ST.

1) Set the ST1, ST2, iron plate and the transfer Press-fit depth of needle bearing:
case to the press. A: 0±0.2 mm (0±0.01 in) from the end of trans-
NOTE: fer case
• Set the ST2 under ST1. ST 899864100 REMOVER
• Set the transfer case so that the hole for shifter
arm is positioned vertically. ST
• Insert the iron plate which is thicker than the ex-
posed length of the transfer case knock pin be-
tween the ST and transfer case.
• Set the iron plate so that the transfer case knock
pin does not ride on the iron plate.
ST1
A
ST2
MT-02142
(A) 3) Remove the iron plate, and turn over the transfer
case.
ST1
NOTE:
Set the transfer case so that the hole for shifter arm
is positioned vertically.
ST2
MT-02141
(A) Iron plate
5MT-38

4) Press-fit the roller bearing using the ST. 8) Install the oil seal.
Press-fit depth of needle bearing: Press-fit depth of oil seal:
A: 0±0.2 mm (0±0.01 in) from the end of trans- A: 1±0.2 mm (0.04±0.01 in) from the end of
fer case transfer case
ST 899864100 REMOVER
A
ST
MT-02299
MT-02140
5) Install the shifter arm to the transfer case, and

make sure that the shift arm moves smoothly.
6) Install the oil guide to the transfer case.
NOTE:
Use a new installing bolt.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
MT-01563
7) Install the reverse check sleeve assembly to the

transfer case. <Ref. to 5MT-45, INSTALLATION,
Reverse Check Sleeve.>
5MT-39
Transfer Drive Gear

10.Transfer Drive Gear C: DISASSEMBLY

1) Remove the snap ring.
A: REMOVAL
tension case assembly. <Ref. to 5MT-34, REMOV-
AL, Transfer Case and Extension Case
Assembly.> MT-00135
4) Remove the extension case assembly. 2) Remove the ball bearing.
5) Remove the transfer driven gear.
6) Remove the transfer drive gear.
MT-00136
MT-00133
D: ASSEMBLY
1) Set the ST against the inner race of the bearing,
B: INSTALLATION and install the drive shaft.
1) Install the transfer drive gear. ST 398177700 INSTALLER
Tightening torque: CAUTION:
26 N·m (2.7 kgf-m, 19.2 ft-lb) Do not apply a load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
NOTE:
Use a new ball bearing.
MT-00133 ST
2) Install the transfer driven gear.
3) Install the extension case assembly.
4) Install the transfer case and the extension case MT-00137
assembly. <Ref. to 5MT-34, INSTALLATION, 2) Install the snap ring on the transfer drive shaft.
Transfer Case and Extension Case Assembly.> 3) Inspect the clearance between the snap ring and
5) Install the back-up light switch and the neutral the ball bearing. <Ref. to 5MT-41, INSPECTION,
position switch. <Ref. to 5MT-32, INSTALLATION, Transfer Drive Gear.>
6) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-24, INSTALLATION, Manual
Transmission Assembly.>
5MT-40
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)
MT-00138
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)
5MT-41
Transfer Driven Gear

11.Transfer Driven Gear B: INSTALLATION

1) Install the bearing outer race to transfer case.
A: REMOVAL
1) Remove the manual transmission assembly (B)
from the vehicle. <Ref. to 5MT-22, REMOVAL, (A)
Assembly.> MT-02300
4) Remove the extension case assembly.
(A) Bearing outer race
(B) Transfer case
2) Apply a coat of grease to the front roller bearing

and rear roller bearing of the transfer driven gear.
Grease:
MT-00118
6) Remove bearing outer races from the extension

case and transfer case.
(A)
MT-00118
4) Select a thrust washer. <Ref. to 5MT-34, IN-

STALLATION, Transfer Case and Extension Case
Assembly.>
5) Install the transfer case and the extension case
assembly. <Ref. to 5MT-34, INSTALLATION,
Transfer Case and Extension Case Assembly.>
6) Install the back-up light switch and the neutral
position switch. <Ref. to 5MT-32, INSTALLATION,
(B) Switches and Harness.>
MT-00140
(A) Bearing outer race (transfer case side)

(B) Bearing outer race (extension case side)
5MT-42

C: DISASSEMBLY 2) Using the ST, install the roller bearing (extension

case side).
1) Using the ST, remove the roller bearing (exten-
ST1 498175500 INSTALLER
sion case side).
ST 498077000 REMOVER ST2 899864100 REMOVER
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1
ST ST2
(A)
MT-00143 (A) ST1
(A) Roller bearing

MT-00145
2) Using ST1 and ST2, remove the roller bearing
(transfer case side). (A) Roller bearing
ST1 498077000 REMOVER
ST2 899864100 REMOVER E: INSPECTION
1) Bearing
ST2 • In case of broken or rusty bearings
• In case of worn or damaged bearings
(A) • When the bearings fail to turn smoothly or emit
ST1 noise in rotation after gear oil lubrication.
2) Driven gear
If the tooth face of driven gear and the shaft are ex-
cessively broken or damaged, replace the driven
MT-00144 gear.
(A) Roller bearing
D: ASSEMBLY
1) Using ST, install the roller bearing (transfer case
side).
ST 927640000 INSTALLER
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1
ST
(A)
MT-00146
(A) Roller bearing
5MT-43
Center Differential
12.Center Differential D: ASSEMBLY

Install the ball bearing to the center differential as-
A: REMOVAL sembly.
from the vehicle. <Ref. to 5MT-22, REMOVAL, CAUTION:
Manual Transmission Assembly.> • Do not apply a load in excess of 10 kN (1 ton,
2) Remove the back-up light switch and the neutral 1.1 US ton, 1.0 Imp ton).
position switch. <Ref. to 5MT-32, REMOVAL, • Use a new ball bearing.
Assembly.>
4) Remove the extension case assembly. <Ref. to
5MT-34, REMOVAL, Transfer Case and Extension
Case Assembly.>
(A)
5) Remove the transfer driven gear. <Ref. to 5MT-
42, REMOVAL, Transfer Driven Gear.> MT-00148
6) Remove the center differential.
(A) Ball bearing
B: INSTALLATION
1) Attach the center differential to transfer case. E: INSPECTION
2) Install the transfer driven gear. <Ref. to 5MT-42, 1) Bearing
INSTALLATION, Transfer Driven Gear.> Replace the bearings in the following cases.
3) Install the extension case assembly. <Ref. to • In case of broken or rusty bearings
5MT-34, INSTALLATION, Transfer Case and Ex- • In case of worn or damaged bearings
tension Case Assembly.>
4) Install the transfer case together with the exten- noise in rotation after gear oil lubrication.
sion case assembly. <Ref. to 5MT-34, INSTALLA-
• When bearing has other defects.
TION, Transfer Case and Extension Case
2) Center differential
Assembly.>
If there is wear or damage, replace the center dif-
ferential case assembly.
C: DISASSEMBLY
Remove the ball bearing using ST.
NOTE:
Center differential is a non-disassembled part
which should not be disassembled.
ST 498077300 CENTER DIFFERENTIAL
BEARING REMOVER
ST
MT-00147
5MT-44
Reverse Check Sleeve

13.Reverse Check Sleeve B: INSTALLATION

1) Install the reverse check sleeve.
A: REMOVAL
1) Remove the manual transmission assembly Tightening torque:
from the vehicle. <Ref. to 5MT-22, REMOVAL, 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
Assembly.>
3) Remove the shifter arm.
4) Remove the plug, gasket, reverse accent spring,
and reverse check ball.
MT-00150
2) Install the reverse check ball, reverse accent

spring, gasket, and plug to the transfer case.
NOTE:
Use a new gasket.
Tightening torque:
9.75 N·m (1.0 kgf-m, 7.2 ft-lb)
MT-00149
5) Remove the reverse check sleeve.
MT-00149
3) Attach the shifter arm to the transfer case as-

MT-00150 sembly.
4) Install the transfer case together with the exten-
Assembly.>
5MT-45

C: DISASSEMBLY D: ASSEMBLY
1) Cover the reverse check sleeve with cloth, and 1) Install the return spring (1st-2nd), return spring
remove the snap ring by using screwdriver. cap, reverse accent shaft, reverse check cam, re-
NOTE: turn spring (5th-Reverse) and reverse check spring
to the reverse check sleeve.
If the snap ring is deformed or the spring repulsive
force is not enough, replace with a new snap ring. NOTE:
(A)
Be sure to insert the curved part of reverse check
spring into the check cam groove.
(A)
(C)
(B) (E)
(D) (G)
(F)
MT-00153
(A) Snap ring MT-00154
2) Remove the reverse check plate, reverse check (A) Reverse check plate
spring, reverse check cam, return spring (5th-Re- (B) Reverse check spring
verse), reverse accent shaft, return spring cap, and (C) Return spring (5th-Reverse)
return spring (1st-2nd).
(D) Reverse check cam
(A) (E) Reverse accent shaft
(C) (F) Return spring cap
(G) Return spring (1st-2nd)
(B) (E)
(D) (G) 2) Hook the curved part of reverse check spring
onto the reverse check plate.
(F)
3) Rotate the cam so that the protrusion on the re-
verse check cam is located at the plate opening.
4) While fixing the cam to that position, attach the
MT-00154 reverse check plate to the reverse check sleeve,
and secure with snap ring.
(A) Reverse check plate
5) Insert the O-ring into the sleeve groove.
(B) Reverse check spring
(C) Return spring (5th-Reverse)
NOTE:
Use new O-rings.
(E) Reverse accent shaft
(F) Return spring cap
(G) Return spring (1st-2nd)
3) Remove the O-ring.

NOTE:
Be careful not to damage the adjusting shim be-
tween reverse check sleeve assembly and case.
5MT-46

E: INSPECTION NOTE:
• When the shim is removed, the neutral position
• Make sure the cutout of the reverse accent shaft
will move closer to reverse; when the shim is add-
is aligned with the opening in the reverse check
ed, the neutral position will move closer to 1st gear.
sleeve.
• Turn the cam by hand to check for smooth rota- • If it is not possible to adjust the clearance with
tion. only shims, replace the reverse accent shaft and
re-adjust.
• Move the cam and shaft all the way toward the
plate, and make sure it releases. Adjusting shim
If the cam does not return properly, replace the re- Part No. Thickness mm (in)
verse check spring. If the shaft does not return, 32190AA000 0.15 (0.0059)
check for scratches on the inner surface of sleeve. 32190AA010 0.30 (0.0118)
If the sleeve is in good order, replace the spring.
Reverse accent shaft
(D) Part No. Mark Remarks
(C)
Neutral position is closer to
32188AA130 S
1st gear.
32188AA140 T Standard
Neutral position is closer to
32188AA150 U
reverse gear.
(A)
(B) 2. REVERSE CHECK PLATE ADJUST-

MT-00156 MENT
(A) Snap ring 1) Shift the shifter arm to “5th” and then to reverse
(B) Reverse check plate to see if the reverse check mechanism operates
(C) Reverse check spring
properly.
2) Also check to see if the arm returns to neutral
when released from the reverse position. If the arm
• Select a suitable reverse accent shaft and re- does not return properly, replace the reverse check
verse check plate. <Ref. to 5MT-47, ADJUST- plate.
MENT, Reverse Check Sleeve.> Reverse check plate
Part No. (A): No. Angle θ Remarks
F: ADJUSTMENT
Arm stops closer to
32189AA001 0 28°
1. NEUTRAL POSITION ADJUSTMENT 5th gear.
1) Shift the gear into 3rd gear position. Arm stops closer to
32189AA011 1 31°
5th gear.
2) Because of the return spring, until the arm con-
tacts the stopper the shifter arm will feel lighter Arm stops in the cen-
32189AA021 2 34°
moving towards 1st/2nd gear and heavier towards ter.
the reverse gear. Arm stops closer to
32189AA031 3 37°
3) Make adjustment so that the heavy stroke (re- reverse gear.
verse side) is a little heavier than the lighter stroke Arm stops closer to
32189AA041 4 40°
(1st/2nd side). reverse gear.
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.
(A)
MT-00157
5MT-47
Transmission Case
14.Transmission Case 7) Remove the drive pinion shaft assembly from

the left side of the transmission case.
A: REMOVAL NOTE:
1) Remove the manual transmission assembly Use a hammer handle, etc. to remove if too tight.
from the vehicle. <Ref. to 5MT-22, REMOVAL, (A)
Manual Transmission Assembly.> (B)
2) Remove the clutch release lever. <Ref. to CL-
15, REMOVAL, Release Bearing and Lever.>
Assembly.>
4) Remove the bearing mounting bolt.
MT-00161
(A) Main shaft ASSY for single-range

(B) Drive pinion shaft ASSY
8) Remove the main shaft assembly for single-

range.
9) Remove the front differential assembly.
MT-01514
5) Remove the main shaft rear plate.

(A)
MT-00162
10) Remove the differential side retainers and

bearing outer races on the left and right side. <Ref.
MT-01515 to 5MT-68, REMOVAL, Front Differential Assem-
bly.>
(A) Main shaft rear plate
NOTE:
6) Remove the coupling bolts and nuts, and sepa- Do not confuse the right and left roller bearing outer
rate the transmission case into the right and left races.
case. 11) Remove the reverse idler gear. <Ref. to 5MT-
76, REMOVAL, Reverse Idler Gear.>
12) Remove the shifter fork and rod. <Ref. to 5MT-
78, REMOVAL, Shifter Fork and Rod.>
B: INSTALLATION
1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with cleaning solvent.
2) Install the shifter fork and rod. <Ref. to 5MT-79,
INSTALLATION, Shifter Fork and Rod.>
3) Install the reverse idler gear. <Ref. to 5MT-76,
MT-00160 INSTALLATION, Reverse Idler Gear.>
4) Select the drive pinion shim. <Ref. to 5MT-57,
INSTALLATION, Drive Pinion Shaft Assembly.>
5MT-48
Transmission Case
5) Install the differential side retainer, from which 12) Adjust the backlash of the hypoid gear and the
the bearing outer race and O-ring have already preload of the roller bearing.
been removed, to the transmission case LH side. (1) Attach the ST on drive pinion assembly.
6) Install the front differential assembly. ST 498427100 STOPPER
7) Install the main shaft assembly for single-range.
Align the transmission case knock pin into the
knock pin hole of the needle bearing.
8) Install the selected drive pinion shims and drive
pinion shaft assembly.
NOTE:
Align the roller bearing knock pin hole to the trans-
mission case knock pin.
9) Tighten the left and right side of the transmission
ST
case with the17 mounting bolts. MT-01516
NOTE: (2) Place the transmission with the LH side of

• Insert bolts (11) and (16) from the LH side of the case facing downward, and put ST1 on the
transmission case. bearing outer race.
• Match the cases together so that the drive pinion (3) Screw the retainer assembly from the bot-
shims are not caught between the cases. tom into left case using ST2. Fit the ST3 on
transmission main shaft. Shift the gear into 4th
Tightening torque:
or 5th, and turn the shaft several times. Screw
8 mm bolt
in the retainer while rotating the ST3 until a
25 N·m (2.5 kgf-m, 18.4 ft-lb) slight resistance is felt on ST2.
10 mm bolt This is the contact point of the hypoid gear and
39 N·m (4.0 kgf-m, 28.8 ft-lb) the drive pinion shaft. Repeat the above se-
(16) quence several times to ensure the contact
(9) (5) (7) point.
(17)
(11)
ST1 399780104 WEIGHT
(13)
ST2 18630AA010 WRENCH COMPL RETAIN-
(1) ER
(3)
ST3 499927100 HANDLE
(15) (2)
ST1
(4)
(14) ST3
(10) ST2
(6) (8) (12) MT-00178
10) Install the bearing outer race to the RH side of

the transmission case.
11) Tighten the bearing mounting bolts.
Tightening torque:
30 N·m (3.1 kgf-m, 22.1 ft-lb)
MT-02407
MT-01514
5MT-49
Transmission Case
(4) Remove the WEIGHT, and screw in the side 17) Apply liquid gasket, then join the right side and
retainer without the O-ring into the RH side of left side of the case together.
the transmission case, and stop at the point
Liquid gasket:
where a slight resistance is felt.
NOTE: equivalent
In this condition, the backlash between hypoid gear
and drive pinion shaft is zero.
ST 18630AA010 WRENCH COMPL RETAIN-
ER
ST
MT-02616
18) With brackets and clips as shown in the figure,

tighten the seventeen bolts.
MT-00176 NOTE:
• Insert bolts (11) and (16) from the LH side of the
(5) Loosen the side retainer on the LH side of
transmission case.
the transmission case by 3 notches, and turn
the side retainer on the RH side of the transmis- • Match the cases together so that the drive pinion
sion case by the same notches in order to apply shims are not caught between the cases.
backlash. Tightening torque:
(6) Screw in the side retainer of the RH side of 8 mm bolt
the transmission case additionally by 1 notch in 25 N·m (2.5 kgf-m, 18.4 ft-lb)
order to apply preload on taper roller bearing. 10 mm bolt
(7) Tighten temporarily both the upper and low- 40 N·m (4.1 kgf-m, 29.5 ft-lb)
er lock plates, and put marks on both the side
retainer and lock plate for later readjustment. (16)
(7) (17)
(9) (5)
NOTE: (11)
If it is hard to install the lock plates, reverse the (13)
sides and install them.
(1) (3)
(8) Turn the transmission main shaft several
(2)
times while tapping around the retainer lightly (15)
with plastic hammer.
(4)
13) Inspect and adjust backlash and tooth contact (14)
(10) (6)
of the hypoid gear. <Ref. to 5MT-72, INSPECTION, (8) (12)
MT-00172
Front Differential Assembly.>
14) Separate the transmission case into left and 19) Tighten the bearing mounting bolts.
right parts. <Ref. to 5MT-48, REMOVAL, Transmis- Tightening torque:
sion Case.> 30 N·m (3.1 kgf-m, 22.1 ft-lb)
15) Select a main shaft rear plate. <Ref. to 5MT-56,
ADJUSTMENT, Main Shaft Assembly for Single-
Range.>
16) Check each shifter fork. <Ref. to 5MT-80, IN-
SPECTION, Shifter Fork and Rod.>
MT-01514
5MT-50
Transmission Case
20) Remove the lock plate. Then loosen the retain-

er until the O-ring groove appears. Fit the O-ring
into the groove and tighten the retainer into the po-
sition where it was not loosened.
NOTE:
• When loosening the retainer, record the number
of the turns made.
• Perform this for both left and right side retainers.
• Use new O-rings.
21) Install the lock plate.
Tightening torque:
T: 25 N·m (2.5 kgf-m, 18.4 ft-lb)
MT-00177

Assembly.>
23) Install the clutch release lever and bearing.
<Ref. to CL-15, INSTALLATION, Release Bearing
and Lever.>
C: INSPECTION
Check the transmission case for cracks, damage,
or oil leaks.
5MT-51
Main Shaft Assembly for Single-Range

15.Main Shaft Assembly for Sin- 3) Install the drive pinion shaft assembly. <Ref. to
5MT-57, INSTALLATION, Drive Pinion Shaft As-
gle-Range sembly.>
A: REMOVAL 4) Install the transmission case. <Ref. to 5MT-48,
INSTALLATION, Transmission Case.>
1) Remove the manual transmission assembly 5) Install the transfer case together with the exten-
from the vehicle. <Ref. to 5MT-22, REMOVAL, sion case assembly. <Ref. to 5MT-34, INSTALLA-
Manual Transmission Assembly.> TION, Transfer Case and Extension Case
2) Remove the transfer case together with the ex- Assembly.>
tension case assembly. <Ref. to 5MT-34, REMOV- 6) Install the manual transmission assembly to the
AL, Transfer Case and Extension Case vehicle. <Ref. to 5MT-24, INSTALLATION, Manual
Assembly.> Transmission Assembly.>
3) Remove the transmission case. <Ref. to 5MT-
48, REMOVAL, Transmission Case.> C: DISASSEMBLY
4) Remove the drive pinion shaft assembly. <Ref. 1) Put vinyl tape around main shaft spline to protect
to 5MT-57, REMOVAL, Drive Pinion Shaft Assem- the oil seal from damage. Then pull out the oil seal
bly.> and needle bearing by hand.
5) Remove the main shaft assembly for single- 2) Remove the lock nut and lock washer from
range. transmission main shaft assembly for single-range.
B: INSTALLATION NOTE:
1) Install the needle bearing and oil seal to the front Flatten the lock nut tab before removing the lock
of the transmission single-range main shaft assem- nut.
bly. ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
NOTE:
• Wrap the clutch splined section with vinyl tape to
prevent damage to the oil seal.
• Apply NICHIMOLY N-130 or the equivalent to
the sealing lip of the oil seal.
• Use a new oil seal.
2) Align 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 ST2 ST1
MT-01517
installing the oil seal.
3) Remove the 5th hub & sleeve No. 2, baulk lever,
baulk ring, 5th drive gear and needle bearing.
(C)
(B)
(A)
(A)
MT-00185
MT-01518
(A) 5th hub & sleeve No. 2

(B) Baulk ring
(C) 5th drive gear
5MT-52

4) Using ST1 and ST2, remove the rest of the D: ASSEMBLY

parts.
1) When the sleeve & hub assemblies have been
NOTE: disassembled, reassemble by aligning the align-
• When replacing the sleeve & hub, replace them ment marks.
as a set. NOTE:
• Do not disassemble the sleeve & hub; the align-
Position the open ends of the spring 120° apart.
ing position is pre-matched.
• If it is necessary to disassemble, mark the en-
gaging points on the splines beforehand. (A)
(A)
(B)
ST1 MT-01852
(A) 3rd-4th coupling sleeve & synchronizer hub

ASSY
(B) 3rd gear side
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.
ST2
NOTE:
Align the groove in baulk ring with the shifting in-
sert.
(A) (D) (E)
MT-00190
(A) Press
(B) (C) (F)

MT-01318
(A) 3rd needle bearing

(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve & hub ASSY
5MT-53

3) Install the 4th needle bearing race onto trans- 5) Press-fit the double taper roller bearing into the
mission main shaft using ST1, ST2 and press. rear section of transmission main shaft using ST1,
CAUTION: ST2 and a press.
Do not apply a load in excess of 10 kN (1 ton, 1.1 CAUTION:
US ton, 1.0 Imp ton). Do not apply a load in excess of 10 kN (1 ton, 1.1
ST1 899714110 REMOVER US ton, 1.0 Imp ton).
ST2 499877000 RACE 4-5 INSTALLER NOTE:
Use a new double taper roller bearing.
ST2 ST1 899714110 REMOVER
(A)
ST2 499877000 RACE 4-5 INSTALLER
ST1 ST2
ST1
MT-00192
(A) 4th needle bearing race
4) Install the baulk ring, needle bearing, 4th drive MT-00194

gear and 4th gear thrust washer to the transmission 6) Install the 5th needle bearing race into the rear
main shaft. section of transmission main shaft using ST1 and
NOTE: ST2.
• Align the baulk ring and hub & sleeve assembly CAUTION:
with the key groove. Do not apply a load in excess of 10 kN (1 ton, 1.1
• Make sure the thrust washer is facing the correct US ton, 1.0 Imp ton).
direction.
NOTE:
Make sure the thrust washer is facing the correct
direction.
(A) ST1 899714110 REMOVER
(B)
(A)
MT-02132
(A) Groove
(B) Face this surface to the 4th gear side.
MT-00195
(A) Face this surface to the 5th gear side.
5MT-54

7) Install rest of the parts to the rear section of the 8) Tighten the lock nuts to the specified torque us-
transmission main shaft. ing ST1 and ST2.
CAUTION: NOTE:
• Install the baulk lever so that the concave Use new lock nuts and lock washers.
side faces toward the 5th hub. ST1 499987003 SOCKET WRENCH (35)
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
(A)
(B) 120 N·m (12.2 kgf-m, 88.5 ft-lb)
9) Crimp lock nuts in two locations after tightening.
E: INSPECTION
Disassembled parts should be washed with clean-
ing solvent first, then inspected carefully.
1) Bearing
MT-01522 Replace the bearings in the following cases.
• When the bearing balls, outer races and inner
(A) Baulk lever races are broken or rusty.
(B) 5th hub • When the bearing is worn.
• Align the protruded section of baulk ring be- noise in rotation after gear oil lubrication.
tween the baulk levers. • When bearing has other defects.
(B) 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 the gear with new part if its tooth surfac-
(C)
es are broken, damaged or excessively worn.
(A) (B)
MT-01531 • Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
(A) Baulk ring • Correct or replace if the inner surface or end face
(B) Baulk lever is damaged.
(C) 5th hub
(A) (B) (C) (D)

(G)
(E)
(F)
MT-01627
(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
5MT-55

4) Baulk ring F: ADJUSTMENT

Replace the baulk ring in the following cases.
Selection of main shaft rear plate:
• When the inner surface and end face are dam- Measure the protrusion amount (A) of double taper
aged. roller bearing from transmission main case surface,
• When the ring inner surface is abnormally or par- and select a suitable plate in the following table.
tially worn down.
• When the contact surface of the synchronizer NOTE:
ring insert section is cracked or abnormally worn. Before measuring, tap the end of main shaft with a
• If the gap between the end faces of the ring and plastic hammer lightly in order to make the clear-
the gear splined part is excessively small, check ance zero between the main case surface and
the clearance (A) while pressing the ring against moving flange of bearing.
the cone. Dimension (A)
Part No. Mark
Clearance (A): mm (in)
0.5 mm (0.020 in) or more 4.00 — 4.13
32294AA041 1
(0.1575 — 0.1626)
(A) 3.87 — 4.00
32294AA051 2
(0.1524 — 0.1575)
(A)
MT-01674
• Apply gear oil to the cone of the gear and while

press-fitting the baulk ring, check there is no rota-
tion in the circumferential direction. MT-01807
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) Coupling sleeve and synchronizer hub
• Check the slipping condition of the coupling
sleeve.
• Check the splines on the coupling sleeve and
synchronizer hub for wear.
8) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn or defective in any way.
9) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent or defective in any way.
5MT-56
Drive Pinion Shaft Assembly

16.Drive Pinion Shaft Assembly 4) Check and adjust the ST.

(1) Loosen the two bolts and adjust so that the
A: REMOVAL scale indicates 0.5 correctly when the plate end
1) Remove the manual transmission assembly and the scale end are on the same level.
from the vehicle. <Ref. to 5MT-22, REMOVAL, (2) Tighten the two bolts.
Manual Transmission Assembly.> ST 499917500 DRIVE PINION GAUGE
2) Remove the transfer case together with the ex- ASSY
(A)
Assembly.>
48, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly.
NOTE:
Use a hammer handle, etc. to remove if too tight.
(A) ST (B)
(B) MT-00242
(A) Plate
(B) Scale
5) Position the ST by inserting the knock pin of ST

into the knock hole of transmission case.
ST 499917500 DRIVE PINION GAUGE
ASSY
MT-00161 6) Slide the drive pinion gauge scale with finger tip
and read the value at the point where it matches
(A) Main shaft ASSY for single-range with the end face of drive pinion.
(B) Drive pinion shaft ASSY ST 499917500 DRIVE PINION GAUGE
ASSY
B: INSTALLATION
1) Remove the front differential assembly. ST
(A)
2) Hypoid gear set match mark/No.: 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 numbers.
The figure (B) below shows a number for shim ad-
justment. If no number is shown, the value is zero.
(A) MT-00243
(A) Adjust the clearance to zero without shim.
+0
.1
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
(A)
(B) drive pinion is prefixed by +, and subtract if the
number is prefixed by –.)
MT-00990
ST 499917500 DRIVE PINION GAUGE
(A) Set number ASSY
(B) Number for shim adjustment
3) Place the drive pinion shaft assembly on trans-

mission main case RH without shim and tighten the
bearing mounting bolts.
5MT-57

8) Select one to three shims in the following table C: DISASSEMBLY

for the value determined as described above, and
take the shim(s) which thickness is closest to the NOTE:
said value. Attach a cloth to the end of driven shaft (on the fric-
tional side of the thrust needle bearing) to prevent
Drive pinion shim damage during disassembly or reassembly.
Part No. Thickness mm (in) 1) Flatten the tab of the lock nut. Remove the lock
32295AA031 0.150 (0.0059) nut with ST1, ST2 and ST3.
32295AA041 0.175 (0.0069) ST1 899884100 HOLDER
32295AA051 0.200 (0.0079) ST2 498427100 STOPPER
32295AA061 0.225 (0.0089) ST3 899988608 SOCKET WRENCH (27)
32295AA071 0.250 (0.0098)
ST1
32295AA081 0.275 (0.0108)
32295AA091 0.300 (0.0118)
ST2
32295AA101 0.500 (0.0197)
9) Install the front differential assembly. <Ref. to

5MT-68, INSTALLATION, Front Differential As-
sembly.>
10) Fit the transmission case knock pin to the ST3
knock pin hole of the roller bearing and install the MT-00244
drive pinion shaft assembly. 2) Draw out the drive pinion shaft from driven shaft.
11) Install the main shaft assembly for single- Remove the differential bevel gear sleeve, adjust-
range. <Ref. to 5MT-52, INSTALLATION, Main ing washer No. 1, adjusting washer No. 2, thrust
Shaft Assembly for Single-Range.> bearing, needle bearing and drive pinion collar.
12) Check each shifter fork. <Ref. to 5MT-80, IN-
SPECTION, Shifter Fork and Rod.> (E)
(F)
(G)
13) Install the transmission case. <Ref. to 5MT-48, (H)
Assembly.>
(A)
(B)
vehicle. <Ref. to 5MT-24, INSTALLATION, Manual (C)
Transmission Assembly.> (D) MT-00245
(A) Differential bevel gear sleeve

(B) Adjusting washer No. 1 (25 × 37.5 × t)
(C) Thrust bearing (25 × 37.5 × 3)
(D) Adjusting washer No. 2 (25 × 37.5 × t)
(E) Needle bearing (25 × 30 × 20)
(F) Drive pinion collar
(G) Needle bearing (30 × 37 × 23)
(H) Thrust bearing (33 × 50 × 3)
5MT-58

3) Remove the roller bearing and washer using ST 7) Remove the double taper roller bearing and 3rd-
and a press. 4th driven gear using ST1 and ST2.
ST 498077000 REMOVER ST1 499757002 INSTALLER
ST1
ST2
ST
MT-00246
4) Flatten the tab of the lock nut. Remove the lock MT-00249
nut using ST1 and ST2. 8) Remove the key.

ST1 499987300 SOCKET WRENCH (50) 9) Remove the 2nd driven gear, inner baulk ring,
ST2 899884100 HOLDER synchro cone and outer baulk ring.
ST2 ST1 (D) (A)
(B) (C)
MT-00247 MT-02396
5) Remove the 5th driven gear using ST. (A) 2nd driven gear
ST 499857000 5TH DRIVEN GEAR REMOV-
(B) Synchro cone
ER
(D) Outer baulk ring
ST
MT-00248
6) Remove the woodruff key.
5MT-59

10) Remove the 1st driven gear, inner baulk ring, D: ASSEMBLY
synchro cone, outer baulk ring, 2nd gear bushing
1) Install the sleeve and the gear and hub assem-
and gear & hub assembly using ST1 and ST2.
bly by matching the alignment marks.
(A) (D) (E)
NOTE:
• Make sure that there is no large clearance at
both sides of ball detent after assembly.
(B) (D)
(C)
(C) (B) (F)

MT-02397
(A) 1st driven gear

(B) Synchro cone (A)
(C) Inner baulk ring MT-01639
(A) Ball detent
(E) Gear & hub ASSY
(B) 1st-2nd synchronizer hub
(F) 2nd gear bushing
(C) Reverse driven gear
NOTE: (D) There is no large clearance at this part.
If necessary, use a new gear and hub assembly as
a set, when replacing the gear or hub. Because • Use the new gear & hub assembly, if replacing
these must engage at the specified point, avoid dis- the gear or hub.
assembly as much as possible. If it must be disas-
(A) (B)
sembled, mark the engaging point on the spline
beforehand.
ST1 499757002 INSTALLER (C)
(D)
ST1
MT-00252
ST2 (A) 1st gear side

(B) 2nd gear side
(C) Flush surface
MT-00251 (D) Stepped surface
5MT-60

2) Install the 1st driven gear, inner baulk ring, syn- 4) Install the 2nd driven gear, inner baulk ring, syn-
chro cone, outer baulk ring, and gear & hub assem- chro cone and outer baulk ring, and insert them
bly onto driven shaft. onto driven shaft.
(A) (D) (E) NOTE:
Align the groove in baulk ring with the insert.
(D) (A)
(C) (B)
MT-02398
(A) 1st driven gear (B) (C)

MT-02396
(B) Synchro cone
(C) Inner baulk ring (A) 2nd driven gear
(D) Outer baulk ring (B) Synchro cone
(E) Gear & hub ASSY (C) Inner baulk ring
NOTE:
• Take care to install the gear and hub assembly in 5) After installing key onto the driven shaft, install
proper direction. the 3rd-4th driven gear using ST1, ST2 and a
• Align the baulk ring and gear & hub assembly press.
with the key groove.
3) Install the 2nd driven gear bushing onto driven CAUTION:
shaft using ST1, ST2 and a press. Do not apply a load in excess of 10 kN (1 ton, 1.1
CAUTION: ST1 499277200 INSTALLER
Do not apply a load in excess of 10 kN (1 ton, 1.1 ST2 499587000 INSTALLER
NOTE:
• Attach a cloth to the end of the driven shaft to
prevent damage.
• When press fitting, align the oil holes of the shaft ST1
and bushing.
ST2 499587000 INSTALLER ST2
MT-02403
ST1
ST2
MT-00253
5MT-61

6) Install a set of double taper roller bearings onto 8) Install the lock washer. Tighten the lock nuts to
the driven shaft using ST1, ST2 and a press. the specified torque using ST1 and ST2.
CAUTION: NOTE:
Do not apply a load in excess of 10 kN (1 ton, 1.1 • Use new lock nuts and lock washers.
US ton, 1.0 Imp ton). • Make sure the lock washer is installed in the
NOTE: proper direction.
Use a new double taper roller bearing. ST1 499987300 SOCKET WRENCH (50)
ST1 499277200 INSTALLER ST2 899884100 HOLDER
ST2 499587000 INSTALLER Tightening torque:
260 N·m (26.5 kgf-m, 191.8 ft-lb)
ST2 ST1
ST1
ST2
MT-02404
7) Position the woodruff key in groove of the rear of

driven shaft. Install the 5th driven gear to the driven
shaft using ST1, ST2 and a press.
CAUTION: (C)
Do not apply a load in excess of 10 kN (1 ton, 1.1 (B)
ST1 499277200 INSTALLER (A)
MT-02391
ST1
(A) Lock nut
(B) Lock washer
ST2 (C) Nut side
9) Using a spring scale, check that starting torque

MT-02405 of the double taper roller bearing is 0.1 to 1.5 N
(0.01 to 0.15 kgf, 0.02 to 0.34 lbf).
MT-00259
5MT-62

10) Crimp the lock nut at two locations so that the 12) Install the washer using ST1, ST2 and a press.
dimension (B) becomes 41.1 mm (1.62 in) or less. CAUTION:
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1
When crimping the lock nut, be careful not to US ton, 1.0 Imp ton).
crack it. ST1 499277100 BUSHING 1-2 INSTALLER
(A)
ST2
(B)
ST1
(A)
MT-02707
MT-00261
(A) Lock nut
(B) Outer dimension after crimping (A) Washer
11) Install the roller bearing onto the drive pinion 13) Install the thrust bearing and needle bearing.
shaft. Install the driven shaft assembly.
NOTE:
• Use a new roller bearing.
• When installing the roller bearing, direct the
knock pin hole of outer race toward rear.
(A)
MT-00262
(B) MT-00260
(A) Roller bearing

(B) Knock pin hole
5MT-63

14) Install the drive pinion collar, needle bearing, E: INSPECTION

adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
this order.
1) Bearing
NOTE: Replace the bearings in the following cases.
Be careful to install the spacer in the proper direc- • When the bearing balls, outer races and inner
tion. races are broken or rusty.
• When the bearing is worn.
(A) (B)
noise in rotation after gear oil lubrication.
• The ball bearing on the rear side of the drive pin-
ion shaft should be checked for smooth rotation be-
fore the drive pinion shaft 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.
(C) (D) (E) (F) (G) (H)
MT-00263
(A) Driven shaft (A)

(B) Drive shaft
(C) Drive pinion collar
(D) Needle bearing (25 × 30 × 20)
(E) Adjusting washer No. 2 (25 × 36 × t)
(F) Thrust bearing (25 × 37.5 × 3) (B)
(G) Adjusting washer No. 1 (25 × 36 × t)
MT-00264
(H) Differential bevel gear sleeve
(A) Drive pinion shaft
15) Adjust the thrust bearing preload. <Ref. to
5MT-65, THRUST BEARING PRELOAD, AD- (B) Ball bearing
JUSTMENT, Drive Pinion Shaft Assembly.>
• When bearing has other defects.
2) Bushing (each gear)
• When the sliding surface is damaged or abnor-
mally worn.
• When the inner wall is abnormally worn.
3) Gear
• Replace the gear with new part if its tooth surfac-
es 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.
5MT-64

4) Baulk ring, synchro cone F: ADJUSTMENT

Replace the baulk ring and synchro cone in the fol-
lowing cases. 1. THRUST BEARING PRELOAD
• When the inner surface and end face are dam- 1) Select a suitable adjusting washer No. 1 so that
aged. dimension (H) will be zero in a visual check. Posi-
• When the baulk ring inner surface is abnormally tion the washer (18.3 × 30 × t) and lock washer (18
or partially worn down. × 30 × 2) and attach the lock nut.
• When the contact surface of the baulk ring insert
section is cracked or abnormally worn.
• If the gap between the end faces of the baulk ring
and the gear splined part is excessively small,
check the clearance (A) while pressing the ring
against the cone.
Clearance (A):
0.5 mm (0.020 in) or more
(A)
(H)
MT-01674
• Apply gear oil to the cone of the gear and while

press-fitting the baulk ring, check there is no rota-
MT-00267
tion in the circumferential direction.
5) Coupling sleeve and synchronizer hub
• Check the slipping condition of the coupling
sleeve.
• Check the splines on the coupling sleeve and
synchronizer hub for wear.
Replace the shifting insert key if deformed, exces-
sively worn or defective in any way.
7) Ball detent
Replace the ball detent if deformed, excessively
worn or defective in any way.
8) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, worn or defective in any way.
9) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn or defective in any way.
5MT-65

2) Using the ST1, ST2 and ST3, tighten the new 3) After removing the ST2, measure the starting
lock nut to the specified torque. torque using torque driver.
NOTE: ST1 899884100 HOLDER
• Use new lock nuts and lock washers. ST3 899988608 SOCKET WRENCH (27)
• Make sure the lock washer is installed in the Starting torque:
proper direction. 0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.22 — 0.59
Tightening torque: ft-lb)
120 N·m (12.2 kgf-m, 88.5 ft-lb) ST1
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3
ST3 899988608 SOCKET WRENCH (27)
ST1
ST2
MT-00269
4) If the starting torque is not within the specified

limit, select new adjusting washer No. 1 and re-
check starting torque.
ST3
(C)
(B)
(A)
(A)
(B) MT-00270
MT-02392 (A) Adjusting washer No. 1

(B) Adjusting washer No. 2
(A) Lock nut
(B) Lock washer Adjusting washer No. 1
(C) Nut side Part No. Thickness mm (in)
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)
5MT-66

5) If the specified starting torque cannot be ob-

tained by the selection of adjusting washer No. 1,
select adjusting washer No. 2 from the list below.
Repeat steps 1) through 4) to adjust starting
torque.
(A)
(B) MT-00270
(A) Adjusting washer No. 1

(B) Adjusting washer No. 2
Adjusting washer
Starting torque Dimension H
No. 2
Low Small Select thicker one.
High Large Select thinner one.
Adjusting washer No. 2

803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
6) Recheck that the starting torque is within the

specified range, then crimp the lock nut at four po-
sitions.
CAUTION:
When crimping the lock nut, be careful not to
crack it.
5MT-67
Front Differential Assembly

17.Front Differential Assembly B: INSTALLATION

1) Install the differential side retainers using ST.
A: REMOVAL ST 18630AA010 WRENCH COMPL RETAIN-
1) Remove the manual transmission assembly ER
from the vehicle. <Ref. to 5MT-22, REMOVAL, 2) Install the bearing outer race to the transmission
Manual Transmission Assembly.> case.
2) Remove the transfer case together with the ex- 3) Install the front differential assembly.
AL, Transfer Case and Extension Case NOTE:
Assembly.> Be careful not to bend the seal lips of oil seal.
4) Remove the drive pinion shaft assembly. <Ref.
to 5MT-57, REMOVAL, Drive Pinion Shaft Assem-
bly.>
range. <Ref. to 5MT-52, REMOVAL, Main Shaft
Assembly for Single-Range.>
6) Remove the front differential assembly.
NOTE: MT-00162
• Do not confuse the right and left roller bearing 4) Install the main shaft assembly for single-range.
outer races. <Ref. to 5MT-52, INSTALLATION, Main Shaft As-
• Be careful not to damage the oil seal of retainer. sembly for Single-Range.>
5) Install the drive pinion shaft assembly. <Ref. to
sembly.>
6) Install the transmission case. <Ref. to 5MT-48,
Assembly.>
MT-00162
7) Remove the differential side retainers using ST. Transmission Assembly.>
ST 18630AA010 WRENCH COMPL RETAIN-
ER
ST
MT-00176
8) Remove the bearing outer race from the trans-

mission case.
5MT-68

C: DISASSEMBLY 3) Pull out the pinion shaft, and remove the differ-
ential bevel pinion, differential bevel gear and
1. DIFFERENTIAL CASE ASSEMBLY washer.
1) Remove the twelve bolts and remove hypoid (B)
(D)
driven gear. (C)
(A) (C) (D)
(B)
(A)
MT-00277
(A) Pinion shaft

(B) Differential bevel pinion
(C) Differential bevel gear
(D) Washer
4) Using the ST, remove the roller bearing.

ST 899524100 PULLER SET
MT-00275
(A) Hypoid driven gear ST
2) Drive out the straight pin from differential assem-

bly toward hypoid driven gear side. MT-00278
ST 899904100 STRAIGHT PIN REMOVER
ST
MT-00276
5MT-69

2. SIDE RETAINER 2) Measure the backlash between differential bevel

1) Remove the O-ring. gear and differential pinion. If backlash is out of
specifications, install a suitable washer to adjust.
<Ref. to 5MT-72, BEVEL PINION GEAR BACK-
LASH, INSPECTION, Front Differential Assem-
bly.>
NOTE:
Be sure the pinion gear teeth contacts adjacent
gear teeth during measurement.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
MT-00279 Standard backlash
2) Remove the oil seal. 0.13 — 0.18 mm (0.0051 — 0.0071 in)
NOTE:
Remove using the flat tip screwdriver.
ST2
ST1
MT-00285
3) Align the pinion shaft and differential case with

MT-01445
each hole, and drive the straight pin into the holes
from the hypoid driven gear using the ST.
D: ASSEMBLY NOTE:
1. DIFFERENTIAL CASE ASSEMBLY • Use a new straight pin.
• Lock the straight pin after installing.
1) Install the differential bevel gear and differential
bevel pinion together with washer, and insert the
pinion shaft.
NOTE: (A)
Face the chamfered side of washer toward gear.
(C)
(B) (B)
MT-00286
(A)
(A) Pinion shaft
(C) (B) Differential case
MT-00284 (C) Straight pin
(A) Differential bevel pinion

(B) Differential bevel gear
(C) Pinion shaft
5MT-70

4) Install the roller bearing to differential case. 2. SIDE RETAINER

CAUTION: 1) Install the oil seal.
Do not apply a load in excess of 10 kN (1 ton, 1.1 NOTE:
US ton, 1.0 Imp ton). • Use a new oil seal.
NOTE: • Apply transmission gear oil to the oil seal lips,
Be careful because the roller bearing outer races and install the oil seal while being careful not to de-
are used as a set. form the lip.
ST1 499277100 BUSHING 1-2 INSTALLER • Using the ST, install the oil seal by lightly tapping
ST2 398497701 ADAPTER with a plastic hammer.
SEAL INSTALLER
ST1
ST
ST2
MT-00287
5) Install the hypoid driven gear to the differential

MT-00289
case using twelve bolts.
2) Install the O-ring.
Tightening torque:
T: 62 N·m (6.3 kgf-m, 45.7 ft-lb) NOTE:
• Use new O-rings.
• Apply gear oil to O-ring.
(A) • Do not stretch or damage the O-ring.
T
(B)
MT-01216
(A) Hypoid driven gear

(B) Differential case MT-00279
5MT-71

E: INSPECTION 1. BEVEL PINION GEAR BACKLASH

Repair or replace the differential gear in the follow- Measure the backlash between the differential bev-
ing cases: el gear and differential bevel pinion. If backlash is
• When the hypoid drive gear and drive pinion out of specifications, install a suitable washer to ad-
shaft tooth surfaces are damaged, excessively just. <Ref. to 5MT-73, ADJUSTMENT, Front Differ-
worn, or seized. ential Assembly.>
• When the roller bearing on the drive pinion shaft NOTE:
has a worn or damaged roller path. Be sure the pinion gear teeth contacts adjacent
• When there is damage, wear or seizure of the dif- gear teeth during measurement.
ferential bevel pinion, differential bevel gear, wash- ST1 498247001 MAGNET BASE
er, pinion shaft or straight pin. ST2 498247100 DIAL GAUGE
• When the differential case sliding surfaces are
worn or damaged. Standard backlash
0.13 — 0.18 mm (0.0051 — 0.0071 in)
(A)
ST2
(G)
(E)
(F)
(F)
ST1
(E)
(H) (B) (C)
(G) MT-00285
2. HYPOID GEAR BACKLASH

(D)
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.
(I) (H) ST3 498255400 PLATE
2) Install SUBARU genuine axle shafts to both
MT-01074 sides, rotate in the inversion direction so that the
gauge contacts the tooth surface, and read the dial
(A) Drive pinion shaft
gauge
(B) Hypoid driven gear
Part No. 38415AA100 Axle shaft
(C) Pinion shaft
(D) Straight pin Backlash
(E) Washer
0.13 — 0.18 mm (0.0051 — 0.0071 in)
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Roller bearing
ST3 ST2
(I) Differential case
ST1
MT-00293
NOTE:
If the backlash is outside the specified range, ad-
just it by turning the side retainer in the right side
case.
5MT-72

3. TOOTH CONTACT OF HYPOID GEAR 2. HYPOID GEAR BACKLASH

Check tooth contact of hypoid gear as follows: Ap- Adjust the backlash by turning the side retainer in
ply a thin uniform coat of red lead on both teeth sur- the RH side case.
faces on 3 or 4 teeth of the hypoid gear. Move the ST 18630AA010 WRENCH COMPL RETAIN-
hypoid gear back and forth by turning the transmis- ER
sion main shaft until a definite contact pattern is de-
veloped on the hypoid gear, and judge whether ST
face contact is correct. When the contact pattern is
not correct, adjust. <Ref. to 5MT-73, ADJUST-
MENT, Front Differential Assembly.>
• Tooth contact is correct.
(A)
(D) (B)
MT-00176
NOTE:
Each time the side retainer rotates by one notch
(A), the backlash changes by 0.05 mm (0.020 in).
(A)
(C) MT-01402
(A) Toe
(B) Coast side
(C) Heel
(D) Drive side
F: ADJUSTMENT
MT-02603
1. BEVEL PINION GEAR BACKLASH
1) Disassemble the front differential assembly. 3. TOOTH CONTACT OF HYPOID GEAR
<Ref. to 5MT-69, DISASSEMBLY, Front Differen- 1) Adjust until correct teeth contact is obtained.
tial Assembly.> 2) Check tooth contact, and perform the adjust-
2) Select a suitable washer for the differential bevel ment as follows.
gear from the table and install. • Correct tooth contact
Washer 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
0.925 — 0.950
803038021 side.)
(0.0364 — 0.0374)
0.975 — 1.000
803038022
(0.0384 — 0.0394) (A)
1.025 — 1.050
803038023
(0.0404 — 0.0413)
3) Adjust until the standard value is obtained.

Backlash: (B)
Standard
0.13 — 0.18 mm (0.0051 — 0.0071 in)
MT-01401
(A) Toe side

(B) Heel side
5MT-73

• Face contact • Toe contact (inside contact)

Check item: Backlash is too large. Check item: Teeth contact area is too small.
Contact pattern Contact pattern
AT-00208 AT-00210
Corrective action: Tighten the side retainer to move Corrective action: Increase the thickness of drive
the driven gear closer to the drive pinion shaft. pinion shim and tighten the side retainer to move
the driven gear closer to the drive pinion shaft ac-
cording to the procedure for bringing drive pinion
shaft away from driven gear.
MT-01799
• Flank contact
Check item: Backlash is too small.
AT-00213
Contact pattern
AT-00209
Corrective action: Loosen the side retainer to move

the driven gear away from the drive pinion shaft.
MT-01800
5MT-74

• Heel contact (outside end contact)

Check item: Teeth contact area is too small.
Contact pattern
AT-00211
Corrective action: Reduce the thickness of drive

pinion shim and loosen the side retainer to move
the driven gear away from the drive pinion accord-
ing to the procedure for moving drive pinion shaft
closer to the driven gear.
AT-00212
5MT-75
Reverse Idler Gear

18.Reverse Idler Gear B: INSTALLATION

1) Install the reverse shifter lever, washer, reverse
A: REMOVAL idler gear, washer and reverse idler gear shaft, and
1) Remove the manual transmission assembly secure them with the straight pin.
Manual Transmission Assembly.> NOTE:
2) Remove the back-up light switch and the neutral • Be sure to install the reverse idler gear shaft from
position switch. <Ref. to 5MT-32, REMOVAL, rear side.
Switches and Harness.> • Use a new straight pin.
(E)
AL, Transfer Case and Extension Case (B)
(F)
Assembly.> (A) (C)
to 5MT-57, REMOVAL, Drive Pinion Shaft Assem- (D)
bly.>
6) Remove the main shaft assembly for single- MT-01565
Assembly for Single-Range.> (A) Straight pin
7) Remove the front differential assembly. <Ref. to (B) Reverse idler gear shaft
5MT-68, REMOVAL, Front Differential Assembly.> (C) Reverse idler gear
8) Remove the shifter forks and rods. <Ref. to 5MT- (D) Washer
78, REMOVAL, Shifter Fork and Rod.> (E) Washer
9) Pull out the straight pin, and remove the reverse (F) Reverse shifter lever
idler gear shaft, washer, reverse idler gear and
washer. 2) Check and adjust clearance between the re-
verse idler gear and the timing case wall surface.
(E)
<Ref. to 5MT-76, INSTALLATION, Reverse Idler
(B) Gear.> <Ref. to 5MT-77, ADJUSTMENT, Reverse
(F) Idler Gear.>
(A) (C)
3) Install the shifter forks and rods. <Ref. to 5MT-
79, INSTALLATION, Shifter Fork and Rod.>
(D) 5MT-68, INSTALLATION, Front Differential As-
sembly.>
MT-01565 5) Install the main shaft assembly for single-range.
<Ref. to 5MT-52, INSTALLATION, Main Shaft As-
(A) Straight pin sembly for Single-Range.>
(B) Reverse idler gear shaft 6) Install the drive pinion shaft assembly. <Ref. to
(C) Reverse idler gear 5MT-57, INSTALLATION, Drive Pinion Shaft As-
(D) Washer sembly.>
(E) Washer
(F) Reverse shifter lever
10) Remove the reverse shifter lever. sion case assembly. <Ref. to 5MT-34, INSTALLA-
Assembly.>
5MT-76
Reverse Idler Gear

C: INSPECTION D: ADJUSTMENT
1) Move the reverse shifter rod toward the reverse 1) Select the appropriate reverse shifter lever from
side. Check the clearance between the reverse the table below, and adjust until the clearance be-
idler gear and the transmission case wall surface. tween the reverse idler gear and transmission case
If out of specification, select the appropriate re- wall is within specification.
verse shifter lever and adjust.
Clearance A:
Clearance A: 6.0 — 7.5 mm (0.236 — 0.295 in)
6.0 — 7.5 mm (0.236 — 0.295 in)
A
A
MT-00305
MT-00305
Reverse shifter lever
2) After installing a suitable reverse shifter lever,
Part No. Mark Remarks
shift into neutral. Check the clearance between the
32820AA070 7 Far from case wall
reverse idler gear and the transmission case wall
surfaces. 32820AA080 8 Standard
If out of specification, select the appropriate washer 32820AA090 9 Closer to case wall
and adjust.
2) Select the appropriate washer from the table be-
Clearance: low, and adjust until the clearance between the re-
0 — 0.5 mm (0 — 0.020 in) verse idler gear and transmission case wall is
within specification.
Clearance:
0 — 0.5 mm (0 — 0.020 in)
MT-00306
3) Check the reverse idler gear and shaft for dam-

age. Replace if it is damaged.
MT-00306
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)
5MT-77
Shifter Fork and Rod

19.Shifter Fork and Rod 10) Drive out the straight pin by tapping with the
ST, and remove the 3rd – 4th fork rod and shifter
A: REMOVAL fork.
1) Remove the manual transmission assembly NOTE:
from the vehicle. <Ref. to 5MT-22, REMOVAL, • When removing the rod, keep other rods in neu-
Manual Transmission Assembly.> tral.
2) Remove the back-up light switch and the neutral • When removing the straight pin, remove it to-
position switch. <Ref. to 5MT-32, REMOVAL, ward the inside of case so that it does not hit
Switches and Harness.> against the case.
3) Remove the transfer case together with the ex- ST 398791700 STRAIGHT PIN REMOVER 2
(C)
Assembly.>
bly.>
(A) (B) MT-00994
Assembly for Single-Range.>
7) Remove the front differential assembly. <Ref. to (A) Straight pin
5MT-68, REMOVAL, Front Differential Assembly.>
(B) 3rd-4th fork rod
8) Drive out the straight pin by tapping with the ST,
(C) Shifter fork
and remove the 5th shifter fork.
ST 398791700 STRAIGHT PIN REMOVER 2
11) Drive out the straight pin by tapping with the
ST, and remove the 1st – 2nd fork rod and shifter
fork.
12) Remove the snap ring (outer), and pull out the
reverse fork rod from the reverse fork rod arm.
Then take out the ball, spring and interlock plunger
from the reverse fork rod arm.
And then remove the rod.
(B) NOTE:
(A) MT-00309
When pulling out the reverse fork rod arm, be care-
(A) Straight pin
ful not to let the ball pop out of arm.
13) Remove the reverse shifter lever.
(B) 5th shifter fork
9) Remove the plugs, springs and check balls.
5MT-78

B: INSTALLATION 10) Install the 5th shifter fork onto the rear of re-
verse fork rod. Align the holes in the two parts and
1) Install the spring and ball to the reverse fork rod
drive straight pin into the specified place.
arm, and press in the ST.
ST 399411700 ACCENT BALL INSTALLER NOTE:
2) Install the reverse fork rod through the hole on Use a new straight pin.
the rear of the transmission case. Press out the ST ST 398791700 STRAIGHT PIN REMOVER 2
using the reverse fork rod, and fix with outer snap
ring. (B)
3) Install the interlock plunger to reverse fork rod
arm.
NOTE:
Apply grease to the plunger to prevent it from fall-
ing.
4) Position the ball, spring and gasket in the re-
verse fork rod hole on the left side of transmission
case, and tighten the checking ball plug. (A) (C) MT-00311
NOTE: (A) 5th shifter fork

Use a new gasket.
(B) Reverse fork rod
Tightening torque: (C) Straight pin
20 N·m (2.0 kgf-m, 14.8 ft-lb)
5) Install the 1st-2nd fork rod to the 1st-2nd shifter 11) Position the balls, checking ball springs and
fork through the hole on the rear of the transmis- gaskets to the 3rd-4th fork rod and 1st-2nd fork rod
sion case. holes, and install plugs.
NOTE: NOTE:
• Set other rods to neutral. Use a new gasket.
• Check that the positions of interlock plunger is Tightening torque:
correct. 20 N·m (2.0 kgf-m, 14.8 ft-lb)
6) Align the holes in the rod and the fork, and drive
in the straight pin using the ST.
NOTE:
Use a new straight pin.
7) Install the interlock plunger (thin) onto the 3rd-
4th fork rod.
NOTE:
Apply grease to the plunger to prevent it from fall-
ing. MT-00366
8) Install the 3rd-4th fork rod to the 3rd-4th shifter 12) Install the front differential assembly. <Ref. to
fork and reverse fork rod arm through the hole on 5MT-68, INSTALLATION, Front Differential As-
the rear of the transmission case. sembly.>
9) Align the holes in the rod and the fork, and drive 13) Install the main shaft assembly for single-
the straight pin into these holes. range. <Ref. to 5MT-52, INSTALLATION, Main
NOTE: Shaft Assembly for Single-Range.>
• Use a new straight pin. 14) Install the drive pinion shaft assembly. <Ref. to
• Set other fork rods to neutral. 5MT-57, INSTALLATION, Drive Pinion Shaft As-
• Check that the positions of interlock plunger is sembly.>
correct. 15) Install the transmission case. <Ref. to 5MT-48,
ST 398791700 STRAIGHT PIN REMOVER 2 INSTALLATION, Transmission Case.>
5MT-79

16) Install the transfer case together with the exten- 4) Inspect the clearance between the 3rd, 4th drive
sion case assembly. <Ref. to 5MT-34, INSTALLA- gear and the coupling sleeve. If any clearance is
TION, Transfer Case and Extension Case not within specifications, replace the shifter fork as
Assembly.> required.
Clearance (a) and (b):
9.3 mm (0.366 in)
(a) (b)
vehicle. <Ref. to 5MT-24, INSTALLATION, Manual (A) (B) (C)
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-
cessively worn, bent or defective in any way. MT-00940
3) Inspect the clearance between 1st, 2nd driven
gear and reverse driven gear. If any clearance is (A) 3rd drive gear
not within specifications, replace the shifter fork as (B) Coupling sleeve
required. (C) 4th drive gear
Clearance (a) and (b):
9.5 mm (0.374 in) 3rd-4th shifter fork
(A) (a) (b)
Approaches 4th gear
(B) (C) 32810AA061 1
by 0.2 mm (0.008 in)
32810AA071 No mark Standard
Approaches 3rd gear
32810AA101 3
by 0.2 mm (0.008 in)
MT-01635
(A) 1st driven gear

(B) Reverse driven gear
(C) 2nd driven gear
1st-2nd shifter fork

Approaches 1st gear
32804AA060 1
by 0.2 mm (0.008 in)
Approaches 2nd gear
32804AA080 3
by 0.2 mm (0.008 in)
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)
(A) (a) (B)
MT-01512
(A) 5th drive gear

(B) Coupling sleeve
5th shifter fork

Approaches 5th gear
32812AA201 7
by 0.2 mm (0.008 in)
Moves away from 5th
32812AA221 9 gear by 0.2 mm (0.008
in)
6) Inspect the rod end clearances (A) and (B). If

any clearance is not within specifications, replace
the rod or fork as required.
Clearance (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)
(B)
MT-00316
5MT-81


A: INSPECTION
1. MANUAL TRANSMISSION
1. Gears are difficult to intermesh. (a) Worn, damaged or burred chamfer at Replace.
NOTE: internal spline of the sleeve and reverse
The cause for difficulty in shifting gears driven gear
can be classified into two types: One is a (b) Worn, damaged or burred chamfer of Replace.
defective gear shift system and the other is gear spline
defective transmission. However, if the op- (c) Worn or scratched bushings Replace.
eration is heavy and engagement of the
gears is difficult, a defective clutch disen- (d) Incorrect contact or wear between syn- Repair or replace.
gagement may also be responsible. Check chronizer ring and gear cone
whether the clutch is correctly functioning,
before checking the gear shift system and
transmission.
2. Gear slip-out (a) Defective pitching stopper adjustment Replace.
• Gear slips out when coasting on rough (b) Loose engine mounting bolts Tighten or replace.
road
(c) Worn shifter fork or broken check ball Replace.
• Gear slips out during acceleration
spring
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines Replace.
of synchronizer hub and synchronizer
sleeve
(f) Worn tooth step of synchronizer hub Replace.
(caused by slip-out of 3rd gear)
(g) Worn 1st driven gear and driven shaft Replace.
(h) Worn 2nd driven gear and bushing Replace.
(i) Worn 3rd drive gear and needle bearing Replace.
(j) Worn 4th drive gear and needle bearing Replace.
(k) Worn 5th drive gear and needle bearing Replace.
(l) Worn reverse idler gear and bushing Replace.
3. Noise emitted from transmission (a) Insufficient or improper lubrication Lubricate with specified oil or replace.
NOTE: (b) Worn or damaged gears and bearings Replace.
If a noise is heard when the vehicle is NOTE:
parked with its engine idling and if a noise If the trouble is only wear of the gear teeth
ceases when the clutch is disengaged, it surfaces, only a high whirring noise will oc-
may be considered that the noise is com- cur at high speeds, but if any part is broken,
ing from the transmission. rhythmical clicking sounds will be heard
even at low speeds.
5MT-82

2. DIFFERENTIAL
1. Broken differential (case, gear, bearing, (a) Insufficient or improper oil Disassemble the differential and
etc.) replace broken components. At the
NOTE: same time check other components for
Noise will occur, and eventually the differ- any trouble, and replace if necessary.
ential will not be able to operate due to bro- (b) Use of vehicle under severe conditions Readjust the preload and backlash of
ken pieces obstructing the gear revolution. such as excessive load or improper use of the bearing, and the contact surface of
the clutch gear.
(c) Improper adjustment of taper roller Adjust.
bearing
(d) Improper adjustment of the drive pinion Adjust.
and the hypoid driven gear
(e) Excessive backlash of a vehicle under Add recommended oil to the specified
severe operating conditions due to worn level. Do not use vehicle under severe
differential side gear, washer or differential operating conditions.
pinion.
(f) Loose hypoid driven gear clamping bolts Tighten.
2. Differential and hypoid gear noises (a) Insufficient oil Add recommended oil to the specified
Troubles of the differential and hypoid gear level.
always appear as noise problems. There- (b) Improper adjustment of hypoid driven Check the tooth contact.
fore noise is the first indication of trouble. gear and drive pinion
However, noises from the engine, muffler,
(c) Worn teeth of hypoid driven gear and Replace as a set.
tire, exhaust gas, bearing, body, etc. are
drive pinion Readjust the bearing preload.
easily mistaken for the differential noise.
Pay special attention to the hypoid gear (d) Loose roller bearing Readjust the backlash of the hypoid
noise because it is easily confused with driven gear to drive pinion, and check
other gear noises. There are the following the tooth contact.
four kinds of noises. (e) Distorted hypoid driven gear or differen- Replace.
• Gear noise when driving: tial case
If noise increases as the vehicle speed (f) Worn washer and differential pinion Replace.
increases, it may be due to insufficient shaft
gear oil, incorrect gear engagement, dam-
aged 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.
5MT-83

DIFFERENTIAL
6MT
Page
2. Transmission Gear Oil .............................................................................26
3. Oil Seal .....................................................................................................27
4. Differential Side Retainer Oil Seal ............................................................28
5. Transmission Mounting System ...............................................................29
6. Manual Transmission Assembly ..............................................................31
7. Preparation for Overhaul ..........................................................................37
8. Air Breather Hose .....................................................................................38
9. Back-up Light Switch ................................................................................39
10. Neutral Position Switch ............................................................................41
11. Extension Case ........................................................................................43
12. Reverse Check System ............................................................................50
13. Transfer Drive Gear .................................................................................53
14. Transfer Driven Gear ...............................................................................55
15. Center Differential ....................................................................................57
16. Transmission Case ..................................................................................58
17. Main Shaft Assembly ...............................................................................65
18. Driven Gear Assembly .............................................................................80
19. Reverse Idler Gear Assembly ..................................................................89
20. Drive Pinion Shaft Assembly ....................................................................94
21. Front Differential Assembly ....................................................................100
22. Shifter Fork and Rod ..............................................................................107
23. Clutch Housing .......................................................................................121
24. Driver’s Control Center Differential Control Module ...............................123
25. General Diagnostic Table .......................................................................124
General Description
A: SPECIFICATION
1. MANUAL TRANSMISSION AND FRONT DIFFERENTIAL
Destination code Except for C6 C6
Type 6-forward speeds and 1-reverse
1st 3.636
2nd 2.235
3rd 1.521 1.590
Transmission gear ratio 4th 1.137
5th 0.971 0.891
6th 0.756 0.707
Reverse 3.545
Front reduction Type of gear Hypoid
Final
gear Gear ratio 3.900
Type of gear Helical
Transfer
Rear reduction Gear ratio 1.103
gear Type of gear Hypoid
Final
Gear ratio 3.545
Type and number of gear Planetary gear (pinion gear: 8, gear: 2)
Front differential
LSD type Helical
Planetary gear
Center differential Type and number of gear (Internal gear: 1, pinion gear: 6, sun gear: 1, and solenoid
compression variable control multiplate clutch)
Transmission gear oil GL-5
Transmission gear oil capacity 4.1 L (4.3 US qt, 3.6 Imp qt)
2. TRANSMISSION GEAR OIL

Recommended oil:
6MT-2
General Description
B: COMPONENT
1. CLUTCH HOUSING
(12)
(4)
(3)
T2
(2)
(9)
T5 (5)
(10)
(1)
(7)
T3
(8)
(6)
T1
T4
(11)
MT-02307
(1) Gasket (7) Oil seal Tightening torque: N·m (kgf-m, ft-lb)
(2) Plug (8) Clutch release bearing guide T1: 6.4 (0.7, 4.7)
(3) Pitching stopper bracket (9) Return spring bracket T2: 41 (4.2, 30.2)
(4) Clip (10) Plug T3: 50 (5.1, 36.9)
(5) Clutch housing (11) Drain plug T4: 70 (7.1, 51.6)
(6) Gasket (12) Transmission radio ground cable T5: 46 (4.7, 33.9)
6MT-3
General Description
2. ADAPTER PLATE
(1)
(11)
T1
T2
(2)
(3)
(4) (6)
(8) (7)
(10) (5) (9)
T2
T1
T3
(12)
T1
MT-02308
(1) Breather hose (7) O-ring Tightening torque: N·m (kgf-m, ft-lb)
(2) Check plug (8) Checking spring T1: 18 (1.8, 13.3)
(3) O-ring (9) Check ball T2: 25 (2.5, 18.4)
(4) Checking spring (10) Oil guide A T3: 50 (5.1, 36.9)
(5) Plunger (11) Oil guide B
(6) Check plug (12) Adapter plate
6MT-4
General Description
3. TRANSMISSION CASE
T5
(13)
(7)
(2)
T2
T3 (10)
(5) T2
(1)
(10)
(10)
(3)
(8)
(10)
(9)
(4)
T4
(12)
(6)
T5
(12)
T5
T1
(6) (12)
(10)
T5
(11)
MT-02710
(1) Pilot bolt (8) Spring Tightening torque: N·m (kgf-m, ft-lb)
(2) Neutral switch (9) Plug T1: 16 (1.6, 11.8)
(3) Back-up light switch (10) Gasket T2: 32 (3.3, 23.6)
(4) Adapter plate (11) Filler plug T3: 34 (3.5, 25.1)
(5) Transmission case (12) Band clip T4: 41 (4.2, 30.2)
(6) Harness bracket (13) Transmission harness stay T5: 50 (5.1, 36.9)
(7) Selector plunger
6MT-5
General Description
4. OIL PAN & OIL GUIDE
(3)
(10)
(2)
(1)
(4)
T3
T3
(6)
(7)
T4
(11)
(5)
(12)
T2
(9)
(6)
T4 T1
(8)
MT-02305
(1) Transmission case (7) Oil guide F Tightening torque: N·m (kgf-m, ft-lb)
(2) Transfer bearing holder (8) Oil guide D T1: 6.4 (0.7, 4.7)
(3) Oil guide G (9) Oil guide E T2: 18 (1.8, 13.3)
(4) Oil guide H (10) Oil guide C T3: 25 (2.5, 18.4)
(5) Oil pan (11) Filler plug T4: 50 (5.1, 36.9)
(6) Gasket (12) Drain plug
6MT-6
General Description
5. EXTENSION CASE AND CENTER DIFFERENTIAL
(5) (19)
(4) (17)
(3) (18)
(2)
(16)
(1)
T3
(20)
(23)
(24)
(12)
(25)
(21) (26)
(11) (15) (22)
(10) (14)
(13) (33)
(27)
(29)
T1 (28)
(30)
(9)
(31) T2
(32)
(8)
(7)
(6)
MT-02934
(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: N·m (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
6MT-7
General Description
6. SHIFTER FORK AND FORK ROD
(10)
(9)
(8)
(7)
(15)
(1)
(1)
(6) (18)
(14) (1)
(5)
(4)
(1)
(3)
(1)
(1)
(2) (22)
(17)
(1)
(1)
(1)
(13)
(1)
(12) (16)
(1)
(20) (21)
(11)
(1)
(19)
(23)
(24)
MT-01735
(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
6MT-8
General Description
7. MAIN SHAFT ASSY
(13)
(1)
(12)
(9)
(11)
(10)
(8)
(7)
(6)
(5)
(4)
(3)
(2)
(22)
(20) (29)
(28)
(27)
(21) (26)
(25)
(19)
(24)
(15)
(18) (23)
(14) (17)
(16)
MT-02935
(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) Double 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) Lock 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: N·m (kgf-m, ft-lb)
(10) 4th baulk ring (21) 6th baulk ring T: 392 (40.0, 289.1)
(11) 4th gear (22) 6th drive gear
6MT-9
General Description
8. DRIVE PINION SHAFT ASSY & DRIVEN GEAR ASSY
(7)
(6)
(5)
(4)
(3)
(2)
T3 T1
(15)
(14)
(13) (24)
(1)
(23)
(12)
(11) (22)
(10)
(9)
(21)
(20)
(27)
(8)
(19) (26)
(25) T2
(18)
(17)
(16)
MT-02936
(1) Drive pinion shaft (13) 1st-2nd sleeve (25) Lock nut
(2) Double taper roller bearing (14) Shifting insert (26) Shim
(3) Drive pinion shim (15) 1st-2nd hub (27) Collar
(4) Lock washer (16) Outer baulk ring
(5) Lock nut (17) Synchro cone Tightening torque: N·m (kgf-m, ft-lb)
(6) Thrust bearing (18) Inner baulk ring T1: 285 (29.1, 210.2)
(7) Needle bearing (19) 2nd driven gear * 265 (27.0, 195.4)
(8) Driven shaft (20) Needle bearing T2: 570 (58.1, 420.4)
(9) Key (21) 2nd bushing * 530 (54.0, 390.9)
(10) Needle bearing (22) 3rd-4th driven gear T3: 54 (5.5, 39.8)
(11) 1st driven gear (23) 5th-6th driven gear * Tightening torque when using the ST
(12) 1st synchronizer set (24) Ball bearing
6MT-10
General Description
9. REVERSE IDLER GEAR ASSY
(21)
(7)
(6)
(5)
(4)
(3) (17)
T
(16)
(2) (20)
(15)
(1)
(14)
(21)
(13)
(8)
(12)
(18) (11)
(19)
(10)
(9)
MT-02306
(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: N·m (kgf-m, ft-lb)
(8) Shifting insert (16) Snap ring T: 25 (2.5, 18.4)
6MT-11
General Description
10.FRONT DIFFERENTIAL ASSY
(1)
(3)
(2)
(4)
T2
(7)
(6)
(5)
(7)
(3)
(5)
(8)
(6)
T1
T1
(8)
MT-01705
(1) Drive pinion shaft (5) Oil seal Tightening torque: N·m (kgf-m, ft-lb)
(2) Hypoid driven gear (6) Differential side retainer T1: 25 (2.5, 18.4)
(3) Roller bearing (7) O-ring T2: 69 (7.0, 50.9)
(4) Differential ASSY (8) Retainer lock plate
6MT-12
General Description
11.TRANSMISSION MOUNTING
(4) (6)
(3)
T3 (5)
(2)
T2
T4
T1
(1) (11)
(8)
(3)
(10)
(2)
(7) (9)
T1
T4
T4
T5
MT-01937
(1) Pitching stopper (7) Upper cushion rubber Tightening torque: N·m (kgf-m, ft-lb)
(2) Spacer (8) Center crossmember T1: 35 (3.6, 25.8)
(3) Lower cushion rubber (9) Rear plate T2: 50 (5.1, 36.9)
(4) Front plate (10) Front crossmember T3: 58 (5.9, 42.8)
(5) Transmission cushion rubber (11) Rear cushion rubber T4: 70 (7.1, 51.6)
(6) Rear crossmember T5: 140 (14.3, 103.3)
6MT-13
General Description
C: CAUTION
any work.
• When disassembling the case and other light alloy parts, disassemble by using a plastic hammer. Do not
pry apart with screwdrivers or other tools.
• Use SUBARU genuine transmission gear oil, grease or equivalent. Do not mix transmission gear oil,
grease etc. of different grades or manufacturers.
• Apply transmission gear oil onto sliding or revolving surfaces before installation.
• Always replace deformed or damaged snap rings.
• Before installing O-rings or oil seals, apply sufficient amount of transmission gear oil to avoid damage and
deformation.
• Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts.
• Before securing a part on a vise, place cushioning materials such as wood blocks, aluminum plates, or
waste cloth between the part and the vise.
• Before applying liquid gasket, completely remove the old liquid gasket.
D: PREPARATION TOOL
1. SPECIAL TOOL
398791700 REMOVER Used for removing and installing the spring pin (6
mm).
ST-398791700
399527700 PULLER SET Used for removing and installing the roller bear-
(3) (2) (1) ing (differential).
(1) BOLT (899521412)
(2) PULLER (399527702)
(3) HOLDER (399527703)
(4) ADAPTER (398497701)
(5) BOLT (899520107)
(6) NUT (021008000)
(4) (5) (6)

ST-399527700
6MT-14
General Description

498515700 REMOVER Used for removing the roller bearing of the trans-
fer driven gear.
ST-498515700
498247001 MAGNET BASE • Used for measuring the backlash between
hypoid gears.
• Used with DIAL GAUGE (498247100).
ST-498247001
498247100 DIAL GAUGE • Used for measuring the backlash between
hypoid gears.
• Used with MAGNET BASE (498247001).
ST-498247100
498077000 REMOVER Used for removing the differential taper roller
bearing.
ST-498077000
899858600 REMOVER Used for removing the roller bearing.
ST-899858600
6MT-15
General Description

499757002 INSTALLER Used for installing the bearing cone of transfer
driven gear (transmission case side).
ST-499757002
18630AA010 WRENCH COMPL • Used for removing and installing the differen-
RETAINER tial side retainer RH.
• WRENCH ASSY (499787000) can also be
used.
ST18630AA010
499877000 RACE 4-5 Used for disassembling the driven shaft and
INSTALLER transfer driven gear.
ST-499877000
899864100 REMOVER Used for removing the transmission main shaft
and drive pinion parts.
ST-899864100
498057300 INSTALLER Used for installing the extension oil seal.
ST-498057300
6MT-16
General Description

498255400 PLATE Used for measuring backlash.
ST-498255400
41099AA010 ENGINE SUPPORT Used for supporting engine.
BRACKET
ST41099AA010
41099AA020 ENGINE SUPPORT Used for supporting engine.
ST41099AA020
398527700 PULLER ASSY • Used for removing the extension case oil seal.
• Used for removing the front differential side
bearing outer race. (Used together
with18760AA000 (CLAW).)
ST-398527700
398643600 GAUGE Used for adjusting total end play, extension end
play and drive pinion shim.
ST-398643600
6MT-17
General Description

398177700 INSTALLER • Used for assembling the main shaft.
ST-398177700
399893600 PLIER • Used for removing and installing the neutral
set spring.
• Used together with CLAW (18756AA000).
ST-399893600
18756AA000 CLAW • Used for removing and installing the neutral
set spring.
• Used together with PLIER (399893600).
ST18756AA000
499247400 INSTALLER Used for installing the ball bearing of the transfer
drive gear.
ST-499247400
398497701 SEAT • Used for installing the ball bearing of the trans-
fer drive gear.
• Used for installing the front differential side
bearing.
ST-398497701
6MT-18
General Description

398437700 INSTALLER Used for installing the front differential side bear-
ing.
ST-398437700
18632AA000 STAND ASSY Used for disassembling and assembling the
transmission.
ST18632AA000
18671AA000 OIL SEAL GUIDE • Used for installing the reverse check shaft oil
seal.
• Used for installing the shifter arm oil seal.
• Used together with INSTALLER
(18657AA010).
ST18671AA000
18657AA010 INSTALLER • Used for installing the reverse check shaft oil
seal.
• Used together with OIL SEAL GUIDE
(18671AA000).
ST18657AA010
18657AA000 INSTALLER • Used for installing the shifter arm oil seal.
• Used together with OIL SEAL GUIDE
(18671AA000).
ST18657AA000
6MT-19
General Description

18758AA000 PULLER Used for removing the transfer driven gear bear-
ing outer race.
ST18758AA000
18831AA000 GAUGE Used for selecting the transfer driven gear bear-
ing thrust washer.
ST18831AA000
18631AA000 HANDLE Used for measuring the front differential back-
lash.
ST18631AA000
18754AA000 REMOVER Used to remove parts of the driven gear.
ST18754AA000
18757AA000 STRAIGHT PIN Used for installing the reverse idler gear.
REMOVER
ST18757AA000
6MT-20
General Description

18665AA000 HOLDER • Used for removing and installing the main
shaft lock nut.
• Used together with BASE (18664AA000).
ST18665AA000
18666AA000 HOLDER • Used for removing and installing the driven
shaft lock nut.
ST18666AA000
18667AA000 HOLDER • Used for removing and installing the drive pin-
ion shaft lock nut.
ST18667AA000
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.
ST18664AA000
18722AA010 REMOVER Used for disassembling the main shaft.
ST18722AA010
6MT-21
General Description

18651AA000 INSTALLER Used for assembling the main shaft.
ST18651AA000
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.
ST18852AA000
18668AA000 PUNCH Used to crimp the main shaft lock nut.
ST18668AA000
18669AA000 PUNCH Used to crimp the driven shaft lock nut.
ST18669AA000
18670AA000 PUNCH Used to crimp the drive pinion shaft lock nut.
ST18670AA000
6MT-22
General Description

18620AA000 ADAPTER Used for removing and installing the driven gear
WRENCH shaft lock nut.
ST18620AA000
18621AA000 ADAPTER Used for removing and installing the drive pinion
WRENCH shaft lock nut.
ST18621AA000
18723AA000 REMOVER Used for disassembling the driven shaft.
ST18723AA000
18630AA000 WRENCH ASSY Used for removing and installing the differential
side retainer LH.
ST18630AA000
18672AA000 GUIDE CLIP Used for installing the reverse idler snap ring.
ST18672AA000
6MT-23
General Description

18720AA000 REMOVER Used for disassembling the main shaft.
ST18720AA000
18654AA000 INSTALLER Used for assembling the driven shaft.
ST18654AA000
18663AA000 SOCKET Used for removing and installing the transfer
bearing holder.
ST18663AA000
18853AA000 HEIGHT GAUGE • Used for selecting the shift rod.
• Used for selecting the snap ring and washer of
the main shaft.
ST18853AA000
18760AA000 CLAW • Used for removing the front differential side
bearing outer race.
• Used together with PULLER ASSY
(398527700).
ST18760AA000
6MT-24
General Description

SIDE OIL SEAL seal.
INSTALLER
ST18675AA000
28399SA010 OIL SEAL PROTEC- Used for protecting oil seal when installing front
TOR drive shaft.
ST28399SA010
18657AA020 OIL SEAL Used for installing the oil seal.
INSTALLER
ST18657AA020
18270KA020 SOCKET (E20) Used for removing and installing the hypoid
driven gear.
ST18270KA020
2. GENERAL TOOL
TOOL NAME REMARKS
TORX® bit T70 Used for removing and installing transmission gear oil drain
plug.
Depth gauge Used for measuring the transmission end play.
6MT-25
Transmission Gear Oil

2. Transmission Gear Oil 4) Remove the two drain plugs (oil pan side, clutch
housing side), and then drain the transmission gear
A: INSPECTION oil completely.
1) Lift up the vehicle. CAUTION:
2) Remove the transmission under cover. • Immediately after running the vehicle or after
3) Remove the filler plug, and then check the trans- idling for a long time, the transmission gear oil
mission gear oil. will be hot. Be careful not to receive burns.
(A)
• 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:
• Tighten the drain plug of the transmission gear
oil after draining the transmission gear oil.
• Always use a new gasket.
MT-01706 • Use TORX® bit T70 to remove and install the
drain plug on clutch housing side.
(A) Filler plug
Tightening torque:
4) Check that the transmission gear oil level is up to Oil pan side
the bottom of the filler plug. If the transmission gear 50 N·m (5.1 kgf-m, 36.9 ft-lb)
oil level is low, refill up to the bottom of filler plug. Clutch housing side
5) Using a new gasket, and tighten the filler plug. 70 N·m (7.1 kgf-m, 51.6 ft-lb)
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
B: REPLACEMENT (A)

2) Remove the transmission under cover. (B)
3) Remove the filler plug.
(A)
MT-01830
(A) Drain plug (oil pan side)

(B) Drain plug (clutch housing side)
5) Pour transmission gear oil to the bottom end of

filler plug.
NOTE:
MT-01706
Carefully refill transmission gear oil while checking
(A) Filler plug the level. Excessive or insufficient oil must be
avoided.
Recommended gear oil
Transmission gear oil capacity
4.1 L (4.3 US qt, 3.6 Imp qt)
6) Check the level of the transmission gear oil.
7) Using a new gasket, and tighten the filler plug.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
6MT-26
Oil Seal
3. Oil Seal 8) Install the propeller shaft. <Ref. to DS-12, IN-

A: INSPECTION 9) Install the heat shield cover.
Check that there is no oil leaking from the oil seal. 10) Install the rear exhaust pipe and muffler. <Ref.
If there is any deformation, hardening, wear or oth- to EX(STI)-13, INSTALLATION, Rear Exhaust
er malfunctions of the oil seal, perform the follow- Pipe.> <Ref. to EX(STI)-15, INSTALLATION, Muf-
ing: fler.>
• Replace the oil seal. 11) Pour in transmission gear oil and check the oil
• Inspect the propeller shaft. level. <Ref. to 6MT-26, REPLACEMENT, Trans-
mission Gear Oil.>
B: REPLACEMENT
1) Clean the transmission exterior.
Oil.>
<Ref. to EX(STI)-13, REMOVAL, Rear Exhaust
Pipe.> <Ref. to EX(STI)-15, REMOVAL, Muffler.>
6) Using the ST, remove the oil seal.
(A)
ST
MT-00451
(A) Oil seal
7) Using the ST, install the oil seal.

NOTE:
• When grease is not applied to the oil seal lips,
apply the transmission gear oil to the oil seal lips.
MT-00099
6MT-27
Differential Side Retainer Oil Seal

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(STI)-6, REMOVAL, Front
Exhaust Pipe.>
Oil.>
4) Separate the front drive shaft from the transmis-
sion. <Ref. to DS-27, REMOVAL, Front Drive
Shaft.>
5) Remove the differential side retainer oil seal by
using a flat tip screwdriver or similar tools.
6) Using the ST, install the differential side retainer
oil seal by lightly tapping with a hammer.
SEAL INSTALLER
7) Apply transmission gear oil to the oil seal lips.
8) Set the ST to the side retainer.
9) Install the front drive shaft into the transmission.
NOTE:
Replace the circlip of drive shaft with a new part.
10) Install the front drive shaft into transmission, re-
move the ST and insert the drive shaft securely.
11) Install the front exhaust pipe and the center ex-
haust pipe. <Ref. to EX(STI)-6, INSTALLATION,
Front Exhaust Pipe.>
12) Pour transmission gear oil to the bottom end of
filler plug. <Ref. to 6MT-26, REPLACEMENT,
Transmission Gear Oil.>
6MT-28

5. Transmission Mounting Sys- B: INSTALLATION

tem 1. PITCHING STOPPER
A: REMOVAL 1) Install the pitching stopper.
Tightening torque:
1. PITCHING STOPPER
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
1) Disconnect the ground cable from battery. T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)
2) Remove the intercooler. <Ref. to IN(STI)-12,
3) Remove the pitching stopper.
T2 T1
MT-01301
2) Install the intercooler. <Ref. to IN(STI)-13, IN-

MT-01938
STALLATION, Intercooler.>
3) Connect the ground cable to battery.
BER
BER
1) Install the transmission cushion rubber.
3) Remove the transmission under cover. Tightening torque:
4) Remove the center exhaust pipe. <Ref. to 35 N·m (3.6 kgf-m, 25.8 ft-lb)
EX(STI)-8, REMOVAL, Center Exhaust Pipe.> 2) Install the crossmember.
Tightening torque:
<Ref. to EX(STI)-13, REMOVAL, Rear Exhaust
Pipe.> <Ref. to EX(STI)-15, REMOVAL, Muffler.> T1: 35 N·m (3.6 kgf-m, 25.8 ft-lb)
T2: 70 N·m (7.1 kgf-m, 51.6 ft-lb)
T3: 140 N·m (14.3 kgf-m, 103 ft-lb)
7) Set the transmission jack under the transmission
body. T2
CAUTION:
Always support the transmission case with a
transmission jack. T2
8) Remove the rear crossmember.
T3 T3
T1
MT-01940
3) Remove the transmission jack.

5) Install the rear exhaust pipe and muffler. <Ref. to
EX(STI)-13, INSTALLATION, Rear Exhaust Pipe.>
<Ref. to EX(STI)-15, INSTALLATION, Muffler.>
MT-01939
6) Install the center exhaust pipe. <Ref. to EX(STI)-
9) Remove the transmission cushion rubber. 9, INSTALLATION, Center Exhaust Pipe.>
6MT-29

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.
BER
Check the crossmember for bending or damage.
Check that the cushion rubber is not stiff, cracked,
or otherwise damaged.
6MT-30

6. Manual Transmission As- 5) Remove the secondary air combination valve.

<Ref. to EC(STI)-29, SECONDARY AIR COMBI-
sembly NATION VALVE LH, REMOVAL, Secondary Air
A: REMOVAL Combination Valve.>
6) Disconnect the transmission radio ground termi-
1) Change the bolt installation position from (A) to nal.
(B), then open the front hood completely.
Tightening torque:
7.5 N·m (0.8 kgf-m, 5.5 ft-lb)
(A) (A)
(B) (B)
MT-01266
7) Remove the starter assembly. <Ref. to SC(STI)-

8, REMOVAL, Starter.>
ME-03614 8) Remove the operating cylinder from the trans-
2) Disconnect the ground cable from battery. mission.
3) Remove the intercooler. <Ref. to IN(STI)-12, NOTE:
REMOVAL, Intercooler.> Hang the removed operating cylinder with a piece
4) Disconnect the following harness connectors, of wire.
and then remove the engine hanger rear.
(B)
(A)
CL-00445
9) Remove the return spring from the release fork.
(C)
MT-01740 MT-02302
10) Remove the pitching stopper. <Ref. to 6MT-29,

(A) Front oxygen (A/F) sensor connector PITCHING STOPPER, REMOVAL, Transmission
(B) Rear oxygen sensor connector Mounting System.>
(C) Neutral position switch backup light switch con- 11) Remove the pitching stopper bracket, return
nector spring bracket, and transmission radio ground ca-
ble.
6MT-31

12) Set the ST. 21) Remove the front stabilizer link.
ST1 41099AA010 ENGINE SUPPORT
BRACKET
ST2 41099AA020 ENGINE SUPPORT
ST2
FS-00117
ST1
22) Remove the ball joint of front arm from the
housing.
MT-01526
13) 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.
14) Remove the bolts which hold upper side of
FS-00106
transmission to engine.
23) Remove the front drive shaft. <Ref. to DS-27,
REMOVAL, Front Drive Shaft.>
24) Set the transmission jack under the transmis-
sion, and remove the front crossmember and rear
crossmember.
MT-01524
15) Remove the front wheels.

16) Lift up the vehicle, and remove the transmis-
sion under cover.
17) Drain transmission gear oil completely. <Ref. to MT-01264
Oil.>
6MT-32

25) Move the transmission to the right side of the B: INSTALLATION

vehicle, and remove the joint COMPL, stay bolts
1) Set the release fork, release bearing and release
and reverse check cable.
shaft to the transmission. <Ref. to CL-15, INSTAL-
NOTE: LATION, Release Bearing and Lever.>
If the transmission is not moved aside, the joint 2) Replace the front differential side retainer oil
COMPL and stay bolts may contact the body and seal. <Ref. to 6MT-28, REPLACEMENT, Differen-
cause damage. tial Side Retainer Oil Seal.>
NOTE:
(C)
Be sure to replace the differential side oil seal after
(A) the procedure of removing front drive shaft from
transmission.
(B) 3) Strike and bend the transmission hanger of
transmission rear with a rubber hammer etc. so that
it gets in contact with the transmission case.
CAUTION:
Do not apply extra overload or impact to the
MT-00886
transmission case.
(A) Joint COMPL bolt
(B) Stay bolt
26) Tighten the turnbuckle of the ST to tilt the en-

gine assembly towards the back.
MT-02303
4) Install the transmission onto the engine.

5) Tighten the bolts and nuts which hold the lower
side of transmission to the engine.
NOTE:
• Make sure that the main shaft spline is complete-
MT-00463 ly inserted.
27) Remove the bolts and nuts holding the bottom • Make sure that the rear end of the engine is set
of transmission to the engine, and remove the low.
transmission from the vehicle.
Tightening torque:
NOTE: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
• 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.
MT-00464
MT-01090
6MT-33

6) Loosen the turnbuckle of ST to return the engine 10) Tighten the bolts which hold the upper side of
to its original position. the transmission to the engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
MT-01527
7) Move the transmission to the right side of the ve-

hicle, and attach the joint COMPL, stay bolts and MT-01524
reverse check cable.
11) Make sure that the release bearing is com-
Tightening torque: pletely inserted.
T1: 12 N·m (1.2 kgf-m, 8.9 ft-lb) NOTE:
T2: 32 N·m (3.3 kgf-m, 23.6 ft-lb) • Push the release fork towards the operating cyl-
(A)
inder side until a clicking sound is heard. Pull the
release fork towards the engine side. If the release
T1 fork is not in contact with the case, the setting is
complete.
T2 • Confirm that the boot cover is set securely.
MT-00465

member.
MT-00467
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb) 12) Install the pitching stopper bracket, return
T2: 140 N·m (14.3 kgf-m, 103 ft-lb) spring bracket, and transmission radio ground ca-
ble.
T1
Tightening torque:
41 N·m (4.2 kgf-m, 30.2 ft-lb)
13) Install the pitching stopper.
T1
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)
T2 T2
MT-01265
T2 T1
MT-01301
6MT-34

14) Install the return spring. 19) Connect the following harness connectors,
then attach the engine hanger rear.
(B)
(A)
MT-02302
15) Install the clutch operating cylinder.

Tightening torque:
41 N·m (4.2 kgf-m, 30.2 ft-lb)
NOTE: (C)
Check that the clutch hose is routed properly.
MT-01740
(A) Front oxygen (A/F) sensor connector

(C) Neutral position switch backup light switch con-
CL-00445
nector
16) Install the starter assembly. <Ref. to SC(STI)-
8, INSTALLATION, Starter.> 20) Lift up the vehicle.
17) Install the transmission radio ground terminal. 21) Set the ST to side retainer.
22) Install the front drive shaft into the transmis-
sion.
NOTE:
Replace the circlip of drive shaft with a new part.
23) Install the front drive shaft into transmission, re-
move the ST and insert the drive shaft securely.
24) Install the ball joint of the front arm.
MT-01266
Tightening torque:
18) Install the secondary air combination valve. 50 N·m (5.1 kgf-m, 36.9 ft-lb)
<Ref. to EC(STI)-30, SECONDARY AIR COMBI-
NATION VALVE LH, INSTALLATION, Secondary
Air Combination Valve.>
FS-00106
6MT-35

25) Install the front stabilizer link.

Tightening torque:
45 N·m (4.6 kgf-m, 33.2 ft-lb)
NOTE:
Use a new self-locking nut.
FS-00117
26) Install the propeller shaft. <Ref. to DS-12, IN-

28) Install the center exhaust pipe. <Ref. to
EX(STI)-9, INSTALLATION, Center Exhaust
Pipe.>
29) Fill the transmission gear oil. <Ref. to 6MT-26,
REPLACEMENT, Transmission Gear Oil.>
30) Install the transmission under cover.
6MT-36
Preparation for Overhaul

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
ST
ST
ST
MT-00468
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.
6MT-37
Air Breather Hose

8. Air Breather Hose

A: REMOVAL
Disconnect the air breather hose.
MT-01707
B: INSTALLATION
Connect the air breather hose.
MT-01707
C: INSPECTION
Make sure the hose is not cracked or clogged.
6MT-38
Back-up Light Switch

9. Back-up Light Switch B: INSTALLATION

1) Install the back-up light switch.
A: REMOVAL
from the vehicle. <Ref. to 6MT-31, REMOVAL, Use a new gasket.
Manual Transmission Assembly.> Tightening torque:
2) Disconnect the back-up light switch connector. 32 N·m (3.3 kgf-m, 23.6 ft-lb)
(A)
(B)
(A)
(C)
(C)
(B) MT-00471 MT-00472
(A) Back-up light switch connector (gray) (A) Back-up light switch
(B) Neutral position switch connector (brown) (B) Neutral position switch
(C) Clip
2) Connect the back-up light switch connector.
3) Disconnect the back-up light switch.
(A)
(B)
(A)
(C)
(C)
(B) MT-00471
MT-00472
(A) Back-up light switch connector (gray)
(A) Back-up light switch (B) Neutral position switch connector (brown)
(B) Neutral position switch (C) Clip

6MT-39
Back-up Light Switch

C: INSPECTION
3) Disconnect the transmission harness and chas-
sis harness.
(B)
(A)
MT-01741
(A) Transmission harness connectors

(B) Pitching stopper
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.
Gear shift position Terminal No. Standard
Back position Less than 1 Ω
3 and 6
3 2 1
6 5 4
MT-00946
6MT-40
Neutral Position Switch

10.Neutral Position Switch B: INSTALLATION

1) Install the neutral position switch.
A: REMOVAL
from the vehicle. <Ref. to 6MT-31, REMOVAL, Use a new gasket.
Manual Transmission Assembly.> Tightening torque:
2) Disconnect the connector and clip of the neutral 32 N·m (3.3 kgf-m, 23.6 ft-lb)
position switch.
(A)
(B)
(A)
(C)
(C)
MT-00472
(B) MT-00471
(A) Back-up light switch
(A) Back-up light switch connector (gray) (B) Neutral position switch
(B) Neutral position switch connector (brown)
(C) Clip 2) Connect the connector and clip of the neutral po-
sition switch.
3) Remove the neutral position switch.
(A)
(B)
(A)
(C)
(C)
(B) MT-00471
MT-00472
(A) Back-up light switch connector (gray)
(A) Back-up light switch (B) Neutral position switch connector (brown)
(B) Neutral position switch (C) Clip

6MT-41
Neutral Position Switch

C: INSPECTION
3) Disconnect the transmission harness and chas-
sis harness.
(B)
(A)
MT-01741
(A) Transmission harness connectors

(B) Pitching stopper
4) Measure the resistance between neutral posi-

tion switch terminals. If not within the standard val-
ues, replace the neutral position switch.
Gear shift position Terminal No. Standard
Neutral position Less than 1 Ω
2 and 5
3 2 1
6 5 4
MT-00947
6MT-42
Extension Case
11.Extension Case 5) Install the extension case.

Tightening torque:
A: REMOVAL 48 N·m (4.9 kgf-m, 35.4 ft-lb)
2) Prepare the transmission for overhaul. <Ref. to
6MT-37, Preparation for Overhaul.>
3) Remove the extension case.
MT-00475
NOTE:
Insert the stopper section of the center differential
between the oil guide.
(B)
MT-00475
4) Remove any remaining liquid gasket from the (C)

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.> (A)
(D)
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:
equivalent
MT-00973
(A) Oil guide

(B) Stopper
(C) Center differential
(D) Extension case
MT-00476 6) Install the manual transmission assembly to the

6MT-43
Extension Case
C: DISASSEMBLY 6) Remove the shifter arm oil seal.

1) Remove the transfer drive gear. <Ref. to 6MT-
53, REMOVAL, Transfer Drive Gear.>
2) Remove the oil guide.
(A)
MT-00481
(A) Oil seal
MT-00477 7) Remove the reverse check system. <Ref. to

3) Remove the shift bracket. 6MT-50, REMOVAL, Reverse Check System.>
8) Remove the extension oil seal. <Ref. to 6MT-27,
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-
27, REPLACEMENT, Oil Seal.>
3) Install a shifter arm oil seal using the ST.
ST1 18657AA000 INSTALLER
MT-00478 ST2 18671AA000 OIL SEAL GUIDE
4) Remove the bearing cone using the ST.
ST 18758AA000 PULLER
ST1
(A)
ST (A)
ST2
MT-00482
(A) Oil seal

MT-00479
(A) Bearing cone 4) Install the oil plate.
5) Remove the thrust washer and oil plate.

(B)
(A)
MT-00483
MT-00480
(A) Thrust washer

(B) Oil plate
6MT-44
Extension Case
5) Select the thrust washer of the bearing, and at- 3) Measure depth “Z” between the extension case
tach to the extension case. <Ref. to 6MT-45, AD- end area and bearing cone contact area.
JUSTMENT, Extension Case.> ST 398643600 GAUGE
6) Apply a thin coat of oil to the outer surface of the NOTE:
bearing cone, and attach to the extension case.
When measuring depth “Z”, subtract the thickness
7) Install the shift bracket. of the ST [15 mm (0.59 in)] from the measured val-
Tightening torque: ue.
25 N·m (2.5 kgf-m, 18.4 ft-lb)
ST
ST
MT-00478
8) Attach the oil guide and the transfer driven gear. (A)
<Ref. to 6MT-53, INSTALLATION, Transfer Drive
Gear.> Z
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 MT-01420
there are oil leaks, replace the oil seal and liquid
gasket. (A) 15 mm (0.59 in)
F: ADJUSTMENT 4) Remove the transfer driven gear. <Ref. to 6MT-

55, REMOVAL, Transfer Driven Gear.>
1. TRANSFER DRIVEN GEAR BEARING
5) Remove the center differential. <Ref. to 6MT-57,
THRUST WASHER ADJUSTMENT REMOVAL, Center Differential.>
1) Remove the bearing cone from the extension 6) Remove the oil guides G and H.
case using the ST.
ST 18758AA000 PULLER (A) (B)
(A)
ST
MT-01728
MT-00479 (A) Oil guide G

(B) Oil guide H
(A) Bearing cone
2) Remove the thrust washer.
6MT-45
Extension Case
7) Remove the snap ring and flat washer from the 10) Remove the selector arm No. 2, shifter arm, se-
selector arm area. lector plunger and spring.
(B)
(A)
(A)
(B)
MT-01616
(A) Snap ring

(B) Flat washer
8) Using an ST, remove the neutral set spring and

support.
ST1 18756AA000 CLAW
ST2 399893600 PLIER
(C)
ST2
MT-02713
(A) Selector arm No. 2

(B) Shifter arm
(C) Selector plunger
ST1
11) Attach the bearing cone to the transfer driven
MT-01092 gear.
9) Lift the striking rod, and remove the spring pin. 12) Set the ST.
ST 18831AA000 GAUGE
(A)
ST
(B) MT-01307
MT-00489
(A) Striking rod 13) Turn the transfer driven gear 10 or more times
(B) Spring pin to seat the bearing properly.
6MT-46
Extension Case
14) Measure depth “Y” between the end of the ST 16) Refer to the calculated value “t” to select the
and the bearing cone. closest thrust washer from the following table.
ST 18831AA000 GAUGE
Standard clearance between the thrust washer
and taper roller bearing
0.02 — 0.11 mm (0.0008 — 0.0043 in)
NOTE:
Match to be within the standard clearance range.
ST
Thrust washer (50 × 61 × t)
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)
Y 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)
MT-00490 803050072 1.10 (0.0433)
803050073 1.15 (0.0453)
15) Using the following calculation, calculate the
transfer driven gear bearing thrust washer value “t”. 803050074 1.20 (0.0472)
t = Z – (100 – Y) – {0.02 — 0.11 mm (0.0008 — 803050075 1.25 (0.0492)
0.0043 in)} 803050076 1.30 (0.0512)
t Transfer driven gear bearing thrust 803050077 1.35 (0.0531)
mm (in) washer thickness 803050078 1.40 (0.0551)
Y Depth between the end of the ST 803050079 1.45 (0.0570)
mm (in) and the bearing cone
Depth between the end of the exten-
Z
sion case and the bearing cone con-
mm (in)
tact area
Standard clearance between the
0.02 — 0.11 mm
thrust washer and taper roller bear-
(0.0008 — 0.0043 in)
ing
100 mm
Height of ST
(3.94 in)
6MT-47
Extension Case
17) Install the selector arm No. 2, shifter arm, se- 20) Install the flat washer and snap ring to the se-
lector plunger and spring. lector arm area.
(B)
(A)
(A)
(B)
MT-01616
(A) Snap ring

(B) Flat washer
21) Install the center differential. <Ref. to 6MT-57,

INSTALLATION, Center Differential.>
2. TRANSFER DRIVE GEAR THRUST
WASHER SELECTION
(C)
1) Measure height “Z” between the transmission
case end area and ST.
MT-02713 ST 398643600 GAUGE
(B) Shifter arm
(C) Selector plunger ST
18) Install a new spring pin.

19) Using the ST, install the neutral set spring and
support. Z
ST1 18756AA000 CLAW
ST2 399893600 PLIER
MT-00949
ST2
ST1
MT-01092
6MT-48
Extension Case
2) Measure depth “Y” between the end of the ST 4) Refer to the calculated value “t” to select the
and the transfer drive gear. closest thrust washer from the following table.
ST 398643600 GAUGE
Standard clearance between the thrust washer
and transfer drive gear
0.75 — 0.95 mm (0.030 — 0.037 in)
ST
NOTE:
Match to be within the standard clearance range.
Thrust washer (36.3 × 52 × t)
803036070 0.80 (0.0315)
803036071 0.95 (0.0374)
803036072 1.10 (0.0433)
ST 803036073 1.25 (0.0492)
803036074 1.40 (0.0551)
Y 803036075 0.65 (0.0256)
5) Install the selected thrust washer.
MT-01421

transfer drive gear thrust washer value “t”.
t = {Y – 15 mm (0.59 in)} – {Z – 15 mm (0.59 in)}
– 0.75 — 0.95 mm (0.030 — 0.037 in)
t Transfer drive gear thrust washer
mm (in) thickness
Y Depth between the end of the ST
mm (in) and the transfer drive gear
Z Height from the end of the transmis-
mm (in) sion case to the end of the ST.
Standard clearance between the
0.75 — 0.95 mm
thrust washer and transfer drive
(0.030 — 0.037 in)
gear
15 mm (0.591 in) Thickness of ST
6MT-49
Reverse Check System

12.Reverse Check System 6) Remove the spring pin, and remove the reverse
check lever and oil seal from the reverse check
A: REMOVAL shaft.
from the vehicle. <Ref. to 6MT-31, REMOVAL, (B)
Manual Transmission Assembly.> (C)

(A)
3) Remove the extension case. <Ref. to 6MT-43,
REMOVAL, Extension Case.>
4) Remove the snap ring and washer from the re-
verse check shaft.
MT-00496
(B)
(A) Spring pin
(B) Reverse check lever
(C) Oil seal
7) Remove the plug from the extension case, and

(A) remove the gasket, spring and plunger.
MT-00494
(A) Snap ring

(D)
(B) Washer
(C)
(B)
5) Remove the reverse check shaft and spring from (A)
the extension case.
MT-01818
(A) Plug
(B) Gasket
(C) Spring
(D) Plunger
MT-00495
6MT-50

8) Remove the reverse lock plunger. 3) Install the spring and reverse check shaft to the
extension case.
NOTE:
(A) Confirm that the end of the spring matches the hole
of the reverse check shaft and the cut out of the ex-
tension case.
MT-00498 (B)
(A) Reverse lock plunger (A)
B: INSTALLATION
1) Insert the reverse lock plunger.
2) Install the reverse check plug, spring, gasket,
and plug in order.
NOTE: (B)
Use a new gasket.
(D)
Tightening torque: (A)
41 N·m (4.2 kgf-m, 30.2 ft-lb)
(C)
(D) MT-00499
(C)
(B) (A) Reverse check shaft
(A)
(B) Spring
(C) Hole
(D) Cut out
MT-01818
4) Install the washer and snap ring.
(A) Plug
(B) Gasket
(B)
(C) Spring
(D) Reverse check plug
(A)
MT-00494
(A) Snap ring

(B) Washer
6MT-51

5) Attach ST1 to the reverse check shaft. Install the 9) Install the extension case. <Ref. to 6MT-43, IN-
new oil seal, and push it in using ST2. STALLATION, Extension Case.>
ST1 18671AA000 OIL SEAL GUIDE 10) Install the manual transmission assembly to the
ST2 18657AA010 INSTALLER vehicle. <Ref. to 6MT-33, INSTALLATION, Manual
ST2
C: INSPECTION
1) Check that there is no damage on any parts.
ST1 2) Check that the reverse check lever is operating
smoothly.
(A)
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.
MT-00500
(1) When the reverse check lever is in the fol-
(A) Oil seal
lowing position, the plunger is pressed, or the
gear can shift into reverse.
6) Insert the reverse check lever, and turn the re-
verse check shaft until the plunger is first pushed in.
(A)
(B)
MT-00501
(A) Plunger
(B) Reverse check shaft
7) Match the hole of the reverse check lever and

the reverse check shaft, and attach the straight pin.
NOTE:
Use a new straight pin.
MT-00503
(C)
(2) When the reverse check lever is in the fol-
lowing position, the plunger is not pressed, or
the gear cannot shift into reverse.
(A) (B) MT-00502
(A) Reverse check shaft

(B) Reverse check lever
(C) Hole
MT-00504
8) Check that the reverse check is operating cor- 5) If it is not as specified, reassemble the reverse
rectly. <Ref. to 6MT-52, INSPECTION, Reverse check system.
Check System.>
6MT-52
Transfer Drive Gear

13.Transfer Drive Gear C: DISASSEMBLY

A: REMOVAL
4) Remove the transfer drive gear.
MT-00506
2) Remove the bearing using the ST.

ST 499877000 RACE 4-5 INSTALLER
ST
MT-00505
B: INSTALLATION
1) Install the transfer drive gear.
MT-00507
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb) D: ASSEMBLY
1) Using the ST, install the ball bearing.
NOTE:
Use a new ball bearing.
ST2 398497701 SEAT
ST2
MT-00505
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, ST1
ASSEMBLY, Extension Case.>
3) Install the extension case. <Ref. to 6MT-43, IN-
STALLATION, Extension Case.> MT-00508
4) Install the manual transmission assembly to the 2) Install the snap ring.
MT-00506
6MT-53
Transfer Drive Gear

3) Inspect the clearance between the snap ring and

the ball bearing. <Ref. to 6MT-54, INSPECTION,
Transfer Drive Gear.>
E: INSPECTION
1) Bearing
• Damage or rust on the bearings
• Wear, or damage
• The bearing does not rotate smoothly or an ab-
normal noise is emitted.
2) Drive gear
Replace the drive gear in following case:
• If the drive gear tooth surface and shaft are ex-
cessively damaged or broken.
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)
MT-00509
4) If the measurement is out of specifications, rese-

lect an appropriate snap ring.
Snap ring
805045050 1.76 (0.069)
805045060 1.88 (0.074)
805045070 2.00 (0.079)
After replacing the snap ring, reinspect the clear-

ance.
6MT-54

14.Transfer Driven Gear C: DISASSEMBLY

1) Using the ST, remove the roller bearing (exten-
A: REMOVAL sion case side).
1) Remove the manual transmission assembly ST 498515700 REMOVER
6MT-37, Preparation for Overhaul.> ST
MT-00511
2) Using the ST, remove the roller bearing (trans-

mission case side).
MT-00951
ST2
B: INSTALLATION ST1
MT-00512
D: ASSEMBLY
1) Using the ST, install the roller bearing (transmis-
sion case side).
MT-00951
2) When the bearing or the transfer driven gear is CAUTION:
replaced, select an appropriate thrust washer for Do not apply pressure in excess of 10 kN (1 ton,
the transfer driven gear. <Ref. to 6MT-45, AD- 1.1 US ton, 1.0 Imp ton).
JUSTMENT, Extension Case.>
ST
STALLATION, Extension Case.>
(A)
MT-00514
(A) Roller bearing
6MT-55

2) Using the ST, install the roller bearing (extension

case side).
CAUTION:
Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
ST2
(A) ST1
MT-00513
(A) Roller bearing
E: INSPECTION
1) Bearing
• Damage or rust on the bearings
• Wear or 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.
• If the driven gear tooth surface and shaft are ex-
cessively damaged or broken.
6MT-56
Center Differential
15.Center Differential 2) Install the thrust washer and center differential.
A: REMOVAL
(A)
1) Remove the manual transmission case from the (B)
vehicle. <Ref. to 6MT-31, REMOVAL, Manual
4) Remove the transfer driven gear. <Ref. to 6MT- MT-00952
5) Disconnect the center differential connector. (A) Thrust washer
6) Remove the thrust washer and center differen- (B) Center differential
tial.
3) When replacing the center differential, select
and install the appropriate transfer drive gear and
(A) thrust washer. <Ref. to 6MT-45, ADJUSTMENT,
(B)
Extension Case.>
4) Connect the center differential connector, and
affix to the oil guide.
5) Install the transfer driven gear. <Ref. to 6MT-55,
INSTALLATION, Transfer Driven Gear.>
MT-00952
7) Install the manual transmission case assembly
(A) Thrust washer to the vehicle. <Ref. to 6MT-33, INSTALLATION,
(B) Center differential
C: INSPECTION
7) Remove the needle bearing.
Check that there is no damage on the center differ-
ential. Replace if damaged.
MT-00516
B: INSTALLATION
1) Install the needle bearing.
MT-00516
6MT-57
Transmission Case
16.Transmission Case 9) Using an ST, remove the neutral set spring and
support.
A: REMOVAL ST1 18756AA000 CLAW
1) Remove the manual transmission assembly ST2 399893600 PLIER
2) Prepare the transmission for overhaul. <Ref. to ST2
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.> ST1
REMOVAL, Extension Case.> MT-01092
55, REMOVAL, Transfer Driven Gear.> 10) Lift the striking rod, and remove the spring pin.
REMOVAL, Center Differential.> (A)
7) Remove the oil guides G and H.
(A) (B)
(B) MT-01307
(A) Striking rod

(B) Spring pin
MT-01728
(A) Oil guide G

(B) Oil guide H
8) Remove the snap ring and flat washer from the

selector arm area.
(A)
(B)
MT-01616
(A) Snap ring

(B) Flat washer
6MT-58
Transmission Case
11) Remove the selector arm No. 2, shifter arm, se- 14) Remove the driven gear assembly shim and
lector plunger and spring. spacer.
(B)
(A) (A)
MT-00526
(A) Driven gear ASSY
(C)
MT-02713

(B) Shifter arm MT-00527
(C) Selector plunger 16) Remove the pilot bolt.
12) Remove the transfer bearing holder.
NOTE:
Using a general tool may cause damage. Remove
the bolt using the ST.
ST 18663AA000 SOCKET
MT-01619
13) Remove the washer on the main shaft section.
MT-00528
6MT-59
Transmission Case
17) Remove the holder reverse bolt. 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.
MT-00529
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 (A)
transmission case with excessive force.
(B)
(C)
MT-01620
(A) Striking rod

MT-01711
(B) Reverse interlock block
19) Remove any remaining liquid gasket from the (C) Interlock block
transmission case and adapter plate.
2) Apply liquid gasket to the adapter plate.
Liquid gasket:
equivalent
MT-00532
3) Install the transmission case.
6MT-60
Transmission Case
4) By inspecting from the pilot bolt attachment hole, 9) Install the snap ring and washer for the main
check that the interlock block and the reverse inter- shaft assembly, and washer and collar for the driv-
lock block are aligned to the neutral position. If not en gear assembly.
aligned, remove the transmission case, and shift
the shifter fork and interlock block to the neutral po- (C)
sition.
(B)
(B)
(A)
(A)
MT-00533
(A)
(A) Interlock block (C)
(B) Reverse interlock block
5) Use a new gasket to temporarily attach the pilot

bolt.
6) Affix the transmission case with the bolts and (B) (D)
nuts.
MT-01621
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb) (A) Washer
7) Tighten the pilot bolt. (B) Snap ring
Tightening torque: (C) Collar
34 N·m (3.5 kgf-m, 25.1 ft-lb) (D) Washer
8) Tighten the holder reverse bolt.
10) Install the transfer bearing holder.
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb) Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
ST 18663AA000 SOCKET
MT-01619
6MT-61
Transmission Case
11) When replacing the transfer bearing holder, se- 15) Install the snap ring and flat washer to the se-
lect the appropriate transfer driven gear and thrust lector arm area.
washer, and install to the extension case. <Ref. to
6MT-45, ADJUSTMENT, Extension Case.>
12) Install the selector arm No. 2, shifter arm, se-
lector plunger and spring.
(B)
(A)
(A)
(B)
MT-01616
(A) Snap ring

(B) Flat washer
16) Install the oil guides G and H.
(A) (B)
(C)
MT-02713 MT-01728
(A) Selector arm No. 2 (A) Oil guide G

(B) Shifter arm (B) Oil guide H
(C) Selector plunger
13) Install a new spring pin. INSTALLATION, Center Differential.>
14) Using the ST, install the neutral set spring. 18) Install the transfer driven gear. <Ref. to 6MT-
ST1 18756AA000 CLAW 55, INSTALLATION, Transfer Driven Gear.>
ST2 399893600 PLIER 19) Install the extension case. <Ref. to 6MT-43, IN-
20) Install the neutral position switch, back-up light
switch and harness. <Ref. to 6MT-41, INSTALLA-
ST2
TION, Neutral Position Switch.> <Ref. to 6MT-39,
INSTALLATION, Back-up Light Switch.>
ST1
MT-01092
6MT-62
Transmission Case
1) Remove the transmission harness from the 1) Apply liquid gasket to the oil pan.
transmission case.
Liquid gasket:
NOTE: THREE BOND 1215 (Part No. 004403007) or
Remove the connector by disengaging the connec- equivalent
tor claw from the inside of the transmission.
2) Remove the oil guides C, D, E, F and harness
bracket.
(A)
MT-00541
2) Install the oil pan.

Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
(D)
(E)
(C)
(B)
MT-01712 MT-01831
(A) Oil guide C

(B) Oil guide D
(C) Oil guide E
(D) Oil guide F
(E) Harness bracket
3) Remove the oil pan.
MT-01831
4) Remove any remaining liquid gasket from the

transmission case and oil pan.
6MT-63
Transmission Case
3) Install the oil guides C, D, E, F and harness 4) Attach the transmission harness to the transmis-
bracket. sion.
T1: 16 N·m (1.6 kgf-m, 11.8 ft-lb) Install the transmission harness connector by align-
T2: 18 N·m (1.8 kgf-m, 13.3 ft-lb) ing the protrusions of the transmission and trans-
mission harness connector.
(A)
(D)
(E)
(A)
T2 T1
(C)
(B) (B)
MT-01713
MT-01777
(A) Oil guide C
(B) Oil guide D (A) Protrusion
(C) Oil guide E (B) Transmission harness connectors
(D) Oil guide F
(E) Harness bracket
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.
6MT-64
Main Shaft Assembly

17.Main Shaft Assembly 11) Remove the reverse idler holder.
A: REMOVAL
(A)
MOVAL, Neutral Position Switch.> <Ref. to 6MT- MT-00544
39, REMOVAL, Back-up Light Switch.>
4) Remove the extension case. <Ref. to 6MT-43, (A) Reverse idler holder
5) Remove the transfer driven gear. <Ref. to 6MT- 12) Remove the check plug, O-ring, check spring,
55, REMOVAL, Transfer Driven Gear.> plunger and check ball from the adapter plate.
6) Remove the center differential. <Ref. to 6MT-57, NOTE:
REMOVAL, Center Differential.> Do not reuse the O-ring.
8) Remove the striking rod.
9) Remove the oil guide B.
MT-01623 (A)
(B)
10) Use a screwdriver to shift to the 4th gear posi- (C)
(A)
(C) (B)
tion. (D) (E)
MT-01931
(A) (A) Check plug

(B) O-ring
(C) Checking spring
MT-01736 (D) Plunger
(E) Check ball
(A) 3rd-4th shift rod
6MT-65
Main Shaft Assembly

13) Remove the bolt and gasket holding the re- 3) Attach the driven gear assembly to the 1st-2nd
verse idler shaft. shifter fork assembly.
(C)
(B)
MT-00546 (A) MT-00548
14) Push the main shaft assembly, driven gear as- (A) 1st-2nd shifter fork
sembly, reverse idler gear and shifter forks to re-
(B) Driven gear ASSY
move from the adapter plate all at once.
(C) 1st-2nd sleeve
NOTE:
A helper is required to perform this work. 4) Attach the main shaft assembly to the 3rd-4th
shifter fork, and assemble to the driven gear as-
B: INSTALLATION sembly.
1) Adjust the 3rd-4th and 5th-6th shifter fork rods.
(A) (B)
<Ref. to 6MT-112, ADJUSTMENT, Shifter Fork
and Rod.> (D)
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
ST
(A)
(C)
(A) (B)
(B) (D)
MT-00547
(A) Sub gear

(B) Reverse idler gear
(C)
MT-00549
(A) 3rd-4th shifter fork

(B) 3rd-4th sleeve
(C) Driven gear ASSY
(D) Main shaft ASSY
6MT-66
Main Shaft Assembly

5) Attach the 5th-6th shifter fork assembly to the 8) Install the thrust bearing of the driven gear as-
main shaft assembly. sembly.
(C) (B)
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:
A helper is required to perform this work.
10) Install the plunger, check spring, new O-ring
and check plugs.
(A) Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
MT-00550
(A) 5th-6th shifter fork

(B) 5th-6th sleeve
(C) Main shaft ASSY
6) Attach the reverse shifter fork assembly to the

reverse idler gear assembly.
(B)
(A)
(A)
(B)
(C)
(D)
(C) MT-00551
(A) Reverse idler gear ASSY

(B) Reverse shifter fork
(C) Reverse sleeve MT-01932
7) Install the reverse idler gear assembly. (A) Check plug

(B) O-ring
(A) (C) Checking spring
(D) Plunger
(B) (C)
MT-00552
(A) Reverse idler gear ASSY

(B) 1st drive gear
(C) Reverse gear
6MT-67
Main Shaft Assembly

11) Install the check ball, check spring, new O-ring 14) Install the reverse idler holder.
and check plugs.
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
(A)
MT-00544
(A) Reverse idler holder
15) Install the oil guide B.

Tightening torque:
18 N·m (1.8 kgf-m, 13.3 ft-lb)
(A)
(C) (B)
(D)
MT-00554
(A) Check plug MT-01623

(B) O-ring 16) Install the striking rod.
(C) Checking spring 17) Install the transmission case. <Ref. to 6MT-60,
(D) Check ball INSTALLATION, Transmission Case.>
18) Install the selected main shaft snap ring and
12) Attach the bolt and a new gasket. washers.
Tightening torque: 19) Install the center differential. <Ref. to 6MT-57,
25 N·m (2.5 kgf-m, 18.4 ft-lb) INSTALLATION, Center Differential.>
20) Install the transfer driven gear. <Ref. to 6MT-
55, INSTALLATION, Transfer Driven Gear.>
MT-00546 Transmission Assembly.>
13) Use a screwdriver to shift to the 4th gear posi- C: DISASSEMBLY
tion.
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 lock nut.
6MT-68
Main Shaft Assembly

3) Set the main shaft assembly to the ST, and re- 6) Remove the 5th-6th sleeve, 6th needle bearing
move the lock nut and lock washer. and 6th baulk ring.
ST1 18665AA000 HOLDER
ST2 18664AA000 BASE
NOTE: (A)
Use a 38 mm socket wrench.
(B)
ST2
(C)
MT-00558
(A) Needle bearing

ST1
(B) 6th baulk ring
(C) 5th-6th sleeve
MT-00556
4) Remove the main shaft assembly from the ST. 7) Set the ST to the 3rd drive gear, and use a press
5) Set the ST1 to the 6th drive gear, and use a to remove individual parts.
press to remove the double taper roller bearing, ST 18720AA000 REMOVER
bushing and 6th drive gear.
ST1 18722AA010 REMOVER
(B)
ST2 (A)
ST1
ST
ST
(A)
ST1 (B)
(B) (C)
MT-01406
(A) 3rd drive gear

MT-00557 (B) 3rd-4th sleeve
(A) Double taper roller bearing

(B) Bushing
(C) 6th drive gear
6MT-69
Main Shaft Assembly

D: ASSEMBLY NOTE:
Install the 3rd synchro cone by aligning the protru-
NOTE: sion of the 3rd synchro cone with the hole on the
When replacing the following parts, replace as a 3rd drive gear.
set.
• Sleeve and hub
• Outer baulk ring, 3rd synchro cone and inner
baulk ring
• Double 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.
MT-01501
4) Install the 3rd-4th hub and 4th bushing.

(1) Being careful of the install direction of the
(A) 3rd-4th hub, set to the main shaft.
(A)
(B) (B)
MT-00560
(A) 3rd drive gear

(B) 3rd needle bearing (C)
MT-00884
3) Install the inner baulk ring, 3rd synchro cone and
outer baulk ring. (A) Main shaft
(B) 3rd-4th hub
(A) (C) 3rd drive gear
(B)
MT-00561
(A) Inner baulk ring

(B) Outer baulk ring
6MT-70
Main Shaft Assembly

(2) With the main shaft oil hole and 4th bushing NOTE:
oil hole out of alignment, attach to the main When pushing into the 3rd-4th hub and 4th bush-
shaft. ing, move the outer baulk ring to match the protru-
sion of the outer baulk ring and the cut out on the
(A) 3rd-4th bushing.
A
(B) (C)
(E) ST1
A
(A)
(D)
ST2
(E)
(C) (C)
(A)
(A)
(D)
(B)
(D)
A-A
MT-01819
(A) 4th bushing MT-00555

(B) 3rd-4th hub
(C) 4th bushing oil hole (A) 3rd-4th hub
(D) Main shaft oil hole (B) Outer baulk ring
(C) Cut out on the 3rd-4th hub
(3) Using the ST, push in to the 3rd-4th hub and (D) Protrusion of the outer baulk ring
4th bushing all at once. (E) 4th bushing
ST2 398177700 INSTALLER 5) Make sure that the 3rd drive gear can be turned
CAUTION: smoothly by hand. If it does not turn smoothly, re-
Do not apply pressure in excess of 40 kN (4.0 assemble.
ton, 4.4 US ton, 3.9 Imp ton).
6MT-71
Main Shaft Assembly

6) Attach the 3rd-4th shifting insert key at the ap- 8) Install the 4th baulk ring.
propriate position of the 3rd-4th sleeve.
NOTE:
• The location angle of each shifting insert key is
120°.
• Refer to the following figure to install the shifting
insert key.
)A( (A)
MT-00564

shaft, 4th needle bearing and 4th drive gear inner
surface.
(B) 10) Install the 4th needle bearing and 4th drive
gear.
(B)
(C)
(A)
(B)
MT-00565
MT-01820 (A) 4th needle bearing

(B) 4th drive gear
(A) Attach the straight part of the shifting insert key
to the sleeve convex portion.
(B) 3rd-4th shifting insert key
(C) 3rd-4th sleeve
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.
(B)
(A)
MT-00563
(A) 3rd drive gear

(B) 3rd-4th sleeve identification groove (1)
6MT-72
Main Shaft Assembly

11) Install the 5th bushing. 12) Make sure that the 4th drive gear can be turned
(1) With the main shaft oil hole and 5th bushing smoothly by hand. If it does not turn smoothly, re-
oil hole out of alignment, attach to the main assemble.
shaft. 13) Apply adequate transmission gear oil to the
main shaft, 5th needle bearing and 5th drive gear
(A) inner surface.
A 14) Install the 5th needle bearing and 5th drive
gear.
(D)
(B)
(C)
(A)
A
(B)
(E)
MT-00568
(D)
(A) 5th needle bearing
(A) (B) 5th drive gear
15) Install the 5th baulk ring.

(B)
A-A
MT-01821
(A) 5th bushing

(B) Main shaft oil hole
(C) Main shaft
(D) 5th bushing oil hole
(E) 4th drive gear
(2) Using the ST, push into the 5th bushing. MT-00569
ST1 18651AA000 INSTALLER 16) Install the 5th-6th hub.
ST2 398177700 INSTALLER (1) Being careful of the install direction of the
CAUTION: 5th-6th hub, set to the main shaft.
Do not apply pressure in excess of 40 kN (4.0
ton, 4.4 US ton, 3.9 Imp ton). (A)
ST1 (B)
(C)
MT-00570
ST2
(A) Main shaft
MT-00567
(B) 5th-6th hub
(C) 5th drive gear
6MT-73
Main Shaft Assembly

(2) Using the ST, push into the 5th-6th hub. 18) Attach the 5th-6th shifting insert key at the ap-
ST1 18651AA000 INSTALLER propriate position of the 5th-6th sleeve.
ST2 398177700 INSTALLER NOTE:
CAUTION: • The location angle of each shifting insert key is
Do not apply pressure in excess of 40 kN (4.0 120°.
ton, 4.4 US ton, 3.9 Imp ton). • Refer to the following figure to install the shifting
insert key.
NOTE:
When pushing into the 5th-6th hub, move the outer
baulk ring to match the protrusion of the outer baulk )A( (A)
ring and the cut out on the 5th-6th bushing.
ST1
(A) (B)
ST2
(C)
(B)
(C) (A)
(D) (B)
MT-01820
(A) Attach the straight part of the shifting insert key

to the sleeve convex portion.
MT-00571 (B) 5th-6th shifting insert key
(A) 5th-6th hub (C) 5th-6th sleeve
19) Attach the 5th-6th sleeve to the 5th-6th hub.
(C) Cut out on the 5th-6th hub
(D) Protrusion of the outer baulk ring
NOTE:
• There are two identification grooves on the 5th-
17) Make sure that the 5th drive gear can be turned 6th sleeve.
smoothly by hand. If it does not turn smoothly, re- • Place the grooves towards the 5th drive gear,
assemble. and attach the 5th-6th sleeve.
(B)
(A)
MT-00572
(A) 5th drive gear

(B) 5th-6th sleeve identification groove (2)
6MT-74
Main Shaft Assembly

20) Install the 6th baulk ring. 25) Using the ST, install the 6th bushing.
CAUTION:
ST1
MT-00573
21) Apply adequate transmission gear oil to the

main shaft, 6th needle bearing and 6th drive gear
inner surface.
22) Install the 6th drive gear. ST2
MT-00577
26) Make sure that the 6th drive gear can be turned
smoothly by hand. If it does not turn smoothly, re-
assemble.
27) Using the ST, install the inner bearing of the
double taper roller bearing.
CAUTION:
MT-00574
23) Install the 6th needle bearing. ton, 4.4 US ton, 3.9 Imp ton).
NOTE:
Use a new double taper roller bearing.
ST1
MT-00575
24) With 6th bushing oil hole and the main shaft oil ST2
hole out of alignment, attach to the main shaft. MT-00578
(A)
(B)
MT-01933
(A) 6th bushing oil hole

(B) Main shaft oil hole
6MT-75
Main Shaft Assembly

28) Using the ST, install the outer race and the out- 31) Set the main shaft assembly to the ST, and
er bearing of the double taper roller bearing. tighten the lock nut.
ST1 18651AA000 INSTALLER ST1 18665AA000 HOLDER
ST2 398177700 INSTALLER ST2 18664AA000 BASE
CAUTION: NOTE:
Do not apply pressure in excess of 40 kN (4.0 Make sure the lock washer is installed in the proper
ton, 4.4 US ton, 3.9 Imp ton). direction.
NOTE: Tightening torque:
• Confirm that the outer race is installed in the 392 N·m (40.0 kgf-m, 289.1 ft-lb)
proper direction.
• Push in until there is no backlash on the outer
race and the bearing turns smoothly by hand.
(C)
ST1
(B)
(A)
(A) (B)
ST2
ST2
ST1
(A)
MT-02714
(A) Lock washer

MT-00579 (B) Lock nut
(C) Nut side
(A) Outer race
(B) Outer bearing of the double taper roller bearing
29) Make sure that the double taper roller bearing

turns smoothly by hand. If it does not turn smoothly,
replace the double taper roller bearing as a set, and
reassemble.
30) Attach a new lock washer and a new lock nut.
6MT-76
Main Shaft Assembly

32) Using the ST, crimp the lock nut in 4 locations, 3) Gear
with dimensions within A 27±0.3 mm (1.06±0.01 Replace gears in the following cases.
in). • The gear teeth surface is damaged or excessive-
ST 18668AA000 PUNCH ly worn.
NOTE: • The contact area of the baulk ring is damaged.
Do not damage the crimp area of the lock nut. • The inner face of the gear is worn.
4) Baulk ring, synchro cone
ST lowing cases.
• Wear, rusting or damage of the baulk ring
A
MT-00581
F: ADJUSTMENT
1. MAIN SHAFT SNAP RING & WASHER
A
MT-00580
SELECTION
NOTE:
E: INSPECTION In the following conditions, perform the procedures
Disassembled parts should be washed with clean- below.
ing solvent first, then inspected carefully. • 1st to 6th driven gear replacement
1) Bearing • 1st and 2nd synchro ring assembly replacement
Replace the bearings in the following cases. • Ball bearing replacement
• Wear, rusting or damage of the bearings • Adapter plate replacement
• The bearing does not rotate smoothly or an ab- • Driven shaft replacement
normal noise is emitted when turning. 1) Insert the drive pinion assembly into the adapter
• The bearing has other defects. plate.
Replace the bushing in following cases. NOTE:
• The sliding surface is damaged or abnormally Confirm that the thrust bearing outer race has not
worn. been removed and the drive pinion is not lifted.
6MT-77
Main Shaft Assembly

2) Set the height gauge to the adapter plate. Lower 3) Measure the height to the ball bearing end face
the height gauge indicator to the mating surface of (height H).
the adapter plate and case, and set to zero points.
ST 18853AA000 HEIGHT GAUGE
ST
(A)
H
MT-00582
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-00955
(A) Ball bearing
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
MT-00583 the bearing.
(2)
(1)
MT-00585
Turn approximately 120° at a time, and measure

the ball bearing in 5 locations. Round down the 2
highest and 2 lowest measurement values. The re-
maining center value is used as the measurement
value.
6MT-78
Main Shaft Assembly

4) According to the measurement value, select the

snap ring and washer from the following table.
Snap ring
H: mm (in) Part No. Thickness: mm (in)
270.83 — 271.40 1.65
805072010
(10.66 — 10.69) (0.065)
271.41 — 271.98 1.95
805072011
(10.69 — 10.71) (0.077)
271.99 — 272.56 2.25
805072012
(10.71 — 10.73) (0.089)
Washer
H: mm (in) Part No. Thickness: mm (in)
270.83 — 271.40 1.6
803067012
(10.66 — 10.69) (0.063)
271.41 — 271.98 1.3
803067011
(10.69 — 10.71) (0.051)
271.99 — 272.56 1.0
803067010
(10.71 — 10.73) (0.039)
6MT-79
Driven Gear Assembly

18.Driven Gear Assembly 4) Install the 1st needle bearing.

5) Install the driven gear assembly. <Ref. to 6MT-
A: REMOVAL 66, INSTALLATION, Main Shaft Assembly.>
1) Remove the manual transmission assembly 6) Install the transmission case. <Ref. to 6MT-60,
from the vehicle. <Ref. to 6MT-31, REMOVAL, INSTALLATION, Transmission Case.>
Manual Transmission Assembly.> 7) Adjust the backlash of the driven gear assembly
2) Prepare the transmission for overhaul. <Ref. to in the axial direction. <Ref. to 6MT-88, ADJUST-
6MT-37, Preparation for Overhaul.> MENT, Driven Gear Assembly.>
3) Remove the neutral position switch, back-up 8) Install the center differential. <Ref. to 6MT-57,
light switch and harness. <Ref. to 6MT-41, RE- INSTALLATION, Center Differential.>
MOVAL, Neutral Position Switch.> <Ref. to 6MT- 9) Install the transfer driven gear. <Ref. to 6MT-55,
39, REMOVAL, Back-up Light Switch.> INSTALLATION, Transfer Driven Gear.>
4) Remove the extension case. <Ref. to 6MT-43, 10) Install the extension case. <Ref. to 6MT-43, IN-
REMOVAL, Extension Case.> STALLATION, Extension Case.>
5) Remove the transfer driven gear. <Ref. to 6MT- 11) Install the neutral position switch, back-up light
55, REMOVAL, Transfer Driven Gear.> switch and harness. <Ref. to 6MT-41, INSTALLA-
6) Remove the center differential. <Ref. to 6MT-57, TION, Neutral Position Switch.> <Ref. to 6MT-39,
REMOVAL, Center Differential.> INSTALLATION, Back-up Light Switch.>
7) Remove the transmission case. <Ref. to 6MT- 12) Install the manual transmission assembly to the
58, REMOVAL, Transmission Case.> vehicle. <Ref. to 6MT-33, INSTALLATION, Manual
8) Remove the driven gear assembly. <Ref. to Transmission Assembly.>
6MT-65, REMOVAL, Main Shaft Assembly.> C: DISASSEMBLY
9) Remove the 1st needle bearing.
NOTE:
Individual sleeves and hubs meet at a specified po-
sition. Before disassembly, mark the meeting posi-
tion of the sleeve and hub.
ST 18664AA000 BASE
3) Attach ST3 to the lock nut, set the driven gear
assembly to the ST, and remove the lock nut.
MT-00586
ST2 18664AA000 BASE
10) Remove the thrust needle bearing. ST3 18620AA000 ADAPTER WRENCH
B: INSTALLATION
1) Adjust the main shaft snap ring. <Ref. to 6MT-
77, ADJUSTMENT, Main Shaft Assembly.> ST3 ST2
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
ST1
the proper direction. MT-00588
MT-00587
6MT-80

4) Attach ST1 to the 6th driven gear, then remove 7) Remove the 2nd gear.
the ball bearing and 5th-6th driven gear.
ST2
(A)
ST1
(B)
MT-00591
8) Remove the needle bearing and 1st-2nd sleeve.

MT-01480
(A) Ball bearing (A)

(B) 5th-6th driven gear (B)
5) Attach ST1 to the 4th driven gear, then remove

the 3rd-4th driven gear.
MT-00592
ST2
(A) Needle bearing
(A) (B) 1st-2nd sleeve
ST1
9) Remove the outer baulk ring, 2nd synchro cone

and inner baulk ring.
(C)
MT-01481
(B)
(A) 3rd-4th driven gear (A)
6) Remove the driven gear key.
MT-01502
(A) Outer baulk ring

(B) 2nd synchro cone
MT-00590
6MT-81

10) Using the ST, remove individual parts. D: ASSEMBLY

ST 18754AA000 REMOVER
NOTE:
When replacing the following parts, replace as a
set.
• Sleeve and hub
• Outer baulk ring, 1st synchro cone and inner
ST baulk ring
• Outer baulk ring, 2nd synchro cone and inner
baulk ring
shaft, 1st needle bearing and 1st driven gear inner
surface.
2) Install the 1st needle bearing.
(A)
(B)
(E) (C)
(D)
ST (F)
(G)
MT-01715 MT-00595
(A) 2nd bushing 3) Attach the 1st driven gear to the driven shaft.
(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-01729
4) Install the inner baulk ring.
MT-01730
6MT-82

5) Match the protrusion of the 1st synchro cone to 7) Install the 1st-2nd hub.
the hole of the 1st driven gear, then install. 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.
(C)
(A)
(D) (B)
MT-01505 (E)
6) Install the outer baulk ring.
(A)
MT-00599
(E)
MT-01716
(A) 1st-2nd hub

(C) 1st-2nd hub cut out section
(D) Protrusion of the outer baulk ring
(E) 1st driven gear
8) Using the ST, install the 1st-2nd hub and 2nd

bush.
ST 18654AA000 INSTALLER
CAUTION:
ST
(A)
(B)
MT-00601
(A) 2nd bushing

(B) 1st-2nd hub
6MT-83

9) Make sure that the 1st driven gear can be turned 11) Attach the shifting insert key to the appropriate
smoothly by hand. If it does not turn smoothly, re- position of the 1st-2nd sleeve.
assemble. NOTE:
10) Attach the 1st-2nd sleeve to the 1st-2nd hub. • The location angle of each shifting insert key is
NOTE: 120°.
• Make sure that the 1st-2nd sleeve is installed in • Install the shifting insert key to the key grooves
the correct direction. (three places) of shifting insert key that are located
• Align the 1st-2nd hub cut out section (three plac- inside the 1st-2nd sleeve.
es) and the key grooves (three places) of shifting
(B)
insert key that are located inside the 1st-2nd (A)
sleeve.
• Set the 1st-2nd sleeve and 1st driven gear so
(A)
that they contact each other.
(C)
(A)
(B)
MT-01732
(A) (A) Shifting insert key

(B) 1st-2nd hub
(C) 1st-2nd sleeve
12) Install the outer baulk ring.
(B)
(C)
MT-00603 MT-01733
(A) 1st driven gear

13) Install the 2nd synchro cone.
(B) 1st-2nd sleeve
(C) 1st driven gear side
(A)
(B)
MT-01506
MT-01731
(A) 1st-2nd hub

(B) 1st-2nd sleeve
6MT-84

14) Install the inner baulk ring. 18) Using the ST, install the 3rd-4th driven gear.
ST 18654AA000 INSTALLER
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.
MT-00606
15) Apply adequate transmission gear oil to the

bushing, 2nd needle bearing and 2nd driven gear ST (A)
inner surface.
16) Install the 2nd needle bearing and 2nd driven
gear. (B)
(C)
NOTE:
Match the protrusion of the 2nd synchro cone to the
hole of the 2nd driven gear, then install.
MT-00609
(A) 4th gear

(A)
(B)
(B) 3rd gear
(C) 2nd gear
19) Make sure that the 2nd driven gear can be

turned smoothly by hand. If it does not turn smooth-
(C)
ly, reassemble.
20) Attach the key.
MT-00607
(A) 2nd needle bearing

(B) 2nd driven gear
(C) Protrusion of the 2nd synchro cone
17) Attach the key.
MT-00610
MT-00608
6MT-85

21) Using the ST, install the 5th-6th driven gear. 22) Using the ST, install the ball bearing.
ST 18654AA000 INSTALLER ST 18654AA000 INSTALLER
CAUTION: CAUTION:
Do not apply pressure in excess of 40 kN (4.0 Do not apply pressure in excess of 40 kN (4.0
ton, 4.4 US ton, 3.9 Imp ton). ton, 4.4 US ton, 3.9 Imp ton).
NOTE: NOTE:
• Make sure that the 5th-6th driven gear is in- Face the sealing section of the ball bearing to the
stalled in the correct direction. lock nut side, and install the ball bearing.
• Match the groove on the 5th-6th driven gear to
the key.
ST
ST
(A)
(B)
(C)
MT-00611
)A( (A)
(A) 6th gear
(B) 5th gear
(C) 4th gear
MT-02108
(A) Sealing
23) Make sure that the ball bearing turns smoothly

by hand. If it does not turn smoothly, reassemble.
24) Install a new lock nut.
6MT-86

25) Attach ST3 to the lock nut, attach ST to the driv- 26) Using the ST, crimp the lock nut in 4 locations,
en gear assembly, and tighten the lock nut. with dimensions within A 44±0.5 mm (1.73±0.02
ST1 18666AA000 HOLDER in).
ST2 18664AA000 BASE ST 18669AA000 PUNCH DRIVEN SHAFT
ST3 18620AA000 ADAPTER WRENCH NOTE:
ST4 18852AA000 TORQUE WRENCH Do not damage the crimp area of the lock nut.
Tightening torque:
530 N·m (54.0 kgf-m, 390.9 ft-lb) ST
ST4
ST3
ST2
ST1
MT-00613
NOTE:
When using a torque wrench other than ST4, use
the calculation below to calculate and tighten the A
lock nut.
T = L1/(0.1 + L1) × 570
T N·m (kgf-m, ft-lb) Torque wrench setting
L1 m (in) Torque wrench length
A
0.1 m (3.94 in) Length of ST MT-00615
570 N·m (58.1 kgf-m, 420 ft-lb) Tightening torque
(lock nut) E: INSPECTION
1) Bearing
(A) L1
• Wear, rusting or damage of the bearings
normal noise is emitted when turning.
• The bearing has other defects.
MT-00614 • The sliding surface is damaged or abnormally
worn.
(A) 0.1 m (3.94 in) 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.
lowing cases.
6MT-87

5) Shifting insert key 3) Select 0 to 3 washers from the following table,

Replace the shifting insert key if deformed, exces- and adjust to the backlash that is closest to the
sively worn or defective in any way. standard value.
Driven gear assembly axial direction backlash
standard:
0.1 — 0.3 mm (0.0039 — 0.0118 in)
Washer
Part No. Thickness T mm (in)
803072030 0.15 (0.0059)
803072031 0.30 (0.0118)
803072032 0.45 (0.0177)
MT-00581 803072033 0.60 (0.0236)
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.
(A)
(C)
H
(B)
MT-00616
(A) Transmission case

(B) Ball bearing
(C) Driven gear ASSY

thickness of the driven gear assembly washer.
T = H – {5.8±0.05 mm (0.23±0.002 in)} – {0.1 — 0.3
mm (0.0039 — 0.0118 in)}
T Washer thickness
H Length from the transmission case
and transfer bearing holder mating
surface to the end face of the ball
bearing
5.8±0.05 mm Collar thickness
(0.23±0.002 in)
0.1 — 0.3 mm Driven gear assembly axial direc-
(0.0039 — 0.0118 in) tion backlash standard
6MT-88
Reverse Idler Gear Assembly

19.Reverse Idler Gear Assembly C: DISASSEMBLY

A: REMOVAL NOTE:
Sleeves and reverse gears meet at a specified po-
1) Remove the manual transmission assembly sition. Before disassembly, mark the meeting posi-
from the vehicle. <Ref. to 6MT-31, REMOVAL, tion of the sleeve and hub.
Manual Transmission Assembly.> 1) Remove the spring pin.
6) Remove the center differential. <Ref. to 6MT-57, MT-00617
REMOVAL, Center Differential.> 2) Remove the snap ring and washer.
8) Remove the reverse idler gear assembly. <Ref.
to 6MT-65, 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-66, INSTALLATION, Main Shaft Assembly.>
3) Install the transmission case. <Ref. to 6MT-60, MT-00618
INSTALLATION, Transmission Case.> 3) Remove the counter high & low washer and re-
4) Install the center differential. <Ref. to 6MT-57, verse idler gear.
5) Install the transfer driven gear. <Ref. to 6MT-55,
INSTALLATION, Transfer Driven Gear.> (A)
TION, Neutral Position Switch.> <Ref. to 6MT-39, (B)
vehicle. <Ref. to 6MT-33, INSTALLATION, Manual MT-00619
(A) Counter high and low washer
(B) Reverse idler gear
6MT-89

4) Remove the knock pin and reverse idler gear 8) Remove reverse idler gear No. 2.
needle bearing.
(B)
(A)
MT-00624
MT-00620
9) Remove the counter high & low washer and nee-
(A) Knock pin
dle bearing.
(B) Reverse idler gear needle bearing
5) Remove the collar.

6) Remove the reverse sleeve.
(A)
(B)
MT-00625
(A) Needle bearing

(B) Counter high and low washer
MT-00622 10) Remove the knock pin.

7) Remove the outer baulk ring, reverse synchro
cone and inner baulk ring from the reverse sleeve.
(B)
(C)
(D)
MT-00626
(A)
11) Remove the snap ring and friction plate from
MT-01507 reverse gear.
(A) Reverse sleeve
(A)
(C) Reverse synchro cone
(D) Inner baulk ring
(B)
MT-00627
(A) Snap ring

(B) Friction plate
6MT-90

12) Remove the sub gear and spring. 2) Install the friction plate and snap ring.
NOTE:
(A) (B) Confirm that the friction plate is installed in the
proper direction.
(C)
(D)
A
(B)
(C) MT-00628
(A) Sub gear (A)
(B) Spring
MT-00630
(C) Stamp (marking A)
(A) Friction plate
D: ASSEMBLY (B) Snap ring
1) Attach the sub gear and spring. (C) Snap ring side
NOTE: (D) Sub gear side
• Turn the white marking on the hook section to-
wards the sub gear side, and attach the spring. 3) Apply adequate transmission gear oil to the
• Point the stamp (marking A) towards the outside, shaft, needle bearing and reverse drive gear inner
and install the sub gear. surface.
4) Install the knock pin.
(A) (B)
A
(C) MT-00628
MT-00626
(A) Sub gear 5) Install the counter high & low washer and needle
(B) Spring bearing.
(C) Stamp (marking A)
NOTE:
Point the groove towards the reverse idler gear,
• While paying attention to the direction of the sub
and attach the washer.
gear attachment hole, attach the spring and sub
gear.
(C)
A
(B)
(A)
MT-00631
(A)
MT-00629 (A) Groove
(A) Attachment hole (B) Counter high and low washer
(C) Needle bearing
6MT-91

6) Install the reverse idler gear No. 2. 8) Attach the reverse sleeve to the reverse idler
gear No. 2.
NOTE:
Confirm that the reverse sleeve is installed in the
proper direction.
MT-00632
7) Attach the shifting insert key to the appropriate

location of the reverse sleeve.
NOTE:
MT-00634
• The location angle of each shifting insert key is
120°. 9) Apply adequate transmission gear oil to the col-
• Refer to the following figure to install the shifting lar, needle bearing and reverse drive gear inner
insert key. surface.
10) Install the outer baulk ring, reverse synchro
(A) (B) cone and inner baulk ring.
(A) (B)
(A) (C)
MT-00635
(A) Outer baulk ring

(B) Reverse synchro cone
(B)
11) Install the collar and needle bearing, then the

knock pin.
MT-00633
(C)
(A) Reverse sleeve
(B) Shifting insert key (B)
(A)
MT-00636
(A) Collar
(B) Needle bearing
(C) Knock pin
6MT-92

12) Match the protrusion of the reverse synchro 3) Gear

cone to the hole on the reverse idler gear, and in- Replace gears in the following cases.
stall the reverse idler gear. • The gear teeth surface is damaged or excessive-
ly worn.
• The contact area of the baulk ring is damaged.
(A)
• The inner face of the gear is worn.
(B)
lowing cases.
MT-01508
(A) Protrusion on the reverse synchro cone

(B) Hole of 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
MT-00581
ST 6) Check clearance between the snap ring and

washer.
Clearance specification:
0.1 — 0.3 mm (0.0039 — 0.0118 in)
MT-00638
15) Inspect and adjust the clearance between the

snap ring and the washer. <Ref. to 6MT-93, IN-
SPECTION, Reverse Idler Gear Assembly.>
16) Install a new spring pin.
E: INSPECTION MT-00639
If the clearance is out of the specification, select a
snap ring from the following table and replace it.
1) Bearing
Replace the bearings in the following cases. Snap ring
• Wear, rusting or damage of the bearings Part No. Thickness mm (in)
• The bearing does not rotate smoothly or an ab- 031319000 1.50 (0.059)
normal noise is emitted when turning. 805019030 1.60 (0.062)
• The bearing has other defects. 805019010 1.72 (0.068)
Replace the bushing in following cases. After replacing the snap ring, inspect the clearance.
• The sliding surface is damaged or abnormally
worn.
6MT-93

20.Drive Pinion Shaft Assembly 3) Install the individual gear assemblies. <Ref. to
6MT-66, INSTALLATION, Main Shaft Assembly.>
A: REMOVAL 4) Install the transmission case. <Ref. to 6MT-60,
1) Remove the manual transmission assembly INSTALLATION, Transmission Case.>
from the vehicle. <Ref. to 6MT-31, REMOVAL, 5) Install the center differential. <Ref. to 6MT-57,
Manual Transmission Assembly.> INSTALLATION, Center Differential.>
2) Prepare the transmission for overhaul. <Ref. to 6) Install the transfer driven gear. <Ref. to 6MT-55,
6MT-37, Preparation for Overhaul.> INSTALLATION, Transfer Driven Gear.>
3) Remove the neutral position switch, back-up 7) Install the extension case. <Ref. to 6MT-43, IN-
light switch and harness. <Ref. to 6MT-41, RE- STALLATION, Extension Case.>
MOVAL, Neutral Position Switch.> <Ref. to 6MT- 8) Install the neutral position switch, back-up light
39, REMOVAL, Back-up Light Switch.> switch and harness. <Ref. to 6MT-41, INSTALLA-
4) Remove the extension case. <Ref. to 6MT-43, TION, Neutral Position Switch.> <Ref. to 6MT-39,
REMOVAL, Extension Case.> INSTALLATION, Back-up Light Switch.>
5) Remove the transfer driven gear. <Ref. to 6MT- 9) Install the manual transmission assembly to the
55, REMOVAL, Transfer Driven Gear.> vehicle. <Ref. to 6MT-33, INSTALLATION, Manual
6) Remove the center differential. <Ref. to 6MT-57, Transmission Assembly.>
REMOVAL, Center Differential.> C: DISASSEMBLY
58, REMOVAL, Transmission Case.> NOTE:
8) Remove the individual gear assemblies. <Ref. to Replace the drive pinion shaft and hypoid driven
6MT-65, REMOVAL, Main Shaft Assembly.> gear as a set.
9) Remove the drive pinion shaft assembly. 1) Remove the oil guide A.
(A)
MT-00640 MT-01624
B: INSTALLATION (A) Oil guide A

1) Remove any remaining gasket material from the 2) Remove the drive pinion shaft and shim from the
drive plate and clutch housing. adapter plate.
2) Apply liquid gasket to the clutch housing.
Liquid gasket:
equivalent
MT-00642

ST 18664AA000 BASE
MT-00532
6MT-94

5) Attach ST3 to the lock nut, and set the drive pin- 2) Using the ST and a press, attach the inner bear-
ion shaft to ST. Remove the lock nut and lock ing of the double taper roller bearing to the drive
washer. pinion shaft.
ST1 18667AA000 HOLDER ST 18723AA000 REMOVER
ST2 18664AA000 BASE CAUTION:
ST3 18621AA000 ADAPTER WRENCH Do not apply pressure in excess of 40 kN (4.0
ST3
ST2
ST
ST1
MT-00643
6) Using the ST, remove the double taper roller MT-00646

bearing assembly. 3) Using the ST and a press, attach the outer race
NOTE: and the double taper roller bearing to the drive pin-
Use a new double taper roller bearing. ion shaft.
ST 18723AA000 REMOVER ST 18723AA000 REMOVER
NOTE:
• Use a new double taper roller bearing.
• Push in to a position where the bearing rotates
ST
smoothly.
(A)
ST
MT-00644
D: ASSEMBLY
1) Using the ST, measure drive pinion measure-
ment A. MT-00647
NOTE:
When selecting the drive pinion shim, refer to mea- (A) Outer race
surement A.
ST 398643600 GAUGE 4) Attach a new lock washer and a new lock nut.
ST
A MT-00645
6MT-95

5) Set the ST to the drive pinion, and tighten the T = L1/(0.1 + L1) × 285
lock nut. T N·m (kgf-m, ft-lb) Torque wrench setting
L1 m (in) Torque wrench length
ST2 18664AA000 BASE
0.1 m (3.94 in) Length of ST
ST3 18621AA000 ADAPTER WRENCH
ST4 18852AA000 TORQUE WRENCH 285 N·m (29.0 kgf-m, 210 ft-lb) Tightening torque (lock
nut)
NOTE:
• Tighten using the ST and the straight line torque
wrench.
• Make sure the lock washer is installed in the
(A) L1
proper direction.
Tightening torque:
265 N·m (27.0 kgf-m, 195.4 ft-lb)
(C) MT-00614
(A) 0.1 m (3.94 in)
6) Measure the starting torque. <Ref. to 6MT-97,

INSPECTION, Drive Pinion Shaft Assembly.>
(A)
(B) 7) Using the ST, crimp the lock nut in 2 locations,
with dimensions within A 37±0.5 mm (1.46±0.02
in).
ST3
ST4 ST 18670AA000 PUNCH
NOTE:
Do not damage the crimp area of the lock nut.
ST2
ST1
ST
MT-02715
(A) Lock washer

(B) Lock nut
(C) Nut side
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. A
MT-00649
6MT-96

8) Using the ST, measure drive pinion measure- 11) Install the oil guide A.
ment B.
Tightening torque:
ST 398643600 GAUGE
18 N·m (1.8 kgf-m, 13.3 ft-lb)
ST
(A)
B
MT-00650
MT-01624
9) Calculate from the calculation below to select 1
or 2 drive pinion shims from the following table. (A) Oil guide A
6.5±0.0625 mm – (B – A) [0.26±0.0025 in – (B – A)]
NOTE:
E: INSPECTION
A: Measurement value in step 1) 1) Using a spring scale, measure the starting
B: Measurement value in step 8) torque. If the starting torque is outside the specifi-
cation range, replace the taper roller bearing.
Drive pinion shim
Part No. Thickness mm (in) Starting torque:
32295AA270 0.15 (0.0059)
0 — 0.95 N (0 — 0.097 kgf, 0 — 0.21 lbf)
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)
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.
MT-00651
Tightening torque:
54 N·m (5.5 kgf-m, 39.8 ft-lb) 2) Gear
• The gear teeth surface is damaged or excessive-
ly worn.
3) Bearing
• Wear, rusting or damage of the bearings
normal noise is emitted when turning.
4) Adapter plate
Replace the adapter plate in the following cases:
MT-00642 • Wear, rusting or damage of the bearings
• 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.
6MT-97

F: ADJUSTMENT 5) Remove the drive pinion shaft assembly, and in-

spect the mating condition of the teeth. If the tooth
1) Inspect and adjust the hypoid driven gear-to-
contact is not correct, adjust the backlash or shim
drive pinion backlash. <Ref. to 6MT-105, HYPOID
thickness.
GEAR BACKLASH, ADJUSTMENT, Front Differ-
• Correct tooth contact
ential Assembly.>
2) Apply a thin uniform coat of lead-free red dye on Check item: Tooth contact surface is slightly
shifted toward the toe side under a no-load con-
the surfaces of 3 or 4 hypoid driven gear teeth.
dition. (When driving, it moves towards the heel
side.)
(A)
(B)
MT-00652
3) Install the drive pinion shaft assembly to the MT-01401

clutch housing, and tighten at least 4 bolts.
(A) Toe side
NOTE:
(B) Heel side
Install with the remaining liquid gasket, so that the
clutch housing and the adapter plate will not be
• Face contact
damaged.
Check item: Backlash is too large.
Tightening torque: Contact pattern
50 N·m (5.1 kgf-m, 36.9 ft-lb)
4) Turn a few times using the ST.
ST 18631AA000 HANDLE
ST
AT-00208
Corrective action: Tighten the side retainer to move

the driven gear closer to the drive pinion shaft.
MT-00653
AT-01253
6MT-98

• Flank contact • Heel contact (outside end contact)

Check item: Backlash is too small. Check item: Teeth contact area is too small.
Contact pattern Contact pattern
AT-00209 AT-00211
Corrective action: Loosen the side retainer to move Adjustment: Increase thickness of the drive pinion
the driven gear away from the drive pinion shaft. shim according to the procedures for moving the
drive pinion closer to the driven gear.
AT-01254
AT-00212
• Toe contact (inside contact)
Contact pattern
AT-00210
Adjustment: Reduce the thickness of the drive pin-

ion shim according to the procedure for moving the
drive pinion away from the driven gear.
AT-00213
6MT-99

21.Front Differential Assembly 11) Remove the differential side retainers on both
sides using the ST.
A: REMOVAL ST1 18630AA010 WRENCH COMPL RETAIN-
1) Remove the manual transmission assembly. ER (RH SIDE)
<Ref. to 6MT-31, REMOVAL, Manual Transmis- ST2 18630AA000 WRENCH ASSY (LH SIDE)
sion Assembly.> NOTE:
2) Prepare the transmission for overhaul. <Ref. to Be careful not to damage the section where the
6MT-37, Preparation for Overhaul.> clutch case retainer will be attached.
light switch and harness. <Ref. to 6MT-41, RE- (B) ST1
REMOVAL, Center Differential.>
(A)
8) Remove the individual gear assemblies. <Ref. to ST2
6MT-65, REMOVAL, Main Shaft Assembly.>
bly.>
10) Remove the lock plates on both sides.
MT-00657
(A) LH side
(B) RH side
12) Remove the front differential.

(A)
MT-01022 B: INSTALLATION
1) Install the differential assembly to the clutch
(A) Lock plate housing.
2) Apply oil to the screw threads of the side retain-
er.
3) Remove the O-rings on both sides of the side re-
tainer.
6MT-100

4) Install the differential side retainers to both 8) Remove the differential side retainers from both
sides, using the ST. sides.
ST1 18630AA010 WRENCH COMPL RETAIN- NOTE:
ER (RH SIDE) When removing the side retainer, record how many
ST2 18630AA000 WRENCH ASSY (LH SIDE) times it was turned to remove.
NOTE: 9) Install new O-rings to the side retainers on both
Be careful not to damage the oil seal. sides.
10) Attach the differential side retainers to both
(B) ST1
sides.
NOTE:
When attaching, turn the side retainer the same
number of turns it took to remove, and align the
marks.
11) Install the lock plate.
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
NOTE:
(A) Be careful not to confuse the left and right side lock
ST2
plates.
(A) (B)
MT-00657
(A) LH side MT-00659

(B) RH side
(A) LH
5) Inspect and adjust the hypoid gear backlash. (B) RH
<Ref. to 6MT-104, HYPOID GEAR BACKLASH,
INSPECTION, Front Differential Assembly.> 12) Remove any remaining liquid gasket from the
6) Inspect and adjust the tooth contact. <Ref. to clutch housing and adapter plate.
6MT-98, ADJUSTMENT, Drive Pinion Shaft As- 13) Apply liquid gasket to the clutch housing.
sembly.> Liquid gasket:
7) Mark the mating positions of the left and right THREE BOND 1215 (Part No. 004403007) or
side retainers and the clutch housing. equivalent
MT-00658
MT-00532
6MT-101

14) Install the drive pinion shaft assembly. <Ref. to 3) Using the ST, remove the roller bearing.
6MT-94, INSTALLATION, Drive Pinion Shaft As- ST 498077000 REMOVER
sembly.>
15) Install the individual gear assemblies all at
once. <Ref. to 6MT-66, INSTALLATION, Main
Shaft Assembly.> ST
18) Install the transfer driven gear. <Ref. to 6MT-
55, INSTALLATION, Transfer Driven Gear.>
MT-00665
STALLATION, Extension Case.> 2. SIDE RETAINER
20) Install the neutral position switch, back-up light 1) Remove the O-ring.
C: DISASSEMBLY
1. DIFFERENTIAL CASE
1) Fix the differential assembly on a vice, and re-
MT-00666
move the hypoid driven gear.
ST 18270KA020 SOCKET (E20) 2) Remove the oil seal.
MT-00660 MT-01454
2) Remove the side bearing of the hypoid driven

gear using the ST.
ST 399527700 PULLER SET
ST
MT-00663
6MT-102

3) Remove the claw of ST1, and attach the claw of D: ASSEMBLY

ST2.
ST1 398527700 PULLER ASSY 1. DIFFERENTIAL CASE
ST2 18760AA000 CLAW 1) Use the ST to attach the RH and LH bearing in-
ner races to the differential case.
ST1 ST2 398497701 SEAT
CAUTION:
(A)
NOTE:
Always replace inner races and outer races as a
set.
ST1
ST2
ST2
MT-00670
MT-00668 2) Attach the hypoid driven gear to the differential

case.
(A) CLAW ST 18270KA020 SOCKET (E20)
4) Remove the bearing outer race from the side re- Tightening torque:
tainer, using the ST. 69 N·m (7.0 kgf-m, 50.9 ft-lb)
ST1 398527700 PULLER ASSY
ST2 18760AA000 CLAW
ST1
ST2
(A) MT-00660
MT-00669
(A) Side retainer
6MT-103

2. SIDE RETAINER 2. TOOTH CONTACT OF HYPOID GEAR

NOTE: 1) Check that the hypoid gear backlash is within the
Install the oil seal and O-ring of side retainer after standard value. Adjust if out of standard. <Ref. to
the adjustment of backlash and tooth contact. 6MT-105, HYPOID GEAR BACKLASH, ADJUST-
1) Install the bearing outer race to side retainer. MENT, Front Differential Assembly.>
2) Using the ST, install the oil seal. 2) Apply a thin uniform coat of lead-free red dye on
ST 18675AA000 DIFFERENTIAL SIDE OIL the surfaces of 3 or 4 hypoid driven gear teeth.
SEAL INSTALLER
NOTE:
• Apply oil to the oil seal lips.
ST
MT-00652
3) Attach the drive pinion shaft assembly, and affix

with at least 4 bolts.
NOTE:
AT-00226 Use old gaskets and washers to prevent the mating
3) Install the O-ring. surfaces of the housing from becoming damaged.
Use new O-rings. 50 N·m (5.1 kgf-m, 36.9 ft-lb)
4) Turn the drive pinion shaft to the left and right for
several turns.
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-98, ADJUSTMENT, Drive Pinion Shaft As-
sembly.>
• Correct tooth contact
NOTE:
AT-00219
In a no load condition, the tooth contact from the
center to the toe side is 50-60% (While driving, the
E: INSPECTION tooth contact will shift towards the heel side).
Repair or replace the differential in the following
cases:
(A)
• 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
(B)
bearing locations.
• If the bearing does not rotate smoothly or an ab-
normal noise is emitted when turning. MT-01401
1. HYPOID GEAR BACKLASH (A) Toe side

Inspect the hypoid gear backlash. Adjust if out of (B) Heel side
standard. <Ref. to 6MT-105, HYPOID GEAR
BACKLASH, ADJUSTMENT, Front Differential As-
sembly.>
6MT-104

F: ADJUSTMENT 6) Mark the mating positions of the left and right

side retainers and the clutch housing.
1. HYPOID GEAR BACKLASH
1) Attach the RH and LH side retainers.
ST1 18630AA010 WRENCH COMPL RETAIN-
ER (RH SIDE)
ST2 18630AA000 WRENCH ASSY (LH SIDE)
NOTE:
• Twist in the RH side side retainer a little further
than the LH side.
• WRENCH ASSY (499787000) can also be used.
2) Attach the drive pinion shaft assembly, and affix MT-00658
with 5 bolts. 7) Turn the back differential side retainer LH by 3
NOTE: notches, and screw in the differential side retainer
Use old gaskets and washers to prevent the mating RH by 3 notches.
surfaces of the housing from becoming damaged. 8) Temporarily attach the LH side retainer lock
plate.
Tightening torque: 9) Turn the differential side retainer RH by 1.25
50 N·m (5.1 kgf-m, 36.9 ft-lb) notches.
3) Using the ST, loosen the differential side retainer 10) Temporarily attach the RH side retainer lock
RH, and twist in the differential side retainer LH un- plate.
til the hypoid driven gear just contacts the drive pin-
ion. NOTE:
ST1 18630AA010 WRENCH COMPL RETAIN- • If the lock plate cannot be aligned, adjust the po-
ER (RH SIDE) sition toward the tightened side.
ST2 18630AA000 WRENCH ASSY (LH SIDE) • The notch on the lock plate moves by 0.5 notch if
4) Use the ST to turn the drive pinion shaft a few the lock plate is turned upside down when installed.
times. 11) Use the ST to fix the drive pinion shaft in place.
ST 18631AA000 HANDLE ST 18621AA000 ADAPTER WRENCH
ST ST
MT-00653 MT-00674
5) Repeat steps 3) and 4) until differential side re- 12) Install the SUBARU genuine axle shaft to the
tainer LH does not turn anymore. For differential front differential left and right sides.
side retainer RH, screw in until the inner race and Part No. 38415AA000 Axle shaft
outer race just comes into contact. This is the “ze-
ro” backlash state.
6MT-105

13) Move the axle shaft, and measure the hypoid

gear backlash.
ST1 498255400 PLATE
Hypoid gear backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
ST3
ST2 ST1
MT-00675
14) If the backlash is out of specified range, re-

move the left and right retainer lock plates and
loosen RH side differential side retainer. Then, ad-
just the LH side differential side retainer by turning
it, and attach the LH side retainer lock plate.
15) Screw in the RH side differential side retainer
until the inner race and outer race just come into
contact.
2. TOOTH CONTACT OF HYPOID GEAR
Regarding teeth contact conditions, refer to the
drive pinion section. <Ref. to 6MT-104, TOOTH
CONTACT OF HYPOID GEAR, INSPECTION,
Front Differential Assembly.>
6MT-106

22.Shifter Fork and Rod C: DISASSEMBLY

A: REMOVAL NOTE:
Discard the removed spring pin, and replace with a
1) Remove the manual transmission assembly new part.
Manual Transmission Assembly.> 1. REVERSE SHIFTER FORK
2) Prepare the transmission for overhaul. <Ref. to 1) Remove the reverse fork using the ST.
6MT-37, Preparation for Overhaul.> ST 398791700 REMOVER
ST
7) Remove the transmission case. <Ref. to 6MT- MT-00680
58, REMOVAL, Transmission Case.> 2) Remove the reverse shifter arm using the ST.
8) Remove the individual gear assemblies. <Ref. to ST 398791700 REMOVER
B: INSTALLATION
1) Install the individual gear assemblies all at once. ST
sembly.>
4) Install the transfer driven gear. <Ref. to 6MT-55, MT-00681
INSTALLATION, Transfer Driven Gear.> 2. 1ST-2ND, 3RD-4TH SHIFTER FORK
STALLATION, Extension Case.> 1) Using the ST, remove the 3rd-4th shifter fork.
6) Install the neutral position switch, back-up light ST 398791700 REMOVER
INSTALLATION, Back-up Light Switch.> ST
MT-00682
6MT-107

2) Using the ST, remove the 3rd-4th shifter arm. 2) Using the ST, remove the 5th-6th shifter arm.
ST 398791700 REMOVER ST 398791700 REMOVER
ST ST
MT-00683 MT-00686
3) Using the ST, remove the 1st-2nd shifter arm 4. SHIFTER ARM SHAFT
and 1st-2nd shifter fork.
ST 398791700 REMOVER Remove the selector arm using the ST.
(B)
(A)
ST
MT-00684
MT-01095
(A) 1st-2nd shifter arm
5. STRIKING ROD
(B) 1st-2nd shifter fork
1) Remove the reverse interlock block and the in-
3. 5TH-6TH SHIFTER FORK terlock block from the striking rod.
1) Using the ST, remove the 5th-6th shifter fork.
ST 398791700 REMOVER (B) (A)
ST
MT-00688
(A) Reverse interlock block

MT-00685 (B) Interlock block
6MT-108

2) Remove the reverse interlock arm using the ST. D: ASSEMBLY

1. REVERSE SHIFTER FORK
1) Using the ST, install the reverse fork.
ST
NOTE:
Confirm that the reverse fork and rod are installed
(B) (A) in the proper direction.
(A)
(C)
MT-00689
(A) Reverse interlock arm

(B) Interlock arm
3) Remove the interlock arm using the ST. (B)

MT-00691
(A) Reverse fork

(B) Reverse rod
ST
(C) Spring pin
(A)
2) Using the ST, install the reverse arm.

NOTE:
Confirm that the reverse arm and rod are installed
MT-00690
in the proper direction.
(A) Interlock arm
(C)
(B)
(A)
MT-00692
(A) Reverse arm

(B) Reverse rod
(C) Spring pin
6MT-109

2. 1ST-2ND, 3RD-4TH SHIFTER FORK 3) Using the ST, install the 3rd-4th shifter arm.
1) Using the ST, install the 1st-2nd shifter fork. ST 398791700 REMOVER
ST 398791700 REMOVER NOTE:
NOTE: Make sure that the 3rd-4th shifter arm and rod are
Make sure that the 1st-2nd shifter fork and rod are installed in the correct direction.
installed in the correct direction.
(A)
(C)
(C)
(B)
(B)
(A)
MT-00695
MT-00693
(A) 3rd-4th shifter rod
(A) 1st-2nd shifter fork (B) 3rd-4th shifter arm
(B) 1st-2nd shifter rod (C) Spring pin
(C) Spring pin
4) Attach the 3rd-4th fork rod to the 1st-2nd shifter
2) Using the ST, install the 1st-2nd shifter arm. arm.
NOTE:
Make sure that the 1st-2nd shifter arm and fork are
installed in the correct direction.
(C)
(A)
(B)
MT-00696
5) Using the ST, install the 3rd-4th shifter fork.

NOTE:
MT-00694 Make sure that the 3rd-4th shifter fork is installed in
the correct direction.
(A) 1st-2nd shifter fork
(B) 1st-2nd shifter arm
(C) Spring pin (B)
(A)
MT-01737
(A) 3rd-4th shifter fork

(B) Spring pin
6MT-110

3. 5TH-6TH SHIFTER FORK 4. SHIFTER ARM SHAFT

1) Using the ST, install the 5th-6th shifter arm. Using the ST, install the selector arm.
ST 398791700 REMOVER ST 398791700 REMOVER
NOTE: NOTE:
Make sure that the 5th-6th shifter arm and rod are Confirm that the selector arm and rod are installed
installed in the correct direction. in the proper direction.
(C)
(B)
(C)
(A) (B)
(A)
MT-00698 MT-01096
(A) 5th-6th shifter arm (A) Selector rod

(B) 5th-6th shifter rod (B) Selector arm
(C) Spring pin (C) Spring pin
2) Using the ST, install the 5th-6th shifter fork. 5. STRIKING ROD
ST 398791700 REMOVER 1) Using the ST, install the reverse interlock arm
NOTE: and interlock arm.
Check that the 5th-6th shifter fork and arm are in- ST 398791700 REMOVER
stalled. NOTE:
• Confirm that the reverse interlock arm and rod
(C)
are installed in the proper direction.
(B)
• Confirm that the interlock arm and rod are in-
stalled in the proper direction.
(C) (C)
(A) (A)
(B)
MT-00699
(A) 5th-6th shifter fork

(B) 5th-6th shifter arm
(C) Spring pin
MT-00701
(A) Reverse interlock arm

(B) Interlock arm
(C) Spring pin
6MT-111

2) Attach the reverse interlock block and interlock 2) Set the height gauge to the adapter plate. Lower
block to the striking rod. the height gauge indicator to the mating surface of
NOTE: the adapter plate and case, and set to zero points.
Confirm that the reverse interlock block and inter- ST 18853AA000 HEIGHT GAUGE
lock block are installed in the proper direction. ST
(B) (A)
MT-00582
MT-00688 NOTE:
• The adapter plate will be the base point for the
(A) Reverse interlock block measurement. Use a scraper to remove any gasket
(B) Interlock block material remaining on the end face.
E: INSPECTION gauge in the shaded area shown in the figure.
1) Check the shift shaft and shift rod for damage.
Replace if damaged.
2) Repair or replace the gearshift mechanism if ex-
cessively worn, bent or defective in any way.
F: ADJUSTMENT
1. 1ST-2ND FORK ROD SELECTION
NOTE:
In the following conditions, perform the procedures
below. MT-00583
• Replacement of the 1st and 2nd driven gear 3) Select the main shaft snap ring. <Ref. to 6MT-
• 1st and 2nd synchro ring assembly replacement 77, ADJUSTMENT, Main Shaft Assembly.>
• Adapter plate replacement 4) Measure “B1” and “B2” as shown in the figure.
• Driven shaft replacement
• 1st-2nd hub and sleeve assembly replacement.
1) Insert the drive pinion assembly into the adapter
plate.
NOTE:
Confirm that the thrust bearing outer race has not
B2
been removed and the drive pinion is not lifted.
B1
MT-00979
6MT-112

5) Shift down the 1st-2nd sleeve all the way to the 7) Shift up the 1st-2nd sleeve all the way to the 2nd
1st driven gear side, and measure “B1”. driven gear side, and measure “B2”.
(B)
(A)
(B)
(A) MT-00702 MT-00704
(A) 1st driven gear (A) 2nd driven gear

(B) 1st-2nd sleeve (B) 1st-2nd sleeve
NOTE: NOTE:
• Set the height gauge indicator near the measure- • Set the height gauge indicator near the measure-
ment target, and lock dial (1) as shown in the figure. ment target, and lock dial (1) as shown in the figure.
Turn dial (2), and set the indicator to the 1st side Turn dial (2), and set the indicator to the 2nd side
end surface of the sleeve. end surface of the sleeve.
• Turn approximately 72° at a time, and measure • The measurement is to be performed with two
the sleeve in 5 locations. Round down the 2 highest persons, while holding the sleeve straight.
and 2 lowest measurement values. The remaining • Turn approximately 72° at a time, and measure
center value is used as the measurement value. the sleeve in 5 locations. Round down the 2 highest
(2) and 2 lowest measurement values. The remaining
center value is used as the measurement value.
(2)
(1)
(1)
MT-00585
6) Set the height gauge indicator upside down.

MT-00585
(A)
MT-00703
(A) Indicator
6MT-113

8) According to both of the measurements, calcu- 2. 3RD-4TH FORK ROD SELECTION

late the neutral position of the 1st-2nd sleeve. From
NOTE:
the following calculation, select a fork rod which
matches the calculated value.
below.
Calculation: T = (B1 + B2) / 2
• Main shaft replacement
T: 1st-2nd sleeve center position
• 3rd, and 3rd to 6th drive gear and bushing re-
B1: Height from the adapter plate end to the sleeve
placement
end, when shifted to 1st gear
• 3rd, and 3rd to 6th synchro assembly replace-
B2: Measured height from the adapter plate end to
ment
the sleeve end, when shifted to 2nd gear: +55 mm
• 3rd-4th hub and sleeve assembly replacement
(2.17 in)
1) Insert the main shaft assembly into the adapter
NOTE: plate.
Attach the indicator upside down in comparison to 2) Set the height gauge to the adapter plate. Lower
the setting procedures for the zero point. Add “d1” the height gauge indicator to the top surface of the
[Value: 55 mm (2.17 in)] from the figure below to snap ring groove, and set to the zero point on the
“B2”, and measure “B2”. upper side of the main rear bearing.
(A)
d1
MT-00705
MT-00706
T mm (in) Lot No. (marking)
62.58 — 62.78 (A) Ball bearing
32801AA310 (5)
(2.4638 — 2.4717)
62.78 — 62.98 NOTE:
32801AA320 (4)
(2.4717 — 2.4795) • The height gauge will be set on the adapter plate
62.98 — 63.18 during the measurement. Use a scraper to remove
32801AA330 (2)
(2.4795 — 2.4874) any gasket material remaining on the end face.
63.18 — 63.38 • During measurement, do not place the height
32801AA340 (1)
(2.4874 — 2.4953) gauge in the shaded area shown in the figure.
63.38 — 63.58
32801AA350 (3)
(2.4953 — 2.5031)
MT-00583
6MT-114

3) Use a height gauge to measure “C1” and “C2” as NOTE:

shown in the figure. • Set the height gauge indicator near the measure-
• Turn dial (2), and set the indicator to the 4th side
end surface of the sleeve.
• The measurement is to be performed with two
persons, while holding the sleeve straight.
• Turn approximately 72° at a time, and measure
the sleeve in 5 locations. Round down the 2 highest
and 2 lowest measurement values. The remaining
C2 center value is used as the measurement value.
C1 (2)
(B) (1)
(A)
MT-00585
(2) Set the height gauge indicator upside down.

MT-00707
(A) 3rd drive gear

(B) 4th drive gear
(1) Shift up the 3rd-4th sleeve all the way to the

4th drive gear side, and measure “C2”.
(A)
(A)
MT-00710
(A) Indicator
MT-00708
(A) 4th drive gear
6MT-115

(3) Shift down the 3rd-4th sleeve all the way to 4) According to both of the measurements, calcu-
the 3rd drive gear side, and measure “C1”. 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)
(A) C2: Measured depth from the main shaft rear bear-
ing snap ring groove to the sleeve end, when shift-
ed to 4th gear
MT-00711
NOTE:
(A) 3rd drive gear Attach the indicator upside down in comparison to
the setting procedures for the zero point. Add “d1”
NOTE: [Value: 55 mm (2.17 in)] from the figure below to
• Set the height gauge indicator near the measure- “C1”, and measure “C1”.
Turn dial (2), and set the indicator to the 3rd side
end surface of the sleeve.
and 2 lowest measurement values. The remaining d1
(2)
(1) MT-00705
Lot No. (marking)

M.SFT M.SFT M.SFT
T mm (in) Snap ring Snap ring Snap ring
805072010 805072011 805072012
[t = 1.65 mm [t = 1.95 mm [t = 2.25 mm
MT-00585 (0.065 in)] (0.077 in)] (0.089 in)]
137.22 —
137.52 32809AA171 32809AA181 32809AA191
(5.4024 — (none) (2) (4)
5.4142)
137.52 —
137.82 32809AA161 32809AA171 32809AA181
(5.4142 — (1) (none) (2)
5.4260)
137.82 —
138.12 32809AA141 32809AA161 32809AA171
(5.4260 — (3) (1) (none)
5.4379)
T = Thickness
6MT-116

3. 5TH-6TH FORK ROD SELECTION 3) Use a height gauge to measure “D1” and “D2” as
shown in the figure.
NOTE:
below.
• Main shaft replacement
• 3rd to 6th drive gear and bushing replacement
• 3rd to 6th synchro ring assembly replacement D2
• 3rd-4th hub and sleeve assembly replacement D1 (B)
• 5th-6th hub and sleeve assembly replacement
1) Insert the main shaft assembly into the adapter
plate.
2) Set the height gauge to the adapter plate. Lower
the height gauge indicator to the upper face of the (A)
snap ring groove or the upper side of the main rear
bearing. Set to zero point.
(A)
MT-00712
(A) 5th drive gear

(B) 6th drive gear
MT-00706
(A) Ball 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.
gauge in the shaded area shown in the figure.
MT-00583
6MT-117

(1) Shift up the 5th-6th sleeve all the way to the (3) Shift down the 5th-6th sleeve all the way to
6th drive gear side, and measure “D2”. the 5th drive gear side, and measure “D1”.
(A)
(A)
MT-00713 MT-00714
(A) 6th drive gear (A) 5th drive gear
NOTE: NOTE:
• Set the height gauge indicator near the measure- • Set the height gauge indicator near the measure-
ment target, and lock dial (1) as shown in the figure. ment target, and lock dial (1) as shown in the figure.
Turn dial (2), and set the indicator to the 6th side Turn dial (2), and set the indicator to the 5th side
end surface of the sleeve. end surface of the sleeve.
• The measurement is to be performed with two • Turn approximately 72° at a time, and measure
persons, while holding the sleeve straight. the sleeve in 5 locations. Round down the 2 highest
• Turn approximately 72° at a time, and measure and 2 lowest measurement values. The remaining
the sleeve in 5 locations. Round down the 2 highest center value is used as the measurement value.
and 2 lowest measurement values. The remaining (2)
(2)
(1)
(1)
MT-00585
MT-00585
(2) Set the height gauge indicator upside down.
(A)
MT-00710
(A) Indicator
6MT-118

4) According to both of the measurements, calcu- 4. REVERSE FORK ROD SELECTION

late the neutral position of the 5th-6th sleeve. From
NOTE:
below.
Calculation: T = (D1 + D2) / 2
• Reverse idler gear replacement.
T: 5th-6th sleeve center position
• Reverse idler gear No. 2 replacement.
D1: Measured length from the shaft rear bearing
snap ring groove to the sleeve groove end, when • Adapter plate replacement.
shifted to 5th gear [Value: +55 mm (2.17 in)] • Base replacement.
D2: Measured length from the main shaft rear bear- 1) Insert the reverse idler gear assembly into the
ing snap ring groove to the sleeve groove end, adapter plate.
when shifted to 6th gear 2) Tighten the base COMPL attachment bolts.
Attach the indicator upside down in comparison to 25 N·m (2.5 kgf-m, 18.4 ft-lb)
the setting procedures for the zero point. Add “d1”
[Value: 55 mm (2.17 in)] from the figure below to
“D1”, and measure “D1”.
d1
MT-00546
3) Set the height gauge to the adapter plate. Lower

the height gauge indicator to the mating surface of
MT-00705 the adapter plate and case, and set to zero points.
Lot No. (marking)
M.SFT M.SFT M.SFT ST
T mm (in) Snap ring Snap ring Snap ring
805072010 805072011 805072012
[t = 1.65 mm [t = 1.95 mm [t = 2.25 mm
(0.065 in)] (0.077 in)] (0.089 in)]
64.12 —
64.42 32945AA021 32945AA031 32945AA041
(2.5244 — (none) (2) (4)
2.5362)
64.42 — MT-00582
64.72 32945AA011 32945AA021 32945AA031
(2.5362 — (1) (none) (2) NOTE:
2.5480) • The adapter plate will be the base point for the
64.72 — measurement. Use a scraper to remove any gasket
65.02 32945AA001 32945AA011 32945AA021 material remaining on the end face.
(2.5480 — (3) (1) (none) • During measurement, do not place the height
2.5598) gauge in the shaded area shown in the figure.
T = Thickness
MT-00583
6MT-119

4) Shift the reverse sleeve to the reverse idler gear 5) Calculate the neutral position of the reverse
No. 2, and measure “T”. 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)
T + 4.8 mm (0.189 in) mm
(A) Lot No. (marking)
(in)
T 33.50 — 33.80
32816AA110 (1)
(1.3189 — 1.3307)
33.80 — 34.10
32816AA130 (none)
(1.3307 — 1.3425)
MT-00715 34.10 — 34.40
32816AA140 (2)
(1.3425 — 1.3543)
(A) Reverse idler gear No. 2 T = Thickness
(A) MT-00716
(A) Reverse idler gear No. 2
NOTE:
• Set the height gauge indicator near the measure-
Turn dial (2), and set the indicator to the end face of
the reverse sleeve side.
and 2 lowest measurement values. The remaining
(2)
(1)
MT-00585
6MT-120
Clutch Housing
23.Clutch Housing 6) Install the center differential. <Ref. to 6MT-57,

A: REMOVAL 7) Install the transfer driven gear. <Ref. to 6MT-55,
1) Remove the manual transmission assembly INSTALLATION, Transfer Driven Gear.>
from the vehicle. <Ref. to 6MT-31, REMOVAL, 8) Install the extension case. <Ref. to 6MT-43, IN-
Manual Transmission Assembly.> STALLATION, Extension Case.>
2) Prepare the transmission for overhaul. <Ref. to 9) Install the neutral position switch, back-up light
6MT-37, Preparation for Overhaul.> switch and harness. <Ref. to 6MT-41, INSTALLA-
3) Remove the neutral position switch, back-up TION, Neutral Position Switch.> <Ref. to 6MT-39,
light switch and harness. <Ref. to 6MT-41, RE- INSTALLATION, Back-up Light Switch.>
MOVAL, Neutral Position Switch.> <Ref. to 6MT- 10) Install the manual transmission assembly to the
39, REMOVAL, Back-up Light Switch.> vehicle. <Ref. to 6MT-33, INSTALLATION, Manual
4) Remove the extension case. <Ref. to 6MT-43, Transmission Assembly.>
REMOVAL, Extension Case.> C: DISASSEMBLY
55, REMOVAL, Transfer Driven Gear.> 1) Remove the clutch release bearing guide.
8) Remove the individual gear assemblies. <Ref. to
bly.>
10) Remove the front differential assembly. <Ref. MT-01383
to 6MT-100, REMOVAL, Front Differential Assem- 2) Remove the oil seal.
bly.>
B: INSTALLATION
1) Install the pitching stopper bracket.
Tightening torque:
41 N·m (4.2 kgf-m, 30.2 ft-lb)
6MT-100, INSTALLATION, Front Differential As-
sembly.>
3) Install the drive pinion shaft assembly. <Ref. to
MT-01381
sembly.>
4) Install the individual gear assemblies all at once.
sembly.>
6MT-121
Clutch Housing
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
ST
MT-01382
2) Install the clutch release bearing guide.

Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
MT-01383
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.
6MT-122
Driver’s Control Center Differential Control Module

24.Driver’s Control Center Dif-

ferential Control Module
A: REMOVAL
2) Remove the instrument panel lower. <Ref. to EI-
53, INSTRUMENT PANEL LOWER, REMOVAL,
Center Console.>
3) Remove the driver’s control center differential
control module by disconnecting the connector.
(A)
MT-01742
(A) Driver’s control center differential control mod-

ule
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
15 N·m (1.5 kgf-m, 11.1 ft-lb)
6MT-123


A: INSPECTION
1. MANUAL TRANSMISSION
1. Gears are difficult to engage. (a) Worn, damaged or burred chamfer at Replace.
NOTE: internal spline of the sleeve
If it is difficult to shift, there are two possible (b) Gear spline wear, damage, dents Replace.
causes. One is a defective gear shift sys- (c) Worn or scratched bushings Replace.
tem and the other is defective transmis-
sion. However, if the operation is heavy (d) Incorrect contact or wear between syn- Repair or replace.
and engagement of the gears is difficult, a chronizer ring and gear cone
defective clutch function may also be re-
sponsible. Check whether the clutch is cor-
rectly functioning, before checking the
gear shift system and transmission.
2. Gear slip-out (a) Defective pitching stopper adjustment Adjust.
• Gear slips out when coasting on rough (b) Loose engine mounting bolts Tighten or replace.
road.
(c) Worn shifter fork, broken shifter fork rail Replace.
• Gear slips out during acceleration.
spring
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines Replace.
of synchronizer hub and synchronizer
sleeve
(f) Worn in the synchronizer hub chamfer Replace.
angle
(g) Worn 1st driven gear, needle bearing Replace.
and race
(h) Worn 2nd driven gear, needle bearing Replace.
and race
(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 (a) Insufficient or improper lubrication Replenish or replace with the specified
NOTE: amount of recommended oil.
If a noise is heard when the vehicle is (b) Worn or damaged gears and bearings Replace.
parked with its engine idling and ceases NOTE:
when the clutch is disengaged, it may be If the trouble is only wear of the gear teeth
considered that the noise is coming from surfaces, only a high whirring noise will oc-
the transmission. cur at high speeds, but if any part is broken,
rhythmical clicking sounds will be heard
even at low speeds.
6MT-124

2. DIFFERENTIAL
1. Broken differential (case, gear, bearing, (a) Insufficient or improper oil Disassemble the differential and
etc.) replace broken components. At the
NOTE: same time check other components for
Noise will occur, and eventually the differ- any trouble, and replace if necessary.
ential will not be able to operate due to bro- (b) Use of vehicle under severe conditions Readjust the preload and backlash of
ken pieces obstructing the gear revolution. such as excessive load and improper use the bearing, and the contact surface of
of the clutch gear.
(c) Improper adjustment of taper roller Adjust.
bearing
(d) Improper adjustment of the drive pinion Adjust.
and the hypoid driven gear
(e) Loose hypoid driven gear clamping Tighten.
bolts
2. Differential and hypoid gear noise (a) Insufficient oil Replenish or replace with the specified
Troubles of the differential and hypoid gear amount of recommended oil.
always appear as noise problems. There- (b) Improper adjustment of hypoid driven Check the tooth contact.
fore noise is the first indication of trouble. gear and drive pinion
However, noise from the engine, muffler,
(c) Worn teeth of hypoid driven gear and Replace as a set.
tire, exhaust gas, bearing, body, etc. are
drive pinion Readjust the bearing preload.
easily mistaken for noise from the differen-
tial. Pay special attention to the hypoid (d) Loose roller bearing Readjust the backlash of the hypoid
gear noise because it is easily confused driven gear to drive pinion, and check
with other gear noises. There are the fol- the tooth contact.
lowing four kinds of noises. (e) Distorted hypoid driven gear or differen- Replace.
• Gear noise when driving: If noise tial case
increases as the vehicle speed increases,
it may be due to insufficient gear oil, incor-
rect gear engagement, damaged gears,
etc.
• Gear noise during coasting: Damaged
gears due to misadjusted bearings and
incorrect shim adjustment.
• Bearing noise when driving or coasting:
Cracked, broken or damaged bearings.
6MT-125

6MT-126

DIFFERENTIAL (DIAGNOSTICS)
6MT(diag)
Page
1. Basic Diagnostic Procedure .......................................................................2
2. Check List for Interview ..............................................................................3
4. Electrical Component Location ..................................................................5
5. Driver’s Control Center Differential (DCCD) Control Module I/O Signal ....8
6. Subaru Select Monitor ..............................................................................10
7. Read Current Data ...................................................................................11
8. Read Diagnostic Trouble Code (DTC) .....................................................12
9. Clear Memory Mode .................................................................................13
10. Driver’s Control Center Differential (DCCD) Manual Mode Display .........14
11. Diagnostic Procedure for Subaru Select Monitor Communication ...........16
12. List of Diagnostic Trouble Code (DTC) ....................................................19
13. Diagnostic Procedure with Diagnostic Trouble Code (DTC) ....................20
14. Diagnostic Procedure without Diagnostic Trouble Code (DTC) ...............27
15. Diagnostics with Phenomenon .................................................................33
Basic Diagnostic Procedure

MANUAL TRANSMISSION AND DIFFERENTIAL (DIAGNOSTICS)
1. Basic Diagnostic Procedure

A: PROCEDURE
Step Check Yes No
1 START INSPECTIONS. Are items related to DCCD OK? Go to step 2. Repair the defec-
1) Use the Check List for Interview to confirm tive items.
the condition of the problem from the user.
<Ref. to 6MT(diag)-3, Check List for Interview.>
2) Check the items related to DCCD.
• General inspection <Ref. to 6MT(diag)-4,
INSPECTION, General Description.>
• Disconnection of harness connector
• Visual check for harness connector damage
• Oil leakage
2 CHECK DTC. Is DTC displayed? Record all DTC. Inspect based on
Read the DTC. <Ref. to 6MT(diag)-10, Subaru Go to step 3. the general diag-
Select Monitor.> nosis table. <Ref.
NOTE: to 6MT(diag)-33,
• Refer to “List of Diagnostic Trouble Code Diagnostics with
(DTC)” for DTC. <Ref. to 6MT(diag)-19, List of Phenomenon.>
• If the communication function of Subaru Se-
lect Monitor cannot be executed normally,
check communication circuit. <Ref. to 6MT(di-
ag)-10, Subaru Select Monitor.>
3 CHECK FREEZE FRAME DATA. Are freeze frame data Record the Freeze Go to step 4.
Using the Subaru Select Monitor, check the recorded? Frame Data.
Freeze Frame Data. Go to step 4.
4 PERFORM DIAGNOSIS. Is DTC displayed? Record all DTC Inspect based on
1) Inspect and repair all DTC using the “Diag- using the “Diag- the general diag-
nostic Procedure with Diagnostic Trouble Code nostic Procedure nosis table. <Ref.
(DTC)”. <Ref. to 6MT(diag)-20, Diagnostic Pro- with Diagnostic to 6MT(diag)-33,
cedure with Diagnostic Trouble Code (DTC).> Trouble Code Diagnostics with
NOTE: (DTC)” for the Phenomenon.>
Refer to “List of Diagnostic Trouble Code inspection. <Ref.
(DTC)” for DTC. <Ref. to 6MT(diag)-19, List of to 6MT(diag)-20,
Diagnostic Trouble Code (DTC).> Diagnostic Proce-
2) Start the engine. dure with Diagnos-
3) Read the DTC using Subaru Select Monitor. tic Trouble Code
<Ref. to 6MT(diag)-10, Subaru Select Monitor.> (DTC).> Repeat
execute diagnosis
until DTC no longer
appears.
6MT(diag)-2
Check List for Interview

2. Check List for Interview

A: CHECK
Check the following items when a problem has occurred.
NOTE:
Use copies of this page for interviewing customers.
Customer’s name
Date of purchase
Date of repair
Transmission model Transmission V.I.N.
Odometer distance km or miles
Frequency Continuous Intermittent ( times a day)
Weather Fine Cloudy Rainy Snowy
Other
( )
Place Highland Suburbs Inner city Uphill Rough road
Other
( )
Ambient air temperature Hot Warm Cool Cold
Vehicle speed km/h (MPH)
DCCD manual mode display Flashing Other than flashing
Driving condition Not affected At starting While turning ( RH/ LH)
While decelerating While accelerating When cruising
Symptoms Will not change to AUTO or MANUAL
The forward/rear torque distribution does not change
Will not become differential free
Will not become differential lock
A tight corner braking symptom occurs in AUTO mode or in MANUAL mode with differential free
Noise or vibration
Other
( )
6MT(diag)-3
General Description
A: CAUTION
The airbag system wiring harness is routed near
the DCCD control module.
CAUTION:
• Airbag system wiring harnesses and connec-
tors are yellow. Do not use an electric test
equipment to check these circuits.
• Be careful not to damage the airbag system
wiring harness when performing diagnostics or
repair of the DCCD control module.
• When measuring the voltage and resistance
of each control module 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. Al-
so, do not insert the pin more than 5 mm (0.2 in)
into the part.
B: INSPECTION
1. POWER SUPPLY
1) Measure the battery voltage and specific gravity
of the electrolyte.
Standard voltage: 12 V or more
Specific gravity: 1.260 or more
2) Check the fuse condition.
3) Check the connecting condition of harness and
harness connector.
C: PREPARATION TOOL
1. SPECIAL TOOL
1B022XU0 SUBARU SELECT Troubleshooting for electrical system
MONITOR III KIT
ST1B022XU0
2. GENERAL TOOL
TOOL NAME REMARKS
Oscilloscope Used for measuring the sensor.
6MT(diag)-4
Electrical Component Location

4. Electrical Component Location

A: LOCATION
(11)
(5)
(8)
(6)
(13)
(9)
(3)
(1)
(2)
(10)
(16)
(14)
(12)
(15) (7) (4)
MT-02121
(1) Engine control module (ECM) (7) Center differential (12) Stop light switch
(2) VDC control module and hydraulic (8) Mode change switch (13) Rear differential oil temperature
control unit (VDCCM&H/U) switch
(3) DCCD control module (9) DCCD relay (14) Data link connector
(4) Throttle position sensor (10) DCCD manual mode display (15) Neutral position switch
(5) Yaw rate & G sensor (11) Parking brake switch (16) Steering angle sensor
(6) C.DIFF +/– switch
6MT(diag)-5

(1)
(2)
MT-02338 MT-01719
(3) (4)
MT-01720 MT-01721
S
Sport SportSharp
(8) (6)
SI-DRIVE PUSH I
Intelligent
AUTO
C.DIFF
MANU
(5) (11)
MT-01722 MT-01693
(9)
(7) MT-01455 MT-02340
(12)
(10)
MT-02311 MT-01724
6MT(diag)-6

(13)
)14 (
MT-02310 MT-02339
(16)
(15)
MT-02130 MT-02117
6MT(diag)-7
Driver’s Control Center Differential (DCCD) Control Module I/O Signal

5. Driver’s Control Center Differential (DCCD) Control Module I/O

Signal
A: ELECTRICAL SPECIFICATION
TO B380
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
MT-01684
6MT(diag)-8
Driver’s Control Center Differential (DCCD) Control Module I/O Signal

Check with ignition switch ON.

Measured terminal
(Connector & Terminal No.) Resistance
Item Measuring condition Voltage (V)
Positive termi- Ground termi- (Ω)
nal nal
When differential is locked
(when DCCD manual mode 5.5 — 8.0
DCCD output (B380) No. 15 (B380) No. 32 display is locked) 1.2 — 2.5
When differential is free (When Less than
the parking brake is pulled) 0.5
(B380) No. 13 —
DCCD power supply Chassis ground Ignition switch ON 10 — 13
(B380) No. 14 —
Backup power supply (B380) No. 12 Chassis ground — 10 — 13 —
Ignition power supply (B380) No. 11 Chassis ground Ignition switch ON 10 — 13 —
Less than
DCCD relay (B380) No. 7 Chassis ground Ignition switch ON —
1.0
When the switch is not
8.0 or more —
Mode change switch (B380) No. 6 Chassis ground pressed
When the switch is pressed Less than 1 —
When the rear differential
0.4 or more —
Rear differential oil temperature switch is ON
(B380) No. 5 Chassis ground
switch When the rear differential Less than
—
switch is OFF 8.0
CAN communication signal (+) (B380) No. 2 Chassis ground Ignition switch ON Pulse signal
CAN communication signal (–) (B380) No. 18 Chassis ground Ignition switch ON Pulse signal
Data link signal (Subaru Select
(B380) No. 1 Chassis ground — — —
Monitor)
(B380) No. 29 Chassis ground Less than
System ground circuit — 0
(B380) No. 30 Chassis ground 1.0
Less than
System ground circuit (B380) No. 17 Chassis ground — 0
1.0
Up switch (B380) No. 22 Chassis ground 8.0/1.0
pressed/is pressed
Down switch (B380) No. 4 Chassis ground 8.0/1.0
pressed/is pressed
B: WIRING DIAGRAM
Refer to “WIRING DIAGRAM”. <Ref. to WI-72, Driver’s Control Center Differential Control System.>
6MT(diag)-9
Subaru Select Monitor

6. Subaru Select Monitor

A: OPERATION
1) Prepare the Subaru Select Monitor kit.
EN-05692
2) Prepare PC with Subaru Select Monitor in-

stalled.
3) Connect the USB cable to SDI (Subaru Diagno-
sis Interface) and USB port on the personal com-
puter (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
4) Connect the diagnosis cable to SDI.
5) Connect SDI to data link connector located in the
lower portion of the instrument panel (on the driv-
er’s side).
EN-06148
CAUTION:
Do not connect scan tools other than the Suba-
ru Select Monitor.
6) Start the PC.
8) Run the “PC application for Subaru Select Mon-
itor”.
6MT(diag)-10
Read Current Data

7. Read Current Data

A: OPERATION
1) Using the Subaru Select Monitor, on the «Main Menu» display, select {Each System Check}.
2) On «System Selection Menu» display, select {Transmission Control System}.
3) After the {Center Differential Control} is displayed, select [OK].
4) On «Transmission Diagnosis» display, select {Current Data Display & Save}.
5) Select {Normal sampling} on the «Current Data Display & Save» screen.
6) Using the scroll key, scroll the display screen up or down until the desired data is shown.
• A list of the support data is shown in the following table.
Item Display Unit of measure
Center differential actual current C-Diff. Real Current A
Center differential indicated current C-Diff. Indicate Current A
Front vehicle speed sensor (RH) FR Wheel Speed km/h or MPH
Front vehicle speed sensor (LH) FL Wheel Speed km/h or MPH
Rear vehicle speed sensor (RH) RR Wheel Speed km/h or MPH
Rear vehicle speed sensor (LH) RL Wheel Speed km/h or MPH
Yaw rate & G sensor Lateral G m/s2
Yaw rate & G sensor Yaw Rate deg/s
Steering angle Steering Angle Sensor deg
Engine speed signal Engine Speed rpm
Stop light switch signal Stop Light Switch ON or OFF
Rear differential oil temperature switch signal RR Diff. Oil Temp SW ON or OFF
Down shift signal Down Switch ON or OFF
Up shift signal Up Switch ON or OFF
AUTO selection mode DCCD Mode *1
Manual mode torque distribution DCCD Torque Distribution *2
Battery voltage Battery Voltage V
Accelerator position Accel. Opening Angle %
Parking switch Parking Position Switch ON or OFF
Center differential relay Center Diff. Relay ON or OFF
Mode change switch AUTO/MANUAL Mode Switch ON or OFF
Neutral signal Neutral Position Switch Neutral or other than neutral
*1: Displayed by the number

0 in the manual mode
1 in AUTO[–] / 2 in AUTO / 3 in AUTO[+]
*2: Displayed by the number
0 in AUTO mode
1 (Free), 2, 3, 4, 5, 6 (LOCK) in manual mode
NOTE:
For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.
6MT(diag)-11
Read Diagnostic Trouble Code (DTC)

8. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
1) Using the Subaru Select Monitor, on the «Main
Menu» display, select {Each System Check}.
2) On «System Selection Menu» display, select
{Transmission Control System}.
3) After the {Center Differential Control} is dis-
played, select [OK].
4) On «Transmission Diagnosis» display, select
{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 procedures, refer to “PC
application help for Subaru Select Monitor”.
• For details concerning DTCs, refer to “List of Di-
agnostic Trouble Code (DTC)”. <Ref. to 6MT(diag)-
19, List of Diagnostic Trouble Code (DTC).>
6MT(diag)-12
Clear Memory Mode

9. Clear Memory Mode

A: OPERATION
1) Place the shift lever in neutral.
2) Using the Subaru Select Monitor, on the «Main
Menu» display, select {Each System Check}.
{Transmission Control System}.
4) After the {Center Differential Control} is dis-
5) On «Transmission Diagnosis» display, select
{Clear Memory}.
6) When “Done. Turn off the ignition switch.” is dis-
7) Turn the 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}.
6MT(diag)-13
Driver’s Control Center Differential (DCCD) Manual Mode Display

10.Driver’s Control Center Differential (DCCD) Manual Mode Display

A: OPERATION
When there is a problem with a part or module, DCCD manual mode display blinks. (DCCD manual mode
display blinks even in AUTO mode condition.) The blinking starts from when the problem is detected, and
continues until the ignition switch is turned OFF. The faulty parts can be recognized by reading DTC with the
DCCD manual mode display is as shown in the figure.
LOCK
(A)
(D) (E) (F) (G) (H) (I) (J)
LOCK
(B)
(C)
MT-01775
(A) If faulty (blinks at 1 Hz cycle) (E) 5 (H) 2

(B) If normal (F) 4 (I) 1 (FREE)
(C) Manual mode display (G) 3 (J) No display (AUTO mode)
(D) 6 (LOCK)
6MT(diag)-14
Driver’s Control Center Differential (DCCD) Manual Mode Display

B: INSPECTION
DIAGNOSIS:
DCCD manual mode display is open or shorted.
TROUBLE SYMPTOM:
DCCD manual mode display does not illuminate in manual mode.
Step Check Yes No
1 CHECK BODY INTEGRATED UNIT. Is DTC displayed? Perform the diag- Go to step 2.
Read the DTC of body integrated unit using nosis according to
Subaru Select Monitor. DTC.
2 CHECK COMBINATION METER. Is the self-diagnosis of combi- Go to step 3. Repair it according
Perform the self-diagnosis of combination nation meter OK? to combination
meter. <Ref. to IDI-5, INSPECTION, Combina- meter diagnostics.
tion Meter System.>
3 CHECK IGNITION POWER SUPPLY CIRCUIT Is the voltage 11 V or more? Go to step 4. Repair the open
OF DCCD CONTROL MODULE. circuit of harness
1) Connect the Subaru Select Monitor to the between fuse (F/B
vehicle. No. 12) and DCCD
2) Turn the ignition switch to ON. control module, or
3) Read the data of «Battery voltage» using between fuse (F/B
Subaru Select Monitor. No. 12) and bat-
tery.
4 CHECK DTC. Is DTC P1720 displayed? Perform the diag- Go to step 5.
nosis according to
DTC.
5 CHECK MODE CHANGE SWITCH. Does the display change to ON/ Go to step 6. Diagnose the
Read the data of «AUTO/MANUAL Mode OFF according to the mode mode change
Switch» using the Subaru Select Monitor. change switch operation? switch.
6 CHECK C.DIFF +/– SWITCH (UP/DOWN). Does the display change to ON/ Go to step 7. Check the C.DIFF
Read the data of «Up Switch» and «Down OFF according to the C.DIFF +/– +/– switch.
Switch» using the Subaru Select Monitor. switch operation?
7 CHECK INDICATION OF DCCD MANUAL Does the DCCD manual mode Go to step 8. Check the poor
MODE DISPLAY. display illuminate? contact.
Press the mode change switch to enter the
manual mode.
8 CHECK INDICATION OF DCCD MANUAL Does the DCCD manual mode Go to step 9. Check the poor
MODE DISPLAY. display change according to the contact.
Read the data of «DCCD Torque Allocation» C.DIFF +/– switch operation?
using the Subaru Select Monitor.
9 CHECK OTHER DTC. Is any other DTC displayed? Perform the diag- DCCD manual
nosis according to mode display is
DTC. OK.
6MT(diag)-15
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:
Drivers control center differential control system <Ref. to WI-72, Driver’s Control Center Differential Control
System.>
IGNITION
SWITCH BATTERY
SBF-6 MAIN SBF
F/B No. 12
M/B No. 12
M/B No. 13
16
25
27
7 DATA LINK
CONNECTOR
DCCD
RELAY 5 B40
B220 4
26
28
11
12
14
13
1
7
REF. TO ENGINE ELECTRICAL

SYSTEM
B380 DCCD CM
30
29
17
28
31
E E
B40 B380 B220
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 9 13 17 21
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 3 4 10 14 18 22
9 10 11 12 13 14 15 16
11 12 15 16 19 20 23 24
5 6
7 8 25 29 33 37
26 30 34 38
27 28 31 32 35 36 39 40
MT-02930
Step Check Yes No

1 CHECK INSTALLATION OF DCCD CON- Is the DCCD control module Go to step 2. Connect the
TROL MODULE. connector connected to DCCD DCCD control
Turn the ignition switch to OFF. control module? module connector
to DCCD control
module.
6MT(diag)-16

Step Check Yes No

2 CHECK SUBARU SELECT MONITOR POW- Is the voltage 10 V or more? Go to step 3. Repair harness
ER SUPPLY CIRCUIT. connector between
Measure the voltage between data link connec- the battery and
tor and chassis ground. data link connec-
Connector & terminal tor, and poor con-
(B40) No. 16 (+) — Chassis ground (–): tact of the
connector.
3 CHECK SUBARU SELECT MONITOR Is the resistance less than 1 Ω? Go to step 4. Repair the open
GROUND CIRCUIT. circuit of harness
Measure the resistance of harness between between data link
data link connector and chassis ground. connector and
Connector & terminal ground terminal,
(B40) No. 4 — Chassis ground: and poor contact of
(B40) No. 5 — Chassis ground: connector.
4 CHECK COMMUNICATION OF SUBARU SE- Is the name of system dis- System is normal. Go to step 5.
LECT MONITOR. played on Subaru Select Moni-
1) Turn the ignition switch to ON. tor?
2) Check communication with the transmission
system.
5 CHECK COMMUNICATION OF SUBARU SE- Is the name of system dis- Go to step 7. Go to step 6.
1) Turn the ignition switch to OFF. tor?
2) Disconnect the connector from DCCD con-
trol module.
4) Check communication with the engine sys-
tem.
6 CHECK COMMUNICATION OF SUBARU SE- Is the name of system dis- Inspect the ECM. Go to step 7.
1) Turn the ignition switch to OFF. tor?
2) Connect the DCCD control module connec-
tor.
3) Disconnect the connector from ECM.
5) Check communication with the transmission
system.
7 CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or Go to step 8. Check harness
EACH CONTROL MODULE AND DATA LINK more? and connector
CONNECTOR. between each con-
1) Turn the ignition switch to OFF. trol module and
2) Disconnect the connectors from DCCD con- data link connec-
trol module and ECM. tor.
3) Measure the resistance between data link
connector and chassis ground.
8 CHECK HARNESS CONNECTOR BETWEEN Is the voltage 1 V or more? Check harness Go to step 9.
EACH CONTROL MODULE AND DATA LINK and connector
1) Disconnect the all modules that communi- trol module and
cate with Subaru Select Monitor. data link connec-
3) Measure the voltage between data link con-
nector and chassis ground.
6MT(diag)-17

Step Check Yes No

9 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 10. Check harness
DCCD CONTROL MODULE AND DATA LINK and connector
CONNECTOR. between DCCD
Measure the resistance between DCCD control control module and
module connector and data link connector. data link connec-
Connector & terminal tor.
(B380) No. 1 — (B40) No. 7:
10 CHECK POOR CONTACT OF DCCD CON- Is there poor contact of connec- Repair the poor Go to step 11.
TROL MODULE CONNECTOR. tor? contact.
11 CHECK POWER SUPPLY OF DCCD CON- Are the voltages 10 — 13 V? Go to step 15. Go to step 12.
TROL MODULE.
1) Disconnect the connector from DCCD con-
trol module.
3) Measure the voltage between DCCD con-
trol module connector and chassis ground.
(B380) No. 12 (+) – Chassis ground (–):
12 CHECK POWER SUPPLY CIRCUIT OF FUSE Is the fuse (M/B No. 12) blown Replace the fuse Go to step 13.
(M/B NO. 12). out? (M/B No. 12). If the
1) Turn the ignition switch to OFF. new fuse (M/B
2) Remove the fuse (M/B No. 12). No. 12) has blown
out easily, repair
the short circuit of
harness between
fuse (M/B No. 12)
and DCCD control
module.
13 CHECK POWER SUPPLY CIRCUIT OF FUSE Is the fuse (F/B No. 12) blown Replace the fuse Go to step 14.
(F/B NO. 12). out? (F/B No. 12). If the
Remove the fuse (F/B No. 12). new fuse (F/B
No. 12) has blown
out easily, repair the
ness between fuse
(F/B No. 12) and
DCCD control mod-
ule.
14 CHECK POWER SUPPLY CIRCUIT OF DCCD Is the resistance less than 1 Ω? Repair the open Go to step 15.
CONTROL MODULE. circuit.
Measure the resistance between the battery (+)
terminal and fuse.
Battery & terminal
Battery (+) — M/B No. 12:
Battery (+) — F/B No. 12:
15 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Check the poor Repair the short
DCCD CONTROL MODULE AND CHASSIS contact. circuit or poor con-
GROUND. tact of harness
1) Turn the ignition switch to OFF. between DCCD
2) Measure the resistance between DCCD control module and
control module and chassis ground. transmission con-
6MT(diag)-18

12.List of Diagnostic Trouble Code (DTC)

A: LIST
1. SUBARU SELECT MONITOR DISPLAY
DTC Item Content of diagnosis Reference
Brake Switch Circuit Stop light switch circuit is open or <Ref. to 6MT(diag)-20, DTC P1521 BRAKE
P1521 Range shorted. SWITCH CIRCUIT RANGE, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
DCCD CAN System CAN communication circuit is <Ref. to 6MT(diag)-20, DTC P1720 DCCD
P1720 Circuit open or shorted. CAN SYSTEM CIRCUIT, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
DCCD Steering Angle Open, short or communication <Ref. to 6MT(diag)-21, DTC P1767 DCCD
P1767 Sensor failure of the steering angle sen- STEERING ANGLE SENSOR, Diagnostic Pro-
sor circuit cedure with Diagnostic Trouble Code (DTC).>
Yaw Rate & Lateral G Yaw rate & lateral G sensor mal- <Ref. to 6MT(diag)-22, DTC P1769 YAW RATE
Sensor Malfunction function & LATERAL G SENSOR MALFUNCTION,
P1769
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Circuit of Center Diff Open or short in the driver’s con- <Ref. to 6MT(diag)-23, DTC P1875 CIRCUIT
P1875 trol center differential circuit OF CENTER DIFF, Diagnostic Procedure with
6MT(diag)-19

13.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC P1521 BRAKE SWITCH CIRCUIT RANGE
DIAGNOSIS:
Stop light switch circuit is open or shorted.
TROUBLE SYMPTOM:
ABS does not operate.
Step Check Yes No
1 CHECK DTC. Does the DTC related to stop Perform the diag- Go to step 2.
light SW appear in the VDC nosis according to
diagnostics test mode? DTC.
tery.
nosis according to
DTC.
4 CHECK DCCD CONTROL MODULE. Does the «Stop Light Switch» Go to step 5. Check the poor
1) Turn the ignition switch to ON. change to ON/OFF according contact.
2) Read the data of «Stop Light Switch» using to the depressing/releasing
Subaru Select Monitor. operation of brake?
5 CHECK OTHER DTC. Is a DTC other than DTC P1521 Perform the diag- The stop light
displayed? nosis according to switch is currently
DTC. normal.
B: DTC P1720 DCCD CAN SYSTEM CIRCUIT

NOTE:
Refer to “LAN SYSTEM” for diagnostic procedure. <Ref. to LAN(diag)-55, DTC U1216 HIGH-SPEED CAN
(DCCD) DATA ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
6MT(diag)-20

C: DTC P1767 DCCD STEERING ANGLE SENSOR

DIAGNOSIS:
Open, short or communication failure of the steering angle sensor circuit
TROUBLE SYMPTOM:
A tight corner braking symptom occurs.
Step Check Yes No
1 CHECK DTC. Does the DTC related to steer- Perform the diag- Go to step 2.
ing angle sensor appear in the nosis according to
VDC diagnostics test mode? DTC.
tery.
nosis according to
DTC.
4 CHECK DCCD CONTROL MODULE. Does the Subaru Select Moni- Go to step 5. Go to step 6.
1) Turn the ignition switch to ON. tor value change according to
2) Read the data of «Steering Angle Sensor» the input from the steering to
using Subaru Select Monitor. the right and left?
5 CHECK DTC. Is DTC P1767 displayed? Replace the steer- Go to step 6.
1) Clear the memory. ing angle sensor.
2) Start the engine.
3) Read the DTC.
6 CHECK OTHER DTC. Is a DTC other than DTC P1767 Perform the diag- The steering angle
displayed? nosis according to sensor circuit is
DTC. currently operating
properly.
6MT(diag)-21

D: DTC P1769 YAW RATE & LATERAL G SENSOR MALFUNCTION

DIAGNOSIS:
Malfunction information transmitted from the yaw rate & G sensor
TROUBLE SYMPTOM:
A tendency to understeer occurs during high speed cornering.
Step Check Yes No
1 CHECK DTC. Does the DTC related to G sen- Perform the diag- Go to step 2.
sor or yaw rate sensor appear nosis according to
in the VDC diagnostics test DTC.
mode?
tery.
nosis according to
DTC.
4 CHECK DCCD CONTROL MODULE. Does the yaw rate and lateral G Go to step 5. Go to step 6.
1) Drive the vehicle on a flat road. value change according to the
2) Stop the vehicle with the front wheels in a vehicle behavior? When the
straight forward direction. vehicle stops, is the yaw rate
3) Read the data of «Yaw Rate» and «Lateral value within –4 — 4 deg/s, and
G» using the Subaru Select Monitor. also is the lateral G value within
–1.5 — 1.5 m/s2?
5 CHECK DTC. Is DTC P1769 displayed? Replace the yaw Go to step 6.
1) Clear the memory. rate & G sensor.
2) Start the engine.
3) Read the DTC.
6 CHECK OTHER DTC. Is a DTC other than DTC P1769 Perform the diag- Yaw rate & G sen-
displayed? nosis according to sors are currently
DTC. normal.
6MT(diag)-22

E: DTC P1875 CIRCUIT OF CENTER DIFF

DIAGNOSIS:
Center differential output signal circuit is open or shorted.
TROUBLE SYMPTOM:
• Center differential does not operate.
• The lock ratio of the center differential does not change, or malfunction occurs.
• A tight corner braking symptom occurs.
• An oversteer tendency will become apparent.
• A tendency to understeer occurs during high speed cornering.
WIRING DIAGRAM:
System.>
TO POWER SUPPLY CIRCUIT

T16
MB-26 FB-38
M/B FUSE NO. 12 F/B FUSE NO. 12 1 2
(B) (IG)
B128
1 2 3
25
27
4 5 6
DCCD RELAY
B220
28
26
B220
1 2 9 13 17 21
3 4 10 14 18 22
11 12 15 16 19 20 23 24
12
11
14
13
5 6
7
7 8 25 29 33 37
B380 26 30 34 38
DCCD CM
27 28 31 32 35 36 39 40
32
15
B128
4
1
T9
B380
T16
2
T17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CENTER
DIFFERENTIAL
MT-02345
6MT(diag)-23

Step Check Yes No

1 CHECK HARNESS BETWEEN DCCD CON- Is the resistance less than 1 Ω? Go to step 2. Repair the bulk
TROL MODULE AND TRANSMISSION HAR- harness open cir-
NESS. cuit between
1) Turn the ignition switch to OFF. DCCD control
2) Disconnect the DCCD control module har- module and trans-
ness connector. mission harness.
3) Disconnect the transmission harness con-
nector and the bulk harness connector.
4) Measure resistance of the harness between
DCCD control module harness connector and
the transmission harness connector.
(B380) No. 15 — (B128) No. 1:
(B380) No. 32 — (B128) No. 4:
2 CHECK HARNESS BETWEEN DCCD CON- Is the resistance 1 MΩ or Go to step 3. Repair the bulk
TROL MODULE AND TRANSMISSION HAR- more? harness short cir-
NESS. cuit between
Measure the resistance between DCCD control DCCD control
module harness connector and chassis ground. module and trans-
Connector & terminal mission harness.
3 CHECK CENTER DIFFERENTIAL. Is the resistance 1.2 — 2.5 Ω? Go to step 4. Replace the center
Measure the resistance between transmission differential.
harness connector terminals.
(T9) No. 1 — No. 4:
4 CHECK OUTPUT SIGNAL OF DCCD CON- Is the voltage 5.5 — 8.0 V? Go to step 5. Go to step 6.
TROL MODULE.
1) Connect all harness connectors.
3) Release the parking brake.
4) Press the mode change switch to enter the
manual mode.
5) Press the C.DIFF +/– switch to enter the
lock position.
trol module harness connectors.
(B380) No. 15 (+) — No. 32 (–):
5 CHECK OUTPUT SIGNAL OF DCCD CON- Does the voltage drop in stages Circuit is currently Go to step 6.
TROL MODULE. according to the DCCD manual operating properly.
1) Move the C.DIFF +/– switch from the differ- mode display?
ential lock position to the differential free posi-
tion.
2) Read the voltage between DCCD control
module harness connectors.
(B380) No. 15 (+) — No. 32 (–):
6MT(diag)-24

Step Check Yes No

6 CHECK FUSE (M/B NO. 12). Is the fuse (M/B No. 12) blown Replace the fuse Go to step 7.
1) Turn the ignition switch to OFF. out? (M/B No. 12). If the
2) Remove the fuse (M/B No. 12). new fuse (M/B No.
12) has blown out
easily, check for
the short circuit to
chassis ground of
harness between
fuse (M/B No. 12)
and DCCD control
module, or
between fuse (M/B
No. 12) and relay.
7 CHECK POWER SUPPLY CIRCUIT OF DCCD Is the voltage 10 V or more? Go to step 8. Repair the open or
RELAY. short circuit
1) Install the fuse. between fuse (M/B
2) Turn the ignition switch to OFF. No. 12), DCCD
3) Disconnect the DCCD relay harness con- relay, and battery.
nector.
4) Measure the voltage between DCCD relay
harness connector and chassis ground.
OF DCCD RELAY. circuit between
1) Turn the ignition switch to ON. fuse (F/B No. 12),
2) Measure the voltage between DCCD relay DCCD relay, and
and chassis ground. battery.
9 CHECK HARNESS BETWEEN DCCD CON- Is the resistance less than 1 Ω? Go to step 10. Repair the open
TROL MODULE AND DCCD RELAY. circuit of harness
1) Turn the ignition switch to OFF. between DCCD
2) Disconnect the connector from DCCD con- control module
trol module. connector and
3) Measure resistance of the harness between DCCD relay con-
DCCD control module connector and DCCD nector.
relay connector.
(B380) No. 7 — (B220) No. 28:
(B380) No. 13 — (B220) No. 26:
(B380) No. 14 — (B220) No. 26:
10 CHECK HARNESS BETWEEN DCCD CON- Is the resistance 1 MΩ or Go to step 11. Repair the short
TROL MODULE AND DCCD RELAY. more? circuit of harness
Measure the resistance of harness between between DCCD
DCCD control module connector and chassis control module
ground. connector and
Connector & terminal DCCD relay con-
(B380) No. 7 — Chassis ground: nector.
11 CHECK DCCD RELAY. Is the resistance 1 MΩ or Go to step 12. Replace the DCCD
Measure the resistance between DCCD relay more? relay.
terminals.
(B220) No. 25 — No. 26:
6MT(diag)-25

Step Check Yes No

12 CHECK DCCD RELAY. Is the resistance less than 1 Ω? Go to step 13. Replace the DCCD
Connect the battery positive lead to terminal relay.
No. 27 and the negative lead to terminal No. 28,
then measure the resistance between DCCD
relay terminals.
(B220) No. 25 — No. 26:
13 CHECK DCCD CONTROL MODULE RELAY Is the voltage less than 1 V? Go to step 14. Go to step 17.
DRIVE CIRCUIT.
1) Connect all connectors.
trol module and chassis ground.
14 CHECK IGNITION POWER SUPPLY CIRCUIT Is the voltage 8 V or more? Go to step 15. Go to step 17.
OF DCCD CONTROL MODULE.
Measure the voltage between DCCD control
module and chassis ground.
15 CHECK CENTER DIFFERENTIAL. Are «C-Diff. Indicate Current» Go to step 16. Go to step 17.
1) Turn the ignition switch to OFF. and «C-Diff. Real Current» both
2) Connect the Subaru Select Monitor to data approximately 3.6 — 4.0 A?
link connector.
4) Run the Subaru Select Monitor.
5) Press the mode change switch to enter the
manual mode.
7) Press the C.DIFF +/– switch to enter the
lock position.
8) Read the data of «C-Diff. Indicate Current»
and «C-Diff. Real Current» using Subaru Select
Monitor.
16 CHECK CENTER DIFFERENTIAL. Is «C-Diff. Real Current» about Go to step 18. Go to step 17.
1) Using Subaru Select Monitor, operate the the same as «C-Diff. Indicate
C.DIFF +/– switch so that «C-Diff. Indicate Cur- Current»?
rent» becomes 1.6A.
2) Read the data of «C-Diff. Real Current»
using Subaru Select Monitor.
17 CHECK POOR CONTACT OF HARNESS Is there poor contact of the har- Repair the poor Go to step 18.
CONNECTORS. ness connector? contact.
18 CHECK DTC. Is P1875 displayed? Check the poor Go to step 19.
1) Clear the memory. <Ref. to 6MT(diag)-13, contact.
Clear Memory Mode.>
2) Read the DTC using the Select Monitor.
<Ref. to 6MT(diag)-12, Read Diagnostic Trou-
ble Code (DTC).>
19 CHECK DTC. Are DTCs other than P1875 Perform the diag- The center differ-
displayed? nosis according to ential circuit is cur-
DTC. rently operating
properly.
6MT(diag)-26

14.Diagnostic Procedure without Diagnostic Trouble Code (DTC)

A: CHECK REAR DIFFERENTIAL OIL TEMPERATURE SWITCH
DIAGNOSIS:
Input signal circuit of rear differential oil temperature switch is open or shorted.
TROUBLE SYMPTOM:
• Center differential remains free
• An oversteer tendency will become apparent.
• Rear differential oil temperature warning light illuminates.
WIRING DIAGRAM:
System.>
FB-36 i102
F/B FUSE NO. 5
(IG) 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
2
REAR
DIFFERENTIAL COMBINATION
OIL TEMPERATURE METER B92
WARNING LIGHT
i10 1 2 3 4 5 6 7 8 9
REVERSE CIRCUIT
10 11 12 13 14 15 16 17 18 19 20
40
i102
B380
8
R167
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
B92 R5 R148 R159
REAR DIFFERENTIAL
OIL TEMPERATURE SWITCH
5
i10
B380
E 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
DCCD CM 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
MT-02318
Step Check Yes No

1 CHECK REAR DIFFERENTIAL OIL TEMPER- Is the voltage less than 0.4 V? Go to step 6. Go to step 2.
ATURE SWITCH WARNING LIGHT CIRCUIT.
2) Disconnect the DCCD control module har-
ness connector.
4) Measure the voltage of the rear differential
oil temperature switch.
6MT(diag)-27

Step Check Yes No

TROL MODULE AND COMBINATION circuit between
METER. DCCD control
1) Turn the ignition switch to OFF. module and the
2) Disconnect the harness connector from the combination meter.
combination meter.
3) Disconnect the connector from the rear dif-
ferential oil temperature switch.
4) Measure the resistance between combina-
tion meter and DCCD control module harness
connectors.
(B380) No. 5 — (i10) No. 40:
TROL MODULE AND REAR DIFFERENTIAL circuit between
OIL TEMPERATURE SWITCH. DCCD control
Measure the resistance between DCCD control module and rear
module harness connector and rear differential differential oil tem-
oil temperature switch harness connector. perature switch.
(B380) No. 5 — (R148) No. 1:
4 CHECK REAR DIFFERENTIAL OIL TEMPER- Is the resistance 1 MΩ or Repair the open Go to step 5.
ATURE SWITCH GROUND CIRCUIT. more? circuit of the rear
1) Disconnect the harness connector from the differential oil tem-
bracket ground of the rear differential. perature switch
2) Measure the resistance between the rear ground circuit, and
differential oil temperature switch ground har- contact failure of
ness connector and chassis ground. the harness con-
5 CHECK REAR DIFFERENTIAL OIL TEMPER- Is the resistance less than 1 Ω? Go to step 6. Replace the rear
ATURE SWITCH. differential oil tem-
Measure the resistance between the rear differ- perature switch.
ential oil temperature switch and the rear differ-
ential oil temperature switch body.
(R148) No. 1 — Rear differential oil tem-
perature switch body:
6 CHECK REAR DIFFERENTIAL OIL TEMPER- Does the rear differential oil Check the poor Check the combi-
ATURE WARNING LIGHT. temperature light turn OFF? contact. nation meter.
2) Short the chassis ground and the combina-
tion meter harness connector.
(i10) No. 40 (+) — Chassis ground (–):
6MT(diag)-28

B: CHECK PARKING BRAKE SWITCH

DIAGNOSIS:
Input signal circuit of parking brake switch is open or shorted.
TROUBLE SYMPTOM:
• It does not show a differential free tendency even when the parking brake switch is applied.
• Remains differential free even when the parking brake switch is released.
WIRING DIAGRAM:
System.>
B437 B438
B380 DCCD CM 1 2 3 4 5
18
2
B99
1 2 3 4 5
6 7 8 9 10 11 12
B438
3
B: B280
B437
3
1 2 3 4 5 6
C15
B9
B3
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26
B: B280 C: B281 B99

5
BODY INTEGRATED UNIT R3

C: B281
1 2 3 4 5 6 7
R4
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
PARKING BRAKE
SWITCH
B380
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
MT-02931
Step Check Yes No

1 CHECK IGNITION CIRCUIT OF DCCD CON- Is the voltage 11 V or more? Go to step 2. Repair the open
TROL MODULE. circuit of harness
tery.
nosis according to
DTC.
3 CHECK DCCD CONTROL MODULE. Is the ON/OFF normally The parking brake Go to step 4.
1) Operate the parking brake lever. detected? switch circuit is
2) Read the data of «Parking Position Switch» currently operating
using Subaru Select Monitor. properly.
4 CHECK BODY INTEGRATED UNIT. Is the ON/OFF normally Go to step 7. Go to step 5.
1) Operate the parking brake lever. detected?
2) Read the data of «Parking Position Switch»
using Subaru Select Monitor.
6MT(diag)-29

Step Check Yes No

5 CHECK HARNESS BETWEEN BODY INTE- Is the harness normal? Go to step 6. Repair or replace
GRATED UNIT AND PARKING BRAKE the harness.
SWITCH.
2) Disconnect the connector from body inte-
grated unit.
3) Check for open circuit, short circuit to bat-
tery and short circuit to ground between the
body integrated unit connector and parking
brake switch connector.
(B281) No. 15 — (R4) No. 1:
6 CHECK PARKING BRAKE SWITCH. Is the resistance less than 10 Ω Replace the body Replace the park-
Measure the resistance between parking brake when the parking brake lever is integrated unit. ing brake switch.
switch terminals. pulled?
Is the resistance 1 MΩ or more
when the parking brake lever is
lowered?
7 CHECK DTC. Is the DTC related to CAN dis- Perform the diag- Check the poor
Check DTC of body integrated unit. played? nosis according to contact of DCCD
DTC. system.
6MT(diag)-30

C: CHECK DCCD MULTI SELECT SWITCH

DIAGNOSIS:
Input signal of DCCD multi select switch is open or shorted.
TROUBLE SYMPTOM:
• Does not enter the manual mode or auto mode when the mode change switch is pressed.
• Mode does not change in AUTO mode.
• Initial torque can not be changed in manual mode.
NOTE:
Other switch input can not be received if either mode change switch or C.DIFF +/– switch is stuck ON.
WIRING DIAGRAM:
System.>
MULTI SELECT SWITCH (DCCD) R33
1 2 3 4
5 6 7 8 9 10
MANUAL
AUTO/
AD10
1
9
2
R33 B98
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
R2
13
14
15
B98
B380
22
4
6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
B380 DCCD CM
MT-02941
Step Check Yes No

1 CHECK DCCD CONTROL MODULE. Does the data change from Go to step 2. Go to step 4.
1) Display the current data «AUTO/MANUAL OFF/ON?
Mode Switch» of DCCD control module, using
2) Press the manual mode change switch.
2 CHECK DCCD CONTROL MODULE. Does the data change from Go to step 3. Go to step 5.
1) Display the current data «Up Switch» of OFF/ON?
DCCD control module, using Subaru Select
Monitor.
2) Push the multi select switch toward plus.
3 CHECK DCCD CONTROL MODULE. Does the data change from The switch circuit Go to step 6.
1) Display the current data «Down Switch» of OFF/ON? is normal.
DCCD control module, using Subaru Select
Monitor.
2) Push the multi select switch toward minus.
6MT(diag)-31

Step Check Yes No

4 CHECK MODE CHANGE SWITCH. Is the resistance less than 1 Ω? Go to step 7. Replace the multi
1) Disconnect the multi select switch connec- select switch.
tor. <Ref. to FU(STI)-
2) Press the mode change switch. 58, SI-DRIVE
3) Using the tester, measure the resistance (SUBARU Intelli-
between terminals. gent Drive) Selec-
Connector & terminal tor.>
(AD10) No. 1 — No. 9:
5 CHECK MULTI SELECT SWITCH. Is the resistance less than 1 Ω? Go to step 7. Replace the multi
1) Push the multi select switch toward plus. select switch.
2) Using the tester, measure the resistance <Ref. to FU(STI)-
between terminals. 58, SI-DRIVE
Connector & terminal (SUBARU Intelli-
(AD10) No. 2 — No. 9: gent Drive) Selec-
tor.>
6 CHECK MULTI SELECT SWITCH. Is the resistance less than 1 Ω? Go to step 7. Replace the multi
1) Push the multi select switch toward minus. select switch.
2) Using the tester, measure the resistance <Ref. to FU(STI)-
between terminals. 58, SI-DRIVE
Connector & terminal (SUBARU Intelli-
(AD10) No. 3 — No. 9: gent Drive) Selec-
tor.>
7 CHECK HARNESS. Is the resistance less than 1 Ω? Go to step 8. Repair or replace
Use a tester to measure the resistance between the ground circuit.
the multi select switch harness connector and
chassis ground.
8 CHECK HARNESS. Is the resistance less than 1 Ω? Go to step 9. Repair or replace
1) Disconnect the connector from DCCD con- the open circuit of
trol module. the harness.
2) Use a tester to measure the resistance
between the DCCD control module and the
multi select switch.
(R33) No. 1 — (B380) No. 6:
(R33) No. 2 — (B380) No. 22:
(R33) No. 3 — (B380) No. 4:
9 CHECK HARNESS. Is the resistance 1 MΩ or Go to step 10. Repair or replace
Using the tester, measure the resistance more? the short of har-
between terminals. ness.
(R33) No. 1 — (R33) No. 2:
(R33) No. 1 — (R33) No. 3:
(R33) No. 3 — (R33) No. 2:
10 CHECK HARNESS. Is the resistance 1 MΩ or Check the poor Repair or replace
Using the tester, measure the resistance more? contact. the short of har-
between terminals. ness.
6MT(diag)-32
Diagnostics with Phenomenon

15.Diagnostics with Phenomenon

A: INSPECTION
A tight corner braking symptom occurs. • VDCCM&H/U
• ABS wheel speed sensor
• Yaw rate & G sensor
• Steering angle sensor
• CAN communication signal
• Center differential
• C.DIFF +/– switch
• Mode change switch
• Tire/Wheel
• DCCD control module
• ECM
• Body integrated unit
An oversteer tendency will become apparent. • Throttle position sensor
• ECM
• Tire/Wheel
• DCCD relay
• Rear differential oil temperature switch
• Neutral position switch
• VDCCM&H/U
A tendency to understeer occurs during high speed cornering. • VDCCM&H/U
• ABS wheel speed sensor
• Throttle position sensor
• ECM
• Engine speed signal
• Neutral position switch
Torque characteristics of the center differential do not change. • C.DIFF +/– switch
• DCCD relay
DCCD indicator does not operate. (is not displayed) • Combination meter
DCCD indicator does not operate even when the C.DIFF +/– • C.DIFF +/– switch
switch is operated. (Displayed but does not change. or, the • Combination meter
display blinks.) • DCCD control module
DCCD AUTO mode does not operate even when the C.DIFF +/– • Mode change switch
switch is operated. (Displayed but does not change.) • Combination meter
6MT(diag)-33
Diagnostics with Phenomenon


DCCD AUTO mode display does not illuminate. • Mode change switch
• Combination meter
Will not become differential free or remains differential free. • Parking brake switch
• Rear differential
• Tire/Wheel
• DCCD relay
• Rear differential oil temperature switch
• ECM
• VDCCM&H/U
ABS does not operate. • VDCCM&H/U
• Stop light switch
• ECM
Will not lock the differential or the differential is continually • VDCCM&H/U
locked. • ABS wheel speed sensor
• Tire/Wheel
• DCCD relay
• ECM
6MT(diag)-34
CLUTCH SYSTEM
CL
Page
2. Clutch Disc and Cover .............................................................................11
3. Flywheel ...................................................................................................14
4. Release Bearing and Lever ......................................................................15
5. Operating Cylinder ...................................................................................19
6. Master Cylinder ........................................................................................22
7. Clutch Pipe and Hose ..............................................................................24
8. Clutch Fluid ..............................................................................................25
9. Clutch Fluid Air Bleeding ..........................................................................26
10. Clutch Pedal .............................................................................................28
11. Clutch Switch ...........................................................................................33
General Description
CLUTCH SYSTEM
A: SPECIFICATION
Model STI Except for STI
Transmission type 6MT 5MT
Type Pull type Push type
Clutch cover
Diaphragm set load N (kgf, lbf) 9,120 (930, 2051) 7,450 (760, 1,675)
Facing material Woven (Non-asbestos)
Clutch
240 × 160 × 3.5 (9.45 × 6.30 × 0.138) 230 × 155 × 3.5 (9.06 × 6.10 × 0.138)
O.D. × I.D. × thickness cover side
mm (in) Flywheel
240 × 160 × 3.2 (9.45 × 6.30 × 0.126) 230 × 155 × 3.2 (9.06 × 6.10 × 0.126)
side
Spline outer diameter mm (in) 25.2 (0.992), (Number of teeth: 24)
Clutch disc Clutch
1.65 — 2.25 (0.065 — 0.089)
cover side
Depth of rivet head Flywheel
1.35 — 1.95 (0.053 — 0.077)
mm (in) side
Limit of
0.8 (0.031)
sinking
Deflection limit mm (in) 0.7 (0.028) at R = 115 (4.53) 0.7 (0.028) at R = 110 (4.33)
Release bearing Grease-packed self-aligning
Full stroke mm (in) 130 — 135 (5.12 — 5.31) 135 — 140 (5.31 — 5.51)
Clutch pedal
Free play mm (in) 5 — 11 (0.20 — 0.43)
Flywheel Type Conventional Flexible
CL-2
General Description
CLUTCH SYSTEM
B: COMPONENT
1. CLUTCH ASSEMBLY
• STI model
(1)
(2)
T3 (5) (3)
(4)
T2
T1
(6)
(7)
(8)
CL-00811
(1) Dust cover (5) Release bearing Tightening torque: N·m (kgf-m, ft-lb)
(2) Release lever (6) Clutch cover T1: 16 (1.6, 11.8)
(3) Clutch release lever shaft (7) Clutch disc T2: 48 (4.9, 35.4)
(4) Plug (8) Conventional flywheel T3: 75 (7.6, 55.3)
CL-3
General Description
CLUTCH SYSTEM
• Except for STI model
(1)
(3)
T2
(2)
(5)
T1
(7)
(8) (4)
T1
(6)
CL-00797
(1) Dust cover (5) Release bearing Tightening torque: N·m (kgf-m, ft-lb)
(2) Lever spring (6) Clutch cover T1: 16 (1.6, 11.8)
(3) Pivot (7) Clutch disc T2: 75 (7.6, 55.3)
(4) Release lever (8) Flywheel
CL-4
General Description
CLUTCH SYSTEM
2. CLUTCH PIPE AND HOSE

• STI model
(9)
(6) (7)
(10)
T1
(8)
(3) T3
(2) T3
T2
T1
(12)
(1) T4
T2
(5)
T5 (4)
(11)
CL-00668
(1) Operating cylinder (7) Clevis pin Tightening torque: N·m (kgf-m, ft-lb)
(2) Washer (8) Snap pin T1: 7.8 (0.8, 5.8)
(3) Clutch hose (9) Lever T2: 15 (1.5, 11.1)
(4) Clip (10) Pedal T3: 18 (1.8, 13.3)
(5) Clutch pipe (11) Clamp T4: 25 (2.5, 18.4)
(6) Master cylinder ASSY (12) Bracket T5: 41 (4.2, 30.2)
CL-5
General Description
CLUTCH SYSTEM
T2 (10)
(8)
(7)
(11)
T2
(6) T1
(9)
T3
T4
T3
(2)
(3)
(4)
(5)
(1) T5
T1
CL-00803
(1) Operating cylinder (7) Master cylinder ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Washer (8) Clevis pin T1: 7.8 (0.8, 5.8)
(3) Clutch hose (9) Snap pin T2: 15 (1.5, 11.1)
(4) Bracket (10) Lever T3: 18 (1.8, 13.3)
(5) Clip (11) Pedal T4: 25 (2.5, 18.4)
(6) Clutch pipe T5: 37 (3.8, 27.3)
CL-6
General Description
CLUTCH SYSTEM
3. OPERATING CYLINDER
(6)
(3)
(2)
(1)
(4) (5)
CL-00504
(1) Push rod (4) Piston spring Tightening torque: N·m (kgf-m, ft-lb)
(2) Boot (5) Operating cylinder T: 7.8 (0.8, 5.8)
(3) Piston (6) Breather screw
CL-7
General Description
CLUTCH SYSTEM
4. MASTER CYLINDER
(1) (10) T2
(9)
(2)
(8)
(3)
(4) (7)
(6)
(11)
(5)
T1
CL-00630
(1) Reservoir cap (6) Return spring (11) Breather screw

(2) Reservoir tank (7) Piston
(3) Oil seal (8) Push rod ASSY Tightening torque: N·m (kgf-m, ft-lb)
(4) Straight pin (9) Piston stop ring T1: 7.8 (0.8, 5.8)
(5) Master cylinder (10) Seat T2: 10 (1.0, 7.4)
CL-8
General Description
CLUTCH SYSTEM
5. CLUTCH PEDAL
(7)
(3)
(21)
(10)
T2 (20)
(4)
T1
T2
(2)
(19)
T2
(18)
(10)
(17)
T1
(22) (2)
(1)
(1)
(13) (13)
(12) (4)
(2)
(11 )
(2)
(16)
(15) (7)
(14)
(11 ) (10)
(1) (5)
(6)
(8)
(9)
CL-00873
(1) Stopper (10) Bushing C (19) Pedal bracket

(2) Bushing (11) Clutch clevis pin (20) Clutch master cylinder bracket
(3) Spring pin (12) Assist rod A (21) Lever
(4) Snap pin (13) Clip (22) Clutch start switch
(5) Brake pedal pad (14) Assist spring
(6) Brake pedal (15) Assist bushing Tightening torque: N·m (kgf-m, ft-lb)
(7) Clevis pin (16) Assist rod B T1: 8 (0.8, 5.9)
(8) Clutch pedal pad (17) Clutch switch T2: 18 (1.8, 13.3)
(9) Clutch pedal (18) Stop light switch
CL-9
General Description
CLUTCH SYSTEM
C: 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
• Keep fluid away from the vehicle body. If any fluid contacts the vehicle body, immediately flush the area
with water.
D: PREPARATION TOOL
1. SPECIAL TOOL
498497100 CRANKSHAFT Used for stopping rotation of the flywheel.
STOPPER
ST-498497100
499747100 CLUTCH DISC Used for installing the clutch disc to the flywheel.
GUIDE
ST-499747100
2. GENERAL TOOL
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.
CL-10
Clutch Disc and Cover

CLUTCH SYSTEM
2. Clutch Disc and Cover 2) Install the clutch cover to the flywheel and tight-
en the bolts to the specified torque.
A: REMOVAL NOTE:
1) Remove the transmission assembly from the ve- • When installing a clutch cover to the flywheel,
hicle. <Ref. to 6MT-31, REMOVAL, Manual Trans- position the clutch cover so that the spacing be-
mission Assembly.> <Ref. to 5MT-22, REMOVAL, tween the unbalance marks (paint mark) on the fly-
Manual Transmission Assembly.> wheel and clutch cover is 120° or more apart. (The
2) Attach the ST on the flywheel. unbalance mark indicates the direction of residual
ST 499747100 CLUTCH DISC GUIDE unbalance.)
(A)
• Temporarily tighten the bolts by hand. Each bolt
should be tightened to the specified torque in a
crisscross order.
Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)
• STI model
ST
CL-00011
(A) Clutch cover
3) Remove the clutch cover and clutch disc.

NOTE:
• Take care not to allow oil to touch the clutch disc
face.
(A)
• Do not disassemble the clutch cover or clutch
disc.
B: INSTALLATION (3)
(1)
1) Insert the ST into the clutch disc and attach to (5) (8)
the flywheel by inserting the ST end into pilot bear-
ing. (6)
NOTE:
(7)
When installing the clutch disc, be careful to attach (4)
in the correct direction. (9)
(2) ST
ST 499747100 CLUTCH DISC GUIDE CL-00792
(A) Unbalance mark (paint)
(A)
ST
CL-00208
(A) Flywheel side
CL-11

CLUTCH SYSTEM
• Except for STI model 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)
(A)
(3) (1)
CL-00015
(5) (A) Clutch facing

(6)
4) Deflection on facing
(2) (4) ST If deflection exceeds the specified value at the out-
CL-00013 er circumference of the facing, replace the clutch
disc.
(A) Unbalance mark (paint)
ST 499747100 CLUTCH DISC GUIDE
3) Remove the ST. Limit for deflection:
ST 499747100 CLUTCH DISC GUIDE STI model
4) Install the transmission assembly. <Ref. to 6MT- 0.7 mm (0.028 in) at R = 115 mm (4.53 in)
33, INSTALLATION, Manual Transmission Assem- Except for STI model
bly.> <Ref. to 5MT-24, INSTALLATION, Manual 0.7 mm (0.028 in) at R = 110 mm (4.33 in)
C: INSPECTION
ST
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 CL-00016
0.8 mm (0.031 in)
NOTE:
Do not wash the clutch disc with any type of clean-
ing fluid.
CL-00014
CL-12

CLUTCH SYSTEM
5) If there is spline wear, loose rivets, failed damper

springs, etc., replace the clutch disc.
CL-00017
(A) Spline
(B) Rivet
(C) Damper spring
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
(A)
(B)
CL-00018
(A) Thrust rivet

(B) Diaphragm spring
3) Damaged or worn disc contact surface of the

pressure plate
4) Loose strap plate installation area
5) Worn diaphragm sliding area
(A) (B)
CL-00176
(A) Pressure plate

(B) Strap plate
CL-13
Flywheel
CLUTCH SYSTEM
3. Flywheel Tightening torque:

75 N·m (7.6 kgf-m, 55.3 ft-lb)
A: REMOVAL
1) Remove the transmission assembly. <Ref. to
6MT-31, REMOVAL, Manual Transmission As-
(5) (1)
sembly.> <Ref. to 5MT-22, REMOVAL, Manual
(7)
Transmission Assembly.> (3)
2) Remove the clutch cover and clutch disc. <Ref. (4)
to CL-11, REMOVAL, Clutch Disc and Cover.> (8)
(2) (6)
3) Using the ST, remove the flywheel.
ST 498497100 CRANKSHAFT STOPPER
CL-00021
3) Install the clutch disc and cover. <Ref. to CL-11,

INSTALLATION, Clutch Disc and Cover.>
4) Install the transmission assembly. <Ref. to 6MT-
33, INSTALLATION, Manual Transmission Assem-
bly.> <Ref. to 5MT-24, INSTALLATION, Manual
(A) C: INSPECTION
ST
CL-00019 CAUTION:
Because the center bearing is grease-sealed
(A) Flywheel and is a non-lubrication type, do not wash with
gasoline or solvents.
B: INSTALLATION 1) If there is damage or defectiveness in the facing
1) Install the flywheel and ST. sliding surface or ring gear, replace the flywheel.
ST 498497100 CRANKSHAFT STOPPER
(B)
(A)
CL-00022
ST
CL-00801
(A) Flywheel
2) Tighten the flywheel mounting bolts to the spec-
(B) Ring gear
ified torque.
NOTE: 2) Smoothness of rotation
Tighten the flywheel attachment bolts gradually. Rotate the ball bearing while applying pressure in
Each bolt should be tightened to the specified the thrust direction.
torque in crisscross order. 3) If noise or excessive play is noted, replace the
flywheel.
CL-14
Release Bearing and Lever

CLUTCH SYSTEM
4. Release Bearing and Lever 3) Remove the lever spring from the pivot with a
screwdriver by accessing it through the clutch
A: REMOVAL housing release lever hole. Then remove the re-
lease lever and release bearing as a unit.
1. STI MODEL
1) Remove the transmission assembly from the ve-
(B)
hicle. <Ref. to 6MT-31, REMOVAL, Manual Trans-
mission Assembly.>
2) Remove the release lever from the transmission.
3) Using a flat tip screwdriver, remove the release
bearing from the clutch cover.
(A) (A)
CL-00024
(A) Release lever

(B) Screwdriver
B: INSTALLATION
CL-00025
1. STI MODEL
NOTE:
(A) Release bearing Apply the specified grease to lubricate to the follow-
ing points before installation.
2. EXCEPT FOR STI MODEL • Release lever shaft
1) Remove the transmission assembly from the ve- • Contact surface of release lever and bearing
hicle. <Ref. to 5MT-22, REMOVAL, Manual Trans- • Transmission main shaft spline
mission Assembly.> • Contact surface of release bearing and clutch re-
2) Remove the dust cover. lease bearing guide
Grease:
1) Attach the release bearing to the transmission.
(A)
2) Insert the release lever into the release bearing
tab.
(A)
(B)
CL-00023
(A) Release lever

(B) Dust cover
(B)
CL-00028
(A) Release lever

(B) Release bearing
CL-15

CLUTCH SYSTEM
3) Insert the release lever shaft into the release le- 6) Apply grease to the contact surface of the re-
ver. lease lever and operating cylinder.
NOTE: Grease:
Make sure the cut portion of the release lever shaft NICHIMOLY N-130 or equivalent
comes into contact with the spring pin. 7) Apply grease to splines.
(B) (A) Grease:
(C)
CL-00030
(A) Release lever

(B) Release lever shaft
(C) Spring pin
4) Tighten the plugs.

(A)
Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
CL-00341
(A) Spline

CL-00031 33, INSTALLATION, Manual Transmission Assem-
bly.>
5) Check the bearing for smooth movement by op-
erating the release lever. 2. EXCEPT FOR STI MODEL
NOTE:
Apply the specified grease to lubricate to the follow-
ing points before installation.
• Contact surface of lever and pivot
• Contact surface of lever and bearing
• Transmission main shaft spline
• Contact surface of release bearing and transmis-
sion case
Grease:
1) Install the release bearing by inserting the re-
lease lever into the clutch housing release lever
hole. Then, fit the lever spring onto the raised por-
tion of the pivot by pushing the release lever to the
pivot and twisting it to both sides.
CL-16

CLUTCH SYSTEM
2) Install the dust cover. • Except for STI model
(A)
(A)
(B)
CL-00023 CL-00744
(A) Release lever (A) Bearing case

(B) Dust cover
2) While applying force to the bearing in the rota-
3) Check the bearing for smooth movement by optional direction, check the bearing for smooth rota-
erating the release lever. tion.
4) Apply grease to the contact surface of the re- • STI model
lease lever and operating cylinder.
Grease:
(A)
24, INSTALLATION, Manual Transmission Assem-
bly.>
C: INSPECTION
1. RELEASE BEARING
CL-00581
CAUTION:
Since this bearing is grease-sealed and is a (A) Bearing case
non-lubrication type, do not wash with gasoline
or any other solvent when servicing the clutch. • Except for STI model
1) Check the bearing for smooth movement by ap-
plying force to the bearing in the radial direction.
(A)
Radial direction stroke:
1.6 mm (0.063 in)
• STI model
(A)
CL-00745
(A) Bearing case
3) Check for wear and damage at the bearing case

surface in contact with the lever.
CL-00527
(A) Bearing case
CL-17

CLUTCH SYSTEM
2. RELEASE LEVER
Check for wear in release shaft contact area and
release bearing case contact area of the lever.
• STI model
(A)
(B)
(C)
CL-00666
(A) Release lever

(B) Release shaft
(C) Release bearing

(A)
(B)
(C)
CL-00746
(A) Release lever

(B) Pivot
(C) Release bearing
CL-18
Operating Cylinder
CLUTCH SYSTEM
5. Operating Cylinder 3) Remove the operating cylinder from the trans-

mission.
A: REMOVAL • STI model
REMOVAL, Intercooler.> <Ref. to IN(w/o STI)-12,
(A)
2) 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.
• STI model CL-00419
(A) Operating cylinder

(C)
(B) • Except for STI model
(A)
(A) CL-00420
(A) Clutch hose

(B) Operating cylinder
CL-00823
(C) Cap bolt
(A)
(C)
(B)
CL-00796
(A) Clutch hose

(C) Cap bolt
CL-19
Operating Cylinder
CLUTCH SYSTEM
B: INSTALLATION • Except for STI model

1) Install in the reverse order of removal. Tightening torque:
NOTE: T1: 18 N·m (1.8 kgf-m, 13.3 ft-lb)
• Use a new gasket. T2: 37 N·m (3.8 kgf-m, 27.3 ft-lb)
• Before installing the operating cylinder, apply
grease to the contact point of the release lever and T1
operating cylinder. T2
Grease
• Be sure to install the clutch hose with the mark
side facing upward.
• Be careful not to twist the clutch hose during in- T2
stallation.
CL-00709
• STI model
T1: 18 N·m (1.8 kgf-m, 13.3 ft-lb)
T2: 41 N·m (4.2 kgf-m, 30.2 ft-lb)
(B)
T1
(C)
CL-00743
(A) Clutch hose

T2
CL-00421 (C) Mark
(C) 2) After bleeding air from the operating cylinder,

ensure that the clutch operates properly.
(A) <Ref. to CL-26, Clutch Fluid Air Bleeding.>
C: DISASSEMBLY
CAUTION:
Do not disassemble the STI model.
(B)
1) Remove the boot and push rod.
CL-00802
(A) Mark
(B) Clutch hose
(C) Operating cylinder
CL-00716
2) Apply compressed air through clutch hose at-

tachment hole.
NOTE:
Face the piston hole down and place a piece of
wood underneath to prevent the piston from pop-
ping out.
CL-20
Operating Cylinder
CLUTCH SYSTEM
3) Separate the piston and piston spring.
CL-00717
D: ASSEMBLY
NOTE:
During assembly, apply hydraulic oil to all parts.
Recommended clutch fluid:
New FMVSS No. 116 DOT3 or DOT4
1) Install the piston spring onto the piston.
CL-00717
2) Insert piston into the operating cylinder.

3) Install push rod to the boot.
4) Install boot and push rod to the operating cylin-
der.
CL-00716
E: INSPECTION
1) Check that the operating cylinder is not dam-
aged. If operating cylinder is damaged, replace it.
2) Check the operating cylinder for fluid leakage or
damage on the boot. Replace the operating cylin-
der if leaks or damages are noted.
CL-21
Master Cylinder
CLUTCH SYSTEM
6. Master Cylinder B: INSTALLATION

1) Install the master cylinder to the vehicle body,
A: REMOVAL and connect the clutch pipe to the master cylinder.
2) Thoroughly drain the clutch fluid from the reser- Tightening torque:
voir tank. T1: 15 N·m (1.5 kgf-m, 11.1 ft-lb)
3) Remove the instrument panel lower cover. <Ref. T2: 18 N·m (1.8 kgf-m, 13.3 ft-lb)
to EI-49, REMOVAL, Instrument Panel Lower Cov-
er.>
4) Remove the snap pin and clevis pin, and then
separate the push rod of the master cylinder from
clutch pedal.
(A)
T2
T1
(B)
(D) CL-00561
2) Connect the push rod of the master cylinder to

(C)
the clutch pedal, and install the clevis pin and snap
pin.
CAUTION:
CL-00042
Always use a new clevis pin.
(A) Clevis pin NOTE:
(B) Snap pin Apply grease to the clevis pin.
(C) Push rod
(A)
(D) Lock nut
5) Remove the intercooler. <Ref. to IN(STI)-12, (B)

6) Remove the clutch pipe from the master cylin- (C)
der.
7) Remove the master cylinder and reservoir tank
as a unit.
CL-00045
CAUTION:
Be careful not to spill the brake fluid. Brake flu- (A) Clevis pin
id spilled on the vehicle body will harm the (B) Snap pin
paint surface; wash it off with water and wipe (C) Push rod
clean quickly if spilled.
3) Refill the reservoir tank with recommended
(A)
clutch fluid.
4) After bleeding air from the clutch system, ensure
that the clutch operates properly.
(B) <Ref. to CL-26, Clutch Fluid Air Bleeding.>
STALLATION, Intercooler.> <Ref. to IN(w/o STI)-
12, INSTALLATION, Intercooler.>
CL-00152
(A) Master cylinder

(B) Clutch pipe
CL-22
Master Cylinder
CLUTCH SYSTEM
1) Remove the straight pin and reservoir tank. 1) Apply a coat of grease to the contact surfaces of
the push rod and piston before installation.
Grease:
SILICONE GREASE G-40M (Part No.
004404003) or equivalent
(A)
(B)
CL-00631
(A) Reservoir tank

(B) Straight pin
2) Remove the oil seal. CL-00633
(A)
2) Assemble in the reverse order of disassembly.
Tightening torque:
10 N·m (1.0 kgf-m, 7.4 ft-lb)
E: INSPECTION
If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
rod, reservoir tank, return spring, breather screw,
(B) seat or hose, replace the faulty part.
CL-00632
(C)
(B)
(A) Oil seal
(A)
(B) Master cylinder
(F)
(D)
3) Move the seat towards the rear.
(A)
(E)
CL-00634
(A) Master cylinder body

(B) Return spring
(C) Piston
(B)
(D) Piston stop ring
CL-00513
(E) Push rod ASSY
(A) Seat (F) Seat
(B) Master cylinder
4) Remove the piston stop ring.

CAUTION:
When removing the piston stop ring, be careful
to prevent the rod, washer, piston and return
spring from popping out.
CL-23
Clutch Pipe and Hose

CLUTCH SYSTEM
7. Clutch Pipe and Hose B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the ground cable from battery. NOTE:
2) Remove the intercooler. <Ref. to IN(STI)-12, Bleed air from the clutch fluid. <Ref. to CL-26,
REMOVAL, Intercooler.> <Ref. to IN(w/o STI)-12, Clutch Fluid Air Bleeding.>
REMOVAL, Intercooler.> Tightening torque:
3) Drain the clutch fluid. <Ref. to CL-25, Clutch Flu- T1: 15 N·m (1.5 kgf-m, 11.1 ft-lb)
id.> T2: 18 N·m (1.8 kgf-m, 13.3 ft-lb)
4) Disconnect the clutch pipe from the clutch hose T3: 25 N·m (2.5 kgf-m, 18.4 ft-lb)
and master cylinder.
5) Remove the clip, then remove the clutch hose
from the bracket.
(A)
T1
T3
(A) T1
(B)
(C)
CL-00057
(B)
(A) Clip
(B) Clutch hose
(D) (C)
6) Disconnect the hose from operating cylinder. T2
7) Remove the clutch bracket.
(E )
CL-00804
(A) Clutch pipe

(B) Clip
(C) Clutch hose
(D) STI model
(E) Except for STI model
C: INSPECTION
Check the pipes and hoses for breaks and dam-
age. Check joints for fluid leakage. If crack, break-
age or damage is found, repair or replace the faulty
pipe or hose.
CL-24
Clutch Fluid
CLUTCH SYSTEM
8. Clutch Fluid 1) Remove the intercooler. <Ref. to IN(STI)-12,

A: INSPECTION REMOVAL, Intercooler.>
1) Park the vehicle on a level surface. 2) Drain the brake fluid from the reservoir tank.
2) Inspect the fluid level using the scale on the out- 3) Refill the reservoir tank with recommended
side of the reservoir tank. If the level is below “MIN”, brake fluid.
add fluid to bring it up to “MAX”, and also inspect for Recommended brake fluid:
leakage. New FMVSS No. 116 DOT3 or DOT4
4) If necessary, bleed air from the clutch fluid. <Ref.
(A) to CL-26, Clutch Fluid Air Bleeding.>
STALLATION, Intercooler.> <Ref. to IN(w/o STI)-
(C) 12, INSTALLATION, Intercooler.>
MA X
MIN
(B)
CL-00567
(A) Reservoir tank

(B) MIN. level
(C) MAX. level
B: REPLACEMENT
CAUTION:
• Use new FMVSS No. 116 DOT3 or DOT4.
• Cover the breather with cloth to prevent
brake fluid from being splashed on surround-
ing parts when loosening the breather.
• Avoid mixing brake fluid of different brands
to prevent fluid performance 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.
• Bleed air from the oil line with help of a co-work-
er.
• The required amount of brake fluid is approxi-
mately 70 mL (2.4 US fl oz, 2.5 Imp fl oz) for total
clutch system.
CL-25
Clutch Fluid Air Bleeding

CLUTCH SYSTEM
9. Clutch Fluid Air Bleeding 5) Slowly depress the clutch pedal and keep it de-
pressed. Open the air breather to discharge air to-
A: PROCEDURE gether with the clutch fluid. Release the air breather
for 1 or 2 seconds. Next, close the air breather, and
1. STI MODEL slowly release the clutch pedal.
NOTE: NOTE:
Bleed air from the oil line with help of a co-worker. When performing this procedure, place the screw
1) Remove the intercooler. <Ref. to IN(STI)-12, portion of the air breather higher than the end of op-
REMOVAL, Intercooler.> erating cylinder.
2) Remove the operating cylinder.
NOTE:
Do not remove the clutch hose.
(B)
(A)
CL-00248

(B) Vinyl tube
CL-00422
3) Hold the piston with a clamp to prevent piston 6) Repeat procedure 5), until there are no more air
from popping out. bubbles appearing from the air breather.
CAUTION:
Cover the air breather with cloth to prevent
clutch fluid from being splashed on surround-
7) Tighten the air breather.
Tightening torque:
7.8 N·m (0.8 kgf-m, 5.8 ft-lb)
8) Install the operating cylinder.
CL-00247 Tightening torque:
4) Fit one end of a vinyl tube into the air breather of 41 N·m (4.2 kgf-m, 30.2 ft-lb)
the operating cylinder, and put the other end into a
clutch fluid container.
CL-00422
9) After stepping on the clutch pedal, make sure

that there are no leaks evident in the entire clutch
system.
10) After bleeding the air from clutch system, en-
sure that the clutch operates properly.
CL-26
Clutch Fluid Air Bleeding

CLUTCH SYSTEM
2. EXCEPT FOR STI MODEL 5) Tighten the air breather.

Bleed air from the oil line with help of a co-worker. T: 7.8 N·m (0.8 kgf-m, 5.8 ft-lb)
2) Fit one end of a vinyl tube into the air breather of
the operating cylinder, and put the other end into a
clutch fluid container.
CL-00712
6) After stepping on the clutch pedal, make sure

that there are no leaks evident in the entire clutch
(A)
system.
7) After bleeding the air from clutch system, ensure
CL-00777
that the clutch operates properly.
(A) Air breather
8) Install the intercooler. <Ref. to IN(w/o STI)-12,
INSTALLATION, Intercooler.>
3) Slowly depress the clutch pedal several times
and keep it depressed. Open the air breather to dis-
charge air together with the clutch fluid. Release
the air breather for 1 or 2 seconds. Next, close the
air breather, and slowly release the clutch pedal.
CAUTION:
Cover the air breather with cloth to prevent
clutch fluid from being splashed on surround-
(A)
(B)
CL-00711

(B) Vinyl tube
4) Repeat procedure 3), until there are no more air

bubbles appearing from the air breather.
CL-27
Clutch Pedal
CLUTCH SYSTEM
10.Clutch Pedal B: INSTALLATION

1) Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the ground cable from battery. CAUTION:
2) Remove the steering column. <Ref. to PS-16, Always use a new clevis pin.
REMOVAL, Steering Column.> 2) Adjust the clutch pedal after installation. <Ref. to
3) Disconnect the connector from the stop light CL-30, ADJUSTMENT, Clutch Pedal.>
switch and clutch switch. 3) Adjust the clutch start switch. <Ref. to CL-35,
4) Remove the snap pins from clevis pins which se- ADJUSTMENT, Clutch Switch.>
cure the lever to the push rod and operating rod. C: DISASSEMBLY
5) Pull out the clevis pins which secures the lever to
1) Remove the clutch switches.
the push rod and operating rod.
2) Remove the clip, assist spring, rod and bushing.
(G)
(A)
(D)
(A)
(D)
(D)
(C) (E)
(C)
(B) (B)
(F)
(C)
CL-00090
CL-00692
(A) Operating rod
(A) Clip
(B) Push rod
(B) Assist spring
(C) Snap pin
(C) Assist rod A
(D) Clevis pin
(D) Assist rod B
6) Remove the intercooler. (E) Assist bushing
<Ref. to IN(STI)-12, REMOVAL, Intercooler.> (F) Clutch clevis pin
<Ref. to IN(w/o STI)-12, REMOVAL, Intercooler.> (G) Bushing
7) Remove the nut which secures the clutch master
cylinder. 3) Remove the spring pin and lever.
(A)
(B)
CL-00093 CL-00095
8) Remove the bolts and nuts which secure the (A) Spring pin
brake pedal and clutch pedal, and remove the ped- (B) Lever
al assembly.
CL-28
Clutch Pedal
CLUTCH SYSTEM
4) Remove the clutch pedal and bushings. D: ASSEMBLY

(B) 1) Attach the stopper and clutch pedal pad to the
clutch pedal.
2) Install the clutch switch to the pedal bracket.
3) Clean the pedal bushing holes of the clutch ped-
(B)
al and the brake pedal, apply grease, and install the
pedal bushings.
4) Install the clutch pedal, brake pedal and lever to
(A)
the pedal bracket, and fix with a spring pin.
5) Install the assist rod A, assist rod B, assist bush-
CL-00602 ing and assist spring to the clutch pedal and pedal
bracket.
(A) Clutch pedal
(B) Bushing E: INSPECTION
Move the clutch pedal pads in the lateral direction
5) Remove the stopper and clutch pedal pad from with a force of approximately 10 N (1 kgf, 2 lbf) to
the clutch pedal. check that the clutch pedal deflection is within the
service limit.
CAUTION:
(A) If the play exceeds the service limit, replace the
bushing with a new part.
Deflection of the clutch pedal:
Service limit
(B)
4.0 mm (0.157 in) or less
CL-00670
(A) Stopper
(A) (B)
(B) Clutch pedal pad
6) Remove the stopper from the clutch pedal brack-

et.
CL-00098
(A) Clutch pedal

(B) Brake pedal
(A)
CL-00603
(A) Stopper
CL-29
Clutch Pedal
CLUTCH SYSTEM
F: ADJUSTMENT 4) Rotate the push rod to adjust.

(1) Make sure that the clutch pedal contacts the
1) Turn the lock nut until the full stroke of clutch
clutch switch side when the pedal is released.
pedal becomes within the specification.
(2) Make sure that the clutch pedal contacts the
CAUTION: clutch pedal bracket stopper when the clutch
When adjusting the full stroke of clutch pedal, pedal is at the maximum stroke position.
do not turn the clutch switch.
NOTE: (A)
If the lock nut cannot adjust the full stroke of clutch
pedal to the specified value, adjust it by turning the
master cylinder push rod. (B)
Clutch pedal full stroke A: (C) (F)

STI model
(E)
130 — 135 mm (5.12 — 5.31 in)
Except for STI model (D)
135 — 140 mm (5.31 — 5.51 in) CL-00080
Tightening torque (Clutch switch lock nut): (A) Clevis hole

T: 8 N·m (0.8 kgf-m, 5.9 ft-lb) (B) Push rod lock nut
(C) In the shorter direction
(D) In the longer direction
(E) Push rod
(F) Clevis
T
5) Turn the push rod to shorten until a clearance is
gained on the clutch switch side.
A
CL-00225
2) If the full stroke is not within the specified value,

loosen the clutch switch lock nut to adjust.
8 N·m (0.8 kgf-m, 5.9 ft-lb)

3) Loosen the push rod lock nuts. (B)
(A) CL-00605
(B) (A) Clutch switch

(B) Stopper
(D)
6) Turn the push rod to lengthen until clutch pedal
(C) contacts the clutch switch.
CL-00042
(A) Clevis pin

(B) Snap pin
(C) Push rod
(D) Push rod lock nut
CL-30
Clutch Pedal
CLUTCH SYSTEM
7) Turn further in the direction that will shorten the 12) Push the release lever until the operating cylin-
push rod (arrow direction shown in figure) by 270°. der push rod retracts. Make sure that the clutch flu-
id level in the reservoir tank increases. If the clutch
(B) 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 with a new part. <Ref. to CL-22, Master Cylin-
(A)
der.>
(B)
CL-00600
(A) Accelerator pedal

(B) Clevis
(C)
8) Check that the clevis pin moves smoothly by
(A)
moving it in the left and right directions. CL-00663
9) Tighten the push rod lock nut.
(A) Push rod
Tightening torque (Push rod lock nut):
(B) Release lever
T: 10 N·m (1.0 kgf-m, 7.4 ft-lb)
(C) Operating cylinder
(A)
13) Push the release lever until the operating cylin-
(B) der push rod retracts. Check that the clutch fluid
T
level in the reservoir tank increases.
(B)
(C)
CL-00226
(A) Clevis pin

(B) Snap pin (C)
(C) Push rod (A)
CL-00663
10) Depress and release the clutch pedal two or (A) Push rod
three times to ensure that the clutch pedal and re-
(B) Release lever
lease lever operate smoothly. If the clutch pedal
and release lever do not operate smoothly, bleed (C) Operating cylinder
air from the clutch hydraulic system. <Ref. to CL-
14) If the clutch fluid level increases, hydraulic
26, Clutch Fluid Air Bleeding.>
clutch play is correct.
11) Measure the clutch pedal full stroke length
15) If the clutch fluid level does not increase or
again to ensure that it is within specifications. If it is
not within specifications, repeat adjustment proce- push rod does not retract, readjust the clutch pedal.
dures again from the beginning.
Clutch pedal full stroke:
STI model
130 — 135 mm (5.12 — 5.31 in)
Except for STI model
135 — 140 mm (5.31 — 5.51 in)
CL-31
Clutch Pedal
CLUTCH SYSTEM
16) Check the fluid level using the scale on the out-
side of the reservoir tank. If the level is below “MIN”,
fill fluid up to “MAX” level.
Recommended clutch fluid:
New FMVSS No. 116 DOT3 or DOT4
(A)
(C)
MA X
MIN
(B)
CL-00567
(A) Reservoir tank

(B) MIN. level
(C) MAX. level
CL-32
Clutch Switch
CLUTCH SYSTEM
11.Clutch Switch 2. CLUTCH START SWITCH

1) Fully depress the clutch pedal and hold it.
A: REMOVAL 2) Install the clutch pedal plate and clutch switch so
1) Disconnect the ground cable from battery. that the gap between them is 1.1 — 2.1 mm (0.04
2) Remove the instrument panel lower cover. — 0.08 in), and then tighten the lock nut.
3) Disconnect the connector from the clutch switch.
Tightening torque:
4) Remove the clutch switches.
8 N·m (0.8 kgf-m, 5.9 ft-lb)
B: INSTALLATION (A) (C)
(B)
1. CLUTCH SWITCH (CRUISE CONTROL)
1) Move the clevis pin of push rod to left and right,
retain it at the position where it moves smoothly,
and measure the clutch pedal stroke.
Clutch pedal full stroke A:
STI model
130 — 135 mm (5.12 — 5.31 in)
Except for STI model CL-00104
135 — 140 mm (5.31 — 5.51 in)
(A) Plate
Tightening torque: (B) Clutch start switch
T: 8 N·m (0.8 kgf-m, 5.9 ft-lb) (C) 1.1 — 2.1 mm (0.04 — 0.08 in)
3) Connect the clutch switch connector.

4) Make sure that engine does not start with clutch
pedal not depressed.
T 5) Make sure that engine starts with clutch pedal
fully depressed.
C: INSPECTION
A
1. CLUTCH START SWITCH
CL-00225 1) Perform the following inspections. If the clutch
2) If the clutch pedal stroke is out of specification, start switch does not operate normally, adjust the
adjust the stroke. <Ref. to CL-30, ADJUSTMENT, switch, and check it again. <Ref. to CL-35, AD-
Clutch Pedal.> JUSTMENT, Clutch Switch.>
3) Connect the clutch switch connector. • Make sure that engine does not start with clutch
pedal not depressed.
• Make sure that engine starts with clutch pedal
fully depressed.
2) When the clutch start switch does not operate
normally even if it is adjusted, check the clutch start
switch for continuity.
(1) Remove the clutch start switch. <Ref. to CL-
33, REMOVAL, Clutch Switch.>
CL-33
Clutch Switch
CLUTCH SYSTEM
(2) Measure the resistance between terminal 1 2. CLUTCH SWITCH

and 2 of the switch. If the resistance is not at the 1) Check the clutch switch for continuity.
standard value, replace the switch. (1) Disconnect the connector of clutch switch.
Specified (2) Measure the resistance between terminal 1
Condition Terminal No.
resistance and 2 of the switch. If the resistance is not within
ON No. 1 — No. 2 Less than 1 Ω the specification, check the clutch stroke and in-
OFF No. 1 — No. 2 1 MΩ or more stallation condition, and check the clutch switch
again.
Specified
resistance
1
2
When clutch pedal is
No. 1 — No. 2 1 MΩ or more
depressed
When the clutch pedal
No. 1 — No. 2 Less than 1 Ω
is not depressed
CL-00102
2 1
(3) Check that the switch is turned on and off in
Dimension L.
Dimension L:
4 — 5.5 mm (0.16 — 0.22 in)
L
CL-00084
2) When the clutch switch does not operate nor-

(B) (A)
mally even if the clutch stroke and installation con-
dition are normal, check the clutch switch for
continuity.
(1) Remove the clutch switches. <Ref. to CL-
33, REMOVAL, Clutch Switch.>
(2) Measure the resistance between terminal 1
CL-00799 and 2 of the switch. If the resistance is not at the
standard value, replace the switch.
(A) ON
(B) OFF Specified
resistance
ON No. 1 — No. 2 Less than 1 Ω
OFF No. 1 — No. 2 1 MΩ or more
2 1
CL-00084
CL-34
Clutch Switch
CLUTCH SYSTEM
(3) Check that the switch is turned on and off in 4) Tighten the lock nut.
Dimension L.
Tightening torque:
Dimension L: 8 N·m (0.8 kgf-m, 5.9 ft-lb)
5 — 6.5 mm (0.2 — 0.26 in)
(B) (A)
CL-00799
(A) ON
(B) OFF
D: ADJUSTMENT
1) Loosen the lock nut of clutch start switch.
(A)
(B)
CL-00105
(A) Lock nut

(B) Clutch start switch
2) Fully depress the clutch pedal and hold it.

3) Adjust the gap of the clutch pedal plate and the
clutch switch to be 1.1 — 2.1 mm (0.04 — 0.08 in).
(A) (C)
(B)
CL-00104
(A) Plate
(B) Clutch start switch
(C) 1.1 — 2.1 mm (0.04 — 0.08 in)
CL-35

CLUTCH SYSTEM

A: INSPECTION
1. CLUTCH
1. Clutch slippage. (a) Oil on the clutch face Replace.
It is hard to perceive clutch slippage in (b) Worn clutch face Replace.
the early stage, but pay attention to the
(c) Deteriorated diaphragm spring Replace.
following symptoms.
• Engine speeds up when shifting. (d) Warped pressure plate or flywheel Repair or replace.
• High-speed driving is not possible; (e) Defective release bearing holder Repair or replace.
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.
2. Clutch drags. (a) Worn or rusty clutch disc hub spline Replace the clutch disc.
As a symptom of this trouble, a harsh (b) Excessive deflection of clutch disc Repair or replace.
scratching noise occurs and control face
becomes difficult when shifting gears.
(c) Crankshaft pilot needle bearing stick- Replace.
The symptom becomes more apparent
ing
when shifting into the 1st gear. However,
because most trouble of this sort is due to (d) Cracked clutch disc face Replace.
a defective synchronization mechanism, (e) Stuck clutch disc (smeared by oil or Replace.
perform the following tests. water)
• Method of testing: <Ref. to CL-37,
DIAGNOSTIC DIAGRAM OF CLUTCH
DRAG, INSPECTION, General Diagnos-
tic Table.>
The problem is caused by insufficient dis-
engagement of the clutch if an abnormal
noise occurs during this test.
3. Clutch chatters. (a) Adhesion of oil on the clutch face Replace the clutch disc.
Clutch chattering is an unpleasant vibra- (b) Weak or broken damper spring Replace the clutch disc.
tion to the whole vehicle when the vehicle
(c) Poor contact of the disc surface or Replace the faulty clutch disc.
is just started with clutch partially
excessively worn disc
engaged.
(d) Warped pressure plate or flywheel Repair or replace.
(e) Loose disc rivets Replace the clutch disc.
(f) Loose engine mounting Retighten or replace mounting.
(g) Loose pitching stopper Retighten or replace the pitching stopper.
CL-36

CLUTCH SYSTEM

4. Noisy clutch (a) Broken, worn or insufficiently lubri- Replace the release bearing.
Examine whether the noise is generated cated release bearing
when the clutch is disengaged, engaged, (b) Insufficient lubrication of the pilot Replace the pilot bearing.
or partially engaged. 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. (a) Grease or oil on facing Replace the clutch disc.
When starting the vehicle with the clutch (b) Deteriorated cushioning spring Replace the clutch disc.
partially engaged, the clutch engages
(c) Worn or rusted spline of clutch disc or Take off rust, apply grease or replace
suddenly and the vehicle jumps instead
main shaft clutch disc or main shaft.
of making a smooth start.
(d) Deteriorated or broken damper spring Replace the clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f) Deteriorated diaphragm spring Replace.
2. CLUTCH PEDAL
Symptoms 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.
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG

Step Check Yes No
1 CHECK GEAR NOISE. Is there any abnormal noise Go to step 2. Clutch is normal.
1) Start the engine. from the transmission gear?
2) While idling the engine, step on the clutch
pedal and quickly shift from neutral to reverse.
2 CHECK GEAR NOISE. Is there any abnormal noise Go to step 3. Defective trans-
Depress the clutch pedal at idle and shift from from the transmission gear? mission or exces-
neutral to reverse within 0.5 — 1.0 second. sive clutch drag
torque. Inspect
pilot bearing,
clutch disc, trans-
mission and clutch
disc hub spline.
3 CHECK GEAR NOISE. Is there any abnormal noise Inadequate clutch Clutch and fly-
1) Depress the clutch pedal at idle and shift from the transmission gear? disengage. Inspect wheel seizure.
from neutral to reverse within 0.5 — 1.0 second. the clutch disc, Inspect the clutch
2) While stepping on the clutch pedal, shift clutch cover, clutch disc and the spline
from neutral to reverse, reverse to neutral sev- release, and clutch of the clutch disc
eral times. pedal free play. hub.
CL-37
2013 IMPREZA WRX STI SERVICE MANUAL QUICK REFERENCE INDEX
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
WHEEL AND TIRE SYSTEM WT
TIRE PRESSURE MONITORING SYSTEM

TPM(diag)
(DIAGNOSTICS)
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data DIFFERENTIALS DI
for the correct maintenance and repair
of SUBARU vehicles.
TRANSFER CASE TC
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of DRIVE SHAFT SYSTEM DS
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual VEHICLE DYNAMICS CONTROL (VDC) VDC
fully to ensure complete repair work for
satisfying our customers by keeping
VEHICLE DYNAMICS CONTROL (VDC)
their vehicle in optimum condition. VDC(diag)
(DIAGNOSTICS)
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts. BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM

PS
(POWER STEERING)
All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD. G1150BE6

FRONT SUSPENSION
FS
Page
2. Wheel Alignment ........................................................................................8
3. Front Crossmember Support Plate ..........................................................16
4. Front Stabilizer .........................................................................................17
5. Front Ball Joint .........................................................................................18
6. Front Arm .................................................................................................20
7. Front Strut ................................................................................................24
8. Front Crossmember .................................................................................27
General Description
FRONT SUSPENSION
A: SPECIFICATION
Model Except for STI model STI model
Wheel arch height
mm (in) 376 (14.8) 371 (14.6)
(Tolerance: +12 mm –24 mm (+0.47 in –0.94 in))
Camber (Tolerance: ±0°45′ Differences between RH and LH:
–0°50′ –0°45′
45′ or less)
Caster (Referential Value) 6°30′ 6°30′
Front
Inner wheel 36.6° 36.6°
Steering angle (Tolerance: ±1.5°)
Outer wheel 32.2° 32.2°
0±3 (0±0.12) Toe angle (sum of both wheels):
Toe-in mm (in)
0°±0°15′
Kingpin angle (Referential Value) 15°15′ 15°15′
Wheel arch height
mm (in) 370 (14.6) 365 (14.4)
(Tolerance: +12 mm –24 mm (+0.47 in –0.94 in))
Camber (Tolerance: ±0°45′ Differences between RH and LH:
17-inch tire: –1°35′ –1°30′
Rear 45′ or less)
0±3 (0±0.12) Toe angle (sum of both wheels):
Toe-in mm (in)
0°±0°15′
Thrust angle (Tolerance: ±0°30′) 0°
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 is not equipped with adjustment mechanisms. If other items ex-
ceed specifications, check the suspension parts and connections for deformation. If defective, replace with
new parts.
(1)
A
FS-00269
(1) Front
A – B = Positive: Toe-in, Negative: Toe-out
α = Individual toe angles
FS-2
General Description
FRONT SUSPENSION
B: COMPONENT
(1)
T4 (18)
(9)
(17)
T6
(16)
(6)
(7) T7
(2) (9)
T6 (15)
(19)
(7)
T5 (9)
(3) (14) T7
T5
(13) T8
(4) (10)
(7) (12)
T2
(5)
T3
T1 (11)
(7)
(6) T1 (8)
T2
FS-00465
(1) Front crossmember (11) Cotter pin Tightening torque: N·m (kgf-m, ft-lb)
(2) Crossmember support plate (12) Castle nut T1: 25 (2.5, 18.4)
(3) Stabilizer (13) Front arm T2: 38 (3.9, 28.0)
(4) Bushing (14) Ball joint T3: 39 (4.0, 28.8)
(5) Bracket (15) Rear bushing T4: 50 (5.1, 36.9)
(6) Flange nut (16) Stud bolt T5: 60 (6.1, 44.3)
(7) Flange nut (17) Stopper T6: 95 (9.7, 70.1)
(8) Stabilizer link (18) Housing T7: 110 (11.2, 81.1)
(9) Bolt (19) Support plate T8: 150 (15.3, 110.6)
(10) Front bushing
FS-3
General Description
FRONT SUSPENSION
• STI model
(1)
(9)
T6
(16)
T4
(6)
(7)
(2) (9)
T6 (15)
(17)
T5
(9)
(3) (14)
T5 T8
(13)
(4) (10)
(7) (12)
T2
(5) (9)
T3
T7
T1
(11)
(7)
(6) T1 (8)
T2
FS-00497
(1) Front crossmember (10) Front bushing Tightening torque: N·m (kgf-m, ft-lb)
(2) Crossmember support plate (11) Cotter pin T1: 25 (2.5, 18.4)
(3) Stabilizer (12) Castle nut T2: 38 (3.9, 28.0)
(4) Bushing (13) Front arm T3: 39 (4.0, 28.8)
(5) Bracket (14) Ball joint T4: 50 (5.1, 36.9)
(6) Flange nut (15) Pillow ball bushing T5: 60 (6.1, 44.3)
(7) Flange nut (16) Housing T6: 95 (9.7, 70.1)
(8) Stabilizer link (17) Support plate T7: 140 (14.3, 103.3)
(9) Bolt T8: 150 (15.3, 110.6)
FS-4
General Description
FRONT SUSPENSION
• Strut
(1)
(2)
T1
T2
(2)
(8) (3)
(4)
(5)
(6)
(11)
(10)
(7)
(9)
T3
FS-00447
(1) Dust seal (7) Helper (standard damper only) Tightening torque: N·m (kgf-m, ft-lb)
(2) Self-locking nut (8) Coil spring T1: 20 (2.0, 14.8)
(3) Strut mount (9) Strut (standard damper) T2: 55 (5.6, 40.6)
(4) Spacer (10) Strut (inverted damper) T3: 155 (15.8, 114.3)
(5) Upper spring seat (11) Flange nut
(6) Dust cover
C: CAUTION
any work.
• Use SUBARU genuine grease etc. or equivalent. Do not mix grease etc. of different grades or manufac-
turers.
FS-5
General Description
FRONT SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOL
927680000 INSTALLER & Used for replacing front arm front bushing.
REMOVER SET
ST-927680000
20099AE020 INSTALLER & Used for replacing pillow ball bushing of alumi-
REMOVER num front arm.
ST20099AE020
28099PA010 HOUSING STAND • Used for removing pillow ball bushing of alumi-
num front arm.
• Used together with INSTALLER & REMOVER
(20099AE020).
ST28099PA010
18723AA000 REMOVER • Used for assembling pillow ball bushing of alu-
minum front arm.
(20099AE020).
ST18723AA000
FS-6
General Description
FRONT SUSPENSION

20299AG000 REMOVER • Used for replacing front arm rear bushing.
• Used together with BASE (20299AG010).
ST20299AG000
20299AG010 BASE • Used for replacing front arm rear bushing.
• Used together with REMOVER
(20299AG000).
ST20299AG010
20299AG020 STUD BOLT Used for removing and installing the stud bolt for
SOCKET front arm installing portion.
ST20299AG020
20399AG000 STRUT MOUNT Used for disassembling and assembling strut
SOCKET mount.
ST20399AG000
2. GENERAL TOOL
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.
FS-7
Wheel Alignment
FRONT SUSPENSION
2. Wheel Alignment
A: INSPECTION
Check the following items before performing the wheel alignment measurement.
• 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-11, CASTER, INSPECTION, Wheel Alignment.>
↓
Steering angle
<Ref. to FS-12, STEERING ANGLE, INSPECTION, Wheel Alignment.>
↓
Front wheel toe-in
<Ref. to FS-12, 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-8
Wheel Alignment
FRONT SUSPENSION
1. WHEEL ARCH HEIGHT

1) Park the vehicle on a level surface.
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 suspension 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 (FS-00442)) and affix at a position directly
above the center of wheel.
5) Measure the distance between the point “A” (end of curve) and the center of wheel.
(2) (3)
A
(1)
(1) A
A
(6)
(7)
(4) (5) (1)
(8)
FS-00442
(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))
Front 376 (14.8) 371 (14.6)
Rear 370 (14.6) 365 (14.4)
FS-9
Wheel Alignment
FRONT SUSPENSION
2. CAMBER 3) Turn the camber adjusting bolt so that the cam-

ber is set at specification.
• Inspection
NOTE:
1) Place the front wheel on the turning radius
gauge. Make sure the ground contact surfaces of Moving the adjusting bolt by one scale changes the
the front and rear wheels are at the same height. camber by approximately 0°15′.
2) Set the adapter into the center of wheel, and (1)
then set the wheel alignment gauge.
(3)
(4) (5)
(6) (7)
(1)
(2)
FS-00213
(1) Alignment gauge

(2) Turning radius gauge
(3) Adapter
3) Measure the camber angle in accordance with

(2)
the operation manual for wheel alignment gauge.
Camber (Difference between (3)
Model FS-00008
RH and LH 45′ or less)
Except for STI model –0°50′±0°45′
(1) Strut
STI model –0°45′±0°45′
(2) Adjusting bolt
• Front camber adjustment (3) Housing
(4) Outer
1) When adjusting the camber, adjust it to the fol-
(5) Inner
lowing value.
(6) Camber is increased.
Camber (Difference between (7) Camber is decreased.
Model
RH and LH 30′ or less)
Except for STI model –0°50′±0°30′
STI model –0°45′±0°30′
2) Loosen the two flange 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
flange nut.
FS-10
Wheel Alignment
FRONT SUSPENSION
To increase camber.
Rotate the left side counterclockwise. Rotate the right side clockwise.
FS-00009 FS-00010
To decrease camber.
Rotate the left side clockwise. Rotate the right side counterclockwise.
FS-00010 FS-00009
4) Tighten two new flange nuts. 3. CASTER

Tightening torque: • Inspection
155 N·m (15.8 kgf-m, 114.3 ft-lb) 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)
(1)
(2)
FS-00213
(1) Alignment gauge

(2) Turning radius gauge
(3) Adapter
3) Measure the caster angle in accordance with the

operation manual for wheel alignment gauge.
Model Caster
Except for STI model 6°30′
STI model 6°30′
FS-11
Wheel Alignment
FRONT SUSPENSION
4. STEERING ANGLE 4) Measure the distance “B” between the left and
right marks. Find toe-in using the following calcula-
• Inspection
tion:
1) Place the vehicle on turning radius gauge.
A – B = Toe-in
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. B A
Model Inner wheel Outer wheel

Except for STI model 36.6°±1.5° 32.2°±1.5°
STI model 36.6°±1.5° 32.2°±1.5°
• Adjustment
1) Turn the tie-rod to adjust the steering angle of FS-00015
both inner and outer wheels.
2) Check the toe-in. • Adjustment
NOTE: When adjusting the toe-in, adjust it to the following
Correct the boot if it is twisted. value.
Toe-in:
0±2 mm (0±0.08 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.
(1) 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
FS-00014
threaded. To increase toe-in, turn both tie-rods
clockwise by equal amount (viewing from the inside
(1) Lock nut of vehicle).
5. FRONT WHEEL TOE-IN

• Inspection
Toe-in:
0±3 mm (0±0.12 in)
1) Set the toe-in gauge in the position at wheel axis (1)
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
FS-00014
marks.
3) Move the vehicle forward to rotate the tires 180°. (1) Lock nut
NOTE:
Be sure to rotate the tires in the forward direction. 4) Tighten the tie-rod lock nut.
Tightening torque:
85 N·m (8.7 kgf-m, 62.7 ft-lb)
NOTE:
Check and correct the tie-rod boot if twisted.
FS-12
Wheel Alignment
FRONT SUSPENSION
6. REAR WHEEL TOE-IN

• Inspection
Toe-in:
0±3 mm (0±0.12 in)
Refer to FRONT WHEEL TOE-IN for rear toe-in in-
spection procedures. <Ref. to FS-12, FRONT
WHEEL TOE-IN, INSPECTION, Wheel Align-
ment.>
• Adjustment
When adjusting, adjust it to the following value.
Toe-in:
0±2 mm (0±0.08 in)
1) Loosen the self-locking nut on the inner side of
front lateral ink.
NOTE:
When loosening or tightening the adjusting bolt,
hold the bolt head and turn the self-locking nut.
(2)
(1)
FS-00372
(1) Adjusting bolt

(2) Lateral link
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
graduation changes toe-in by approx. 1.3 mm (0.05
in).
FS-13
Wheel Alignment
FRONT SUSPENSION
To increase toe-in.
Rotate the left side clockwise. Rotate the right side counterclockwise.
FS-00018 FS-00019
To decrease toe-in.
Rotate the left side counterclockwise. Rotate the right side clockwise.
FS-00019 FS-00018
3) Attach and tighten a new self-locking nut.

Tightening torque:
100 N·m (10.2 kgf-m, 73.8 ft-lb)
FS-14
Wheel Alignment
FRONT SUSPENSION
7. THRUST ANGLE 3) When the left and right adjusting bolts are turned
by one graduation, the thrust angle will change ap-
• Inspection
prox. 15′ (“L” is approx. 11 mm (0.43 in)).
1) Park the vehicle on a level surface.
NOTE:
2) Move the vehicle 3 to 4 meters (10 to 13 feet)
Thrust angle is a mean value of left and right wheel
straight forward.
toe angles in relation to the vehicle body center
3) Draw the center of loci for both the front and rear
line. Vehicle is driven straight in the thrust angle di-
axles.
rection while slanting in the oblique direction de-
4) Measure distance “L” between the center lines of pending on the degree of the mean thrust angle.
the axle loci.
(1)
Thrust angle
0°±30′ (3)
Less than 30′ when “L” is 23 mm (0.9 in) or
less (2)
(1)
FS-00024
(1) Front
(2) Thrust angle
(2) (3) Body center line
Thrust angle: γ = (α – β)/2

α: Rear RH wheel toe-in angle
β: Rear LH wheel toe-in angle
Substitute only the positive toe-in values from each
wheel into α and β in the calculation.
(1) (2)
L
FS-00022
(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)
FS-00976
• Adjustment
(1) Front
When adjusting, adjust it to the following value.
(2) Body center line
Thrust angle
0°±20′
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.
FS-15
Front Crossmember Support Plate

FRONT SUSPENSION
3. Front Crossmember Support

Plate
A: REMOVAL
2) Remove the front under cover. <Ref. to EI-28,
REMOVAL, Front Under Cover.>
3) Remove the bolt, and remove the front cross-
member support plate.
FS-00104
B: INSTALLATION
Install each part in the reverse order of removal.
Tightening torque:
60 N·m (6.1 kgf-m, 44.3 ft-lb)
FS-16
Front Stabilizer
FRONT SUSPENSION
4. Front Stabilizer B: INSTALLATION

A: REMOVAL
1) Lift up the vehicle, and then remove the front CAUTION:
wheels. • Use a new flange nut.
2) Remove the front under cover. <Ref. to EI-28, • Ensure the stabilizer bushing and stabilizer
REMOVAL, Front Under Cover.> have the same identification colors.
3) Remove the front crossmember support plate. • Install the stabilizer bushing (front cross-
<Ref. to FS-16, REMOVAL, Front Crossmember member side) while aligning it with the paint
Support Plate.> mark on stabilizer.
4) Remove the stabilizer link. • The stabilizer bracket has a set orientation.
Install it with the arrow mark facing the upper
side of the vehicle.
(1)
FS-00262
5) Remove the stabilizer bracket. FS-00116
(1) Front side of vehicle
Tightening torque:
Stabilizer link:
38 N·m (3.9 kgf-m, 28.0 ft-lb)
Stabilizer bracket:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
Tie-rod end (castle nut):
27 N·m (2.75 kgf-m, 19.9 ft-lb)
FS-00114
C: INSPECTION
1) Check the bushing for abnormal cracks, fatigue
or damage.
2) Check the stabilizer link for damage.
FS-17
Front Ball Joint

FRONT SUSPENSION
5. Front Ball Joint B: INSTALLATION

1) Insert the ball joint into housing.
A: REMOVAL
wheels. Do not apply grease to the tapered portion of
2) Remove the front under cover. <Ref. to EI-28, ball stud.
REMOVAL, Front Under Cover.> Tightening torque (Bolt):
3) Remove the bolt, and remove the front cross- 50 N·m (5.1 kgf-m, 36.9 ft-lb)
member support plate. 2) Install the ball joint into front arm.
Tightening torque (Castle nut):
39 N·m (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
FS-00104
with the arrow mark facing the upper side of the ve-
4) Remove the both sides of stabilizer bracket. hicle.
(1)
FS-00114 FS-00116
5) Pull out the pin from ball stud, remove the castle
nut, and extract the ball stud from front arm.
6) Remove the bolt installing ball joint to housing. Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
5) Install the front crossmember support plate.
Tightening torque:
60 N·m (6.1 kgf-m, 44.3 ft-lb)
6) Install the front wheels.
FS-00115
7) Extract the ball joint from housing.
FS-18
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 lbf) loaded in direc-
tion shown in the figure, measure the length L1.
FS-00035
(2) With 686 N (70 kgf, 154 lbf) loaded in direc-

tion shown in the figure, measure the length L2.
FS-00036
(3) Determine free play using the following for-

mula.
S = L2 – L1
(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-19
Front Arm
FRONT SUSPENSION
6. Front Arm ST 20299AG020 STUD BOLT SOCKET
A: REMOVAL
1) Lift up the vehicle, and then remove the front
wheels. (1)
2) Remove the front crossmember support plate.
<Ref. to FS-16, REMOVAL, Front Crossmember
Support Plate.> (2)
3) Remove the front stabilizer. <Ref. to FS-17, RE-

MOVAL, Front Stabilizer.>
ST
4) Remove the ball joint of front arm. FS-00279
(1) Vehicle body

(2) Stud bolt
B: INSTALLATION
1) Using the ST, install the stud bolt. (Except for
STI model)
ST 20299AG020 STUD BOLT SOCKET
Tightening torque:
FS-00106
110 N·m (11.2 kgf-m, 81.1 ft-lb)
5) Remove the nut securing the front arm to cross- 2) Using new bolts and self-locking nuts, temporari-
member. (Do not remove the bolt.) ly tighten the front arm to crossmember.
3) Attach the support plate.
Secure the front arm to body, and then install the
support plate with new bolts and self-locking nuts.
• STI model
Secure the front arm to body, and then install the
support plate with new bolts.
Tightening torque:
Support plate to Front arm:
FS-00107 Except for STI model: 110 N·m (11.2 kgf-m,
6) Remove the front arm support plate. 81.1 ft-lb)
STI model: 140 N·m (14.3 kgf-m, 103.3 ft-lb)
Support plate to Body:
150 N·m (15.3 kgf-m, 110.6 ft-lb)
4) Install the ball joint into housing.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
5) Install the stabilizer. <Ref. to FS-17, INSTALLA-
TION, Front Stabilizer.>
FS-00108 7) Lower the vehicle from lift, and tighten the bolt
which secures the front arm to crossmember with
7) Remove the bolt securing front arm to cross-
wheels in full contact with the ground and the vehi-
member and pull the front arm out of the cross-
cle at curb weight.
member.
8) To remove the stud bolt, use the ST. (Except for Tightening torque:
STI model) 95 N·m (9.7 kgf-m, 70.1 ft-lb)
CAUTION: 8) Inspect the wheel alignment and adjust if neces-
Do not remove the stud bolt unnecessarily. Al- sary.
ways replace the parts with new parts when re-
moved.
FS-20
Front Arm
FRONT SUSPENSION
C: DISASSEMBLY 2) Using the ST and a press, remove the rear bush-

ing.
1. FRONT BUSHING ST1 20299AG000 REMOVER
Using the ST and a press, remove the front bush- ST2 20299AG010 BASE
ing. (1)
ST 927680000 INSTALLER & REMOVER
SET ST1
(2)
ST2
ST
(3) FS-00126
(1) Press
FS-00110 (2) Front arm
(3) Rear bushing
2. REAR BUSHING
Steel front arm Aluminum front arm
1) Put an alignment mark on the front arm based on 1) Put an alignment mark on the front arm based on
the center of rear bushing recess portion. the center of pillow ball bushing recess portion.
CAUTION: CAUTION:
Always put an alignment mark for aligning the Always put an alignment mark for aligning the
position on bushing installation. position on bushing installation.
(1) (1)
(2) (2)
(1) (1)
FS-00111 FS-00440
(1) Put an alignment mark. (1) Put an alignment mark.

(2) Recess section (2) Recess section
FS-21
Front Arm
FRONT SUSPENSION
2) Using the ST and a press, remove the pillow ball D: ASSEMBLY

bushing.
ST1 20099AE020 INSTALLER & REMOVER 1. FRONT BUSHING
ST2 28099PA010 HOUSING STAND Assemble each part in the reverse order of disas-
sembly.
(1) 2. REAR BUSHING
(4) Steel front arm
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
ST1 figure.
(2)
(1)
(5)
(3)
(3)
(4)
(2)
ST2
FS-00113
(1) Front arm

FS-00425 (2) Bushing inner cylinder
(3) Longer
(1) Press (4) Shorter
(2) Front arm (5) Protrusion portion
(3) Pillow ball bushing
(4) Plate 2) Align the center of rear bushing recess portion
with the aligning mark on the front arm.
NOTE:
Place the plate on the ST1 to use the press.
(1)
(2)
(1)
FS-00111
(1) Alignment mark

(2) Recess section
FS-22
Front Arm
FRONT SUSPENSION
3) Using the ST and a press, install the rear bush- 3) Using the ST and a press, install the rear bush-
ing. ing.
ST1 20299AG000 REMOVER ST1 20299AE020 INSTALLER & REMOVER
ST2 20299AG010 BASE ST2 18723AA000 REMOVER ASSY (GEAR
(1)
DRIVEN)
ST1
(2)
(3)
(1)
(4)
ST2
FS-00127
ST1
(1) Press
(2) Front arm
(3) Rear bushing (2) (3)
Aluminum front arm

1) Install the pillow ball bushing with its longer inner
ST2
cylinder facing upward and the shorter facing
downward as shown in the figure.
(1) FS-00426
(3)
(1) Press
(2) Front arm
(3) Rear bushing
(4) (4) Plate
(2)
FS-00441
NOTE:
Place the plate on the ST1 to use the press.
(1) Front arm
E: INSPECTION
(2) Bushing inner cylinder
1) Check the front arm for damage or cracks, and
(3) Longer
correct or replace if defective.
(4) Shorter
2) Check the bushing for abnormal fatigue or dam-
2) Align the center of rear bushing recess portion age.
with the aligning mark on the front arm. 3) Check the pillow ball bushing for damage or
cracks, and replace if defective.
4) Try to wobble the pillow ball bushing. Replace
(1) the pillow ball bushing if backlash or resistance are
found.
(2)
(1)
FS-00440
(1) Alignment mark

(2) Recess section
FS-23
Front Strut
FRONT SUSPENSION
7. Front Strut 6) Remove the three nuts securing strut mount to

body.
A: REMOVAL
wheels.
2) Place an alignment mark on the camber adjust-
ing bolt and strut.
3) Remove the brake hose bracket.
FS-00037
4) Remove the bolt securing the ABS wheel speed

sensor harness.
FS-00039
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 N·m (2.0 kgf-m, 14.8 ft-lb)
FS-00038
2) Align alignment marks on the camber adjusting
bolt and strut.
5) Remove the two bolts securing the housing to Using new flange nuts, install the strut to the hous-
the strut. ing.
NOTE: NOTE:
While holding the head of the adjusting bolt, loosen While holding the head of adjusting bolt, tighten the
the flange nut. flange nut.
Tightening torque:
155 N·m (15.8 kgf-m, 114.3 ft-lb)
3) Secure the ABS wheel speed sensor harness to
the strut.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
4) Install the brake hose bracket.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
6) Inspect the wheel alignment and adjust if neces-
sary.
FS-24
Front Strut
FRONT SUSPENSION
C: DISASSEMBLY 2) Set the coil spring correctly so that its end face
seats well in the spring seat as shown in the figure.
1) Using a coil spring compressor, compress the
coil spring.
(1)
FS-00043
FS-00040 (1) Coil spring end face

2) Using the ST, remove the self-locking nut.
ST 20399AG000 STRUT MOUNT SOCKET 3) Install the dust cover to the piston rod.
4) Pull the piston rod fully upward, and install the
spring seat.
ST
NOTE:
Position the upper spring seat as shown in the fig-
ure.
FS-00041
3) Remove the strut mount and upper spring seat

from strut.
4) Gradually decrease the compression force of
compressor, and remove the coil spring. (1)
5) Remove the dust cover. FS-00128
D: ASSEMBLY (1) Outside of body

1) Using a coil spring compressor, compress the
5) Install the strut mount and spacer to piston rod,
coil spring.
and temporarily attach and tighten a new self lock-
NOTE: ing nut.
Make sure that the vertical install direction of the 6) Using a hexagon wrench to prevent strut rod
coil spring is as shown in the figure. from turning, tighten the new self-locking nut with
(1) ST.
ST 20399AG000 STRUT MOUNT SOCKET
(2) Tightening torque:
55 N·m (5.6 kgf-m, 40.6 ft-lb)
ST
(3)
FS-00042
(1) Diameter is small (upper part)

(2) Identification paint
(3) Diameter is large (bottom part)
FS-00041
7) Loosen the coil spring compressor carefully.
FS-25
Front Strut
FRONT SUSPENSION
E: INSPECTION F: DISPOSAL
Check the removed part for wear, damage and CAUTION:
cracks, and then repair or replace it if defective. • Before handling struts, be sure to wear gog-
1. STRUT gles to protect eyes from gas, oil and cutting
powder.
1) Check for oil leaks. • Do not disassemble the strut damper or
2) Move the piston rod up and down to check that it throw into flames.
operates smoothly without any hitch. • When discarding gas filled struts, drill holes
3) Piston rod play in them to purge the gas.
• Measure the play as follows: 1) Place the strut on a level surface with the piston
Fix the outer shell in place and fully extend the rod. rod fully expanded.
Set a dial gauge at the end of rod L [10 mm (0.39 2) Using a 2 — 3 mm (0.08 — 0.12 in) dia. drill,
in)], and then read the dial gauge indication P1 make a hole into the position (1) first, and then (2).
while applying a force of W [20 N (2 kgf, 4 lbf)] to
the threaded portion. Apply a force of 20 N (2 kgf, 4
lbf) from the opposite direction of “W”, and then (3)
read the dial gauge indication P2.
(1) (2)
(4)
L FS-00096
(1) 20 mm (0.78 in)

(2) 10 mm (0.39 in)
FS-00046
(3) Strut
Play limit (P1 + P2): (4) Damping tube
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 cracks or damage are found, replace 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. (Except for STI model)
FS-26
Front Crossmember
FRONT SUSPENSION
8. Front Crossmember B: INSTALLATION

1) Install each part in the reverse order of removal.
A: REMOVAL
wheels. • Use a new bolt and self-locking nut. For parts
2) Remove the front exhaust pipe. which are not reusable, refer to COMPONENT.
<Ref. to FS-3, COMPONENT, General Descrip-
3) Remove the front crossmember support plate.
tion.>
<Ref. to FS-16, REMOVAL, Front Crossmember
Support Plate.> • Always tighten the bushing in the state where
the vehicle is at curb weight and the wheels are
4) Remove the front stabilizer. <Ref. to FS-17, RE-
in full contact with the ground.
MOVAL, Front Stabilizer.>
5) Disconnect the tie-rod ends from the housing. Tightening torque:
6) Remove the front arm. <Ref. to FS-20, REMOV- Crossmember to Body:
AL, Front Arm.> 95 N·m (9.7 kgf-m, 70.1 ft-lb)
7) Remove the nuts which install the engine mount- Engine mounting to Crossmember:
ing cushion rubber onto the crossmember. 45 N·m (4.6 kgf-m, 33.2 ft-lb)
Front arm to Crossmember:
95 N·m (9.7 kgf-m, 70.1 ft-lb)
Support plate to Front arm:
Except for STI model: 110 N·m (11.2 kgf-m,
81.1 ft-lb)
STI model: 140 N·m (14.3 kgf-m, 103.3 ft-lb)
Front arm to Support plate (except for STI
model):
110 N·m (11.2 kgf-m, 81.1 ft-lb)
FS-00118
Support plate body:
150 N·m (15.3 kgf-m, 110.6 ft-lb)
8) Remove the steering universal joint. Tie-rod end to Housing:
9) Disconnect the power steering hose from the 27 N·m (2.8 kgf-m, 19.9 ft-lb)
steering gearbox. After tightening to the specified torque, tighten the
10) Lift the engine by approx. 10 mm (0.39 in) by castle nut further but within 60° until the hole in the
using the chain block. ball stud is aligned with a slot in castle nut.
11) Support the crossmember with jack, remove
the bolts which secure the crossmember to the ve- Tightening torque:
hicle body, and gradually lower the crossmember Universal joint:
together with the steering gearbox. 24 N·m (2.4 kgf-m, 17.7 ft-lb)
CAUTION: Stabilizer bracket:
When removing the crossmember downward, 25 N·m (2.5 kgf-m, 18.4 ft-lb)
make sure that the tie-rod end does not inter- Stabilizer link:
fere with the drive shaft boot. 38 N·m (3.9 kgf-m, 28.0 ft-lb)
Power steering hose to Steering gearbox:
15 N·m (1.5 kgf-m, 11.1 ft-lb)
2) Purge air from the power steering system.
sary.
C: INSPECTION
Check the crossmember for damage or cracks, and
correct or replace if defective.
FS-00119
FS-27

FRONT SUSPENSION

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible cause Corrective action
(1) Permanent distortion or damage of the coil spring Replace.
(2) Rough operation of 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.
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
(1) Damaged coil spring Replace.
(2) Overinflation of tires Adjust.
(3) Improper wheel arch height Replace the coil springs with new parts.
(4) Fault in operation of strut or shock absorber Replace.
(5) Damage or deformation of strut mount or shock absorber mount Replace.
(6) Unsuitable length (maximum or minimum) of strut or shock absorber Replace with appropriate parts.
(7) Abnormal deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly or shock absorber Replace.
(9) Oil leakage from the strut or shock absorber Replace.
3. NOISE
(1) Wear or damage of strut or shock absorber component parts Replace.
(2) Loosening of the suspension link installing bolt Tighten to the specified torque.
(3) Abnormal deformation or loss of bushing Replace.
(6) Wear or damage of the ball joint Replace.
(7) Deformation of the stabilizer clamp Replace.
FS-28
REAR SUSPENSION
RS
Page
2. Wheel Alignment ........................................................................................8
3. Rear Stabilizer ............................................................................................9
4. Rear Trailing Link .....................................................................................10
5. Upper Arm ................................................................................................13
6. Rear Shock Absorber ...............................................................................14
7. Front Lateral Link .....................................................................................15
8. Rear Lateral Link ......................................................................................16
9. Rear Sub Frame .......................................................................................17
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 is not
equipped with adjustment mechanisms. If other
items exceed specifications, check the suspension
parts and connections for deformation. If defective,
replace with new parts.
(1)
A
FS-00269
(1) Front
A – B = Positive: Toe-in, Negative: Toe-out
α = Individual toe angles
RS-2
General Description
REAR SUSPENSION
B: COMPONENT
1. REAR SUSPENSION
(2)
T1
(17) (1)
T5
(3)
(22) (2)
(24)
(17)
(16) T1
T8 (5)
(4)
(21)
T8
T2
(24) (6)
T6 T5
(22) (2)
T2
(20)
T7 (2)
(13) (21)
(2)
(21)
(14) (2)
T6 (7)
(19) (15)
(9) (24) (2)
T3
T5
(18) (12) T6
(11) (8)
(23) (2)
(10) T5
(24)
T8 (24)
T4
(2)
T6
(24)
RS-00383
(1) Shock absorber (13) Front lateral link bushing Tightening torque:N·m (kgf-m, ft-lb)
(2) Self-locking nut (14) Snap pin T1: 30 (3.1, 22.1)
(3) Rear stabilizer (15) Front sub frame support plate T2: 38 (3.9, 28)
(4) Stabilizer bushing (16) Rear sub frame T3: 60 (6.1, 44.3)
(5) Stabilizer clamp (17) Rear sub frame stopper plate T4: 70 (7.1, 51.6)
(lower)
(6) Stabilizer link (18) Adjusting bolt T5: 80 (8.2, 59)
(7) Rear lateral link (19) Adjusting washer T6: 90 (9.2, 66.4)
(8) Rear housing (20) Rear lateral link bushing T7: 100 (10.2, 73.8)
(9) Upper arm (21) Flange nut T8: 145 (14.8, 106.9)
(10) Trailing link (22) Rear sub frame stopper plate
(upper)
(11) Trailing link bushing (23) Rear housing bushing
(12) Front lateral link (24) Bolt
RS-3
General Description
REAR SUSPENSION
2. SHOCK ABSORBER
(4)
(6)
(1)
(2)
(3)
(5)
(7)
RS-00286
(1) Mount (5) Shock absorber Tightening torque: N·m (kgf-m, ft-lb)
(2) Upper rubber sheet (6) Self-locking nut T: 25 (2.5, 18.4)
(3) Dust cover (7) Helper
(4) Coil spring
RS-4
General Description
REAR SUSPENSION
C: CAUTION
Please clearly understand and adhere to the following general precautions. They must be strictly followed to
avoid minor or serious injury to the person doing the work or people in the area.
1. CAUTIONS
any work.
• Before disposing of shock absorbers, be sure to bleed the gas out completely. Also, do not expose to
flames or fire.
turers.
2. OIL
When handling oil, adhere to the following to prevent unexpected accident.
• Prepare container and waste cloths when performing work which oil could possibly spill. If oil spills, wipe
it off immediately to prevent from penetrating into floor or flowing outside, for environmental protection.
• Follow all government regulations concerning disposal of refuse when disposing.
D: PREPARATION TOOL
1. SPECIAL TOOL
20099AE000 INSTALLER & Used for replacing the front lateral link bushing.
REMOVER
ST20099AE000
499755602 PRESS Used for replacing the rear trailing link bushing.
ST-499755602
RS-5
General Description
REAR SUSPENSION

20099AE010 INSTALLER & Used for replacing the rear lateral link bushing.
REMOVER
ST20099AE010
20299AG010 BASE Used for replacing the rear trailing link bushing.
ST20299AG010
899874100 INSTALLER Used for replacing the rear trailing link bushing.
ST-899874100
20399FG000 STRUT MOUNT • Used for removing and installing shock mount.
SOCKET • Used for checking torque of shock mount cen-
ter nut.
ST20399FG000
28099PA090 OIL SEAL PROTEC- • Used for installing the rear drive shaft to the
TOR rear differential.
• For oil seal protection
ST28099PA090
RS-6
General Description
REAR SUSPENSION

20099PA010 INSTALLER & • Used for replacing the bushing of the rear
REMOVER housing.
• Used together with BUSHING REMOVER
(20099FG000).
ST20099PA010
20099FG000 BUSHING • Used for replacing the bushing of the rear
REMOVER housing.
(20099PA010).
ST20099FG000
2. GENERAL TOOL
TOOL NAME REMARKS
Alignment tester Used for measuring wheel alignment.
Toe-in gauge Used for toe-in measurement.
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 Install each part in the reverse order of removal.

Tightening torque:
A: REMOVAL Stabilizer link
1) Lift up the vehicle, and then remove the rear 38 N·m (3.9 kgf-m, 28 ft-lb)
wheels. Stabilizer clamp
2) Remove the stabilizer link. 30 N·m (3.1 kgf-m, 22.1 ft-lb)
C: INSPECTION
1) Check the bushing for abnormal cracks, fatigue
or damage.
2) Check the stabilizer link for damage.
RS-00251
3) Remove the stabilizer clamp.
RS-00252
B: INSTALLATION
CAUTION:
• Be sure to use a new flange nut and self-lock-
ing nut.
• Always tighten the bushing in the state where
• Align the paint mark end of stabilizer to the
end of bushing when installing.
(1)
(2)
RS-00273
(1) Identification paint

(2) Bushing
RS-9
Rear Trailing Link

REAR SUSPENSION
4. Rear Trailing Link C: DISASSEMBLY

A: REMOVAL 1. REAR TRAILING LINK BUSHING
1) Lift up the vehicle, and then remove the rear Using the ST A and ST B, press the bushing out.
wheels. ST A 8998741000 INSTALLER
2) Remove the bracket, and remove the parking ST B 499755602 PRESS
brake cable from the guide.
ST-A
(1)
RS-00253
(1) Guide
3) Remove the trailing link.
ST-B
RS-00255
RS-00254
B: INSTALLATION
CAUTION:
• Be sure to use a new self-locking nut.
Tightening torque:
90 N·m (9.2 kgf-m, 66.4 ft-lb)
RS-10
Rear Trailing Link

REAR SUSPENSION
2. REAR HOUSING BUSHING D: ASSEMBLY

1) Remove the rear housing. <Ref. to DS-20, RE-
MOVAL, Rear Axle.>
1. REAR TRAILING LINK BUSHING
2) Using the ST and a hydraulic press, push out the Using the ST A and ST B, press-fit the bushing.
bushing. CAUTION:
ST 1 200099FG000 BUSHING REMOVER Make sure to press the bushing straight in.
ST 2 20099PA010 INSTALLER & REMOVER ST A 8998741000 INSTALLER
(BASE) ST B 20299AG010 BASE
ST1
ST-A
ST2
DS-00458
ST1
ST-B
(1) RS-00256
(2)
ST2
DS-00459
(1) Rear housing

(2) Bushing
RS-11
Rear Trailing Link

REAR SUSPENSION
2. REAR HOUSING BUSHING

Press-fit the bushing using ST and the hydraulic
press.
CAUTION:
Make sure to press the bushing straight in.
ST 1 20099FG000 BUSHING REMOVER
ST 2 20099PA010 INSTALLER & REMOVER
(BASE)
ST1
(2)
(1)
ST2
RS-00381
ST1
(1)
(2)
ST2
DS-00461
(1) Rear housing

(2) Bushing
E: INSPECTION
Perform visual check for damage or bend on the
trailing link.
RS-12
Upper Arm
REAR SUSPENSION
5. Upper Arm
A: REMOVAL
1) Remove the rear sub frame. <Ref. to RS-17, RE-
MOVAL, Rear Sub Frame.>
2) Remove the rear ABS wheel speed sensor
bracket.
RS-00257
3) Remove the bolts, then remove the upper arm.
RS-00258
B: INSTALLATION
CAUTION:
• Always tighten the bushing when the arm is
positioned in the state where the vehicle is at
curb weight and the wheels are in full contact
with the ground.
sary.
Tightening torque:
Upper arm — Rear sub frame
90 N·m (9.2 kgf-m, 66.4 ft-lb)
Upper arm — Rear housing
80 N·m (8.2 kgf-m, 59 ft-lb)
Rear ABS wheel speed sensor bracket
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
1) Visually check the upper arm for damage and
deformation.
2) Visually check the bushing for abnormal cracks,
fatigue or damage.
RS-13
Rear Shock Absorber

REAR SUSPENSION
6. Rear Shock Absorber D: ASSEMBLY

Refer to “Front Strut” for installation procedures.
A: REMOVAL <Ref. to FS-25, ASSEMBLY, Front Strut.>
1) Remove the luggage floor mat. (5 door model)
2) Remove the strut cap of the quarter trim. E: INSPECTION
3) Remove the trunk room mat. (4 door model) Refer to “Front Strut” for inspection procedures.
4) Lift up the vehicle, and then remove the rear <Ref. to FS-26, INSPECTION, Front Strut.>
wheels.
5) Remove the nut and disconnect the rear stabiliz-
F: DISPOSAL
er link. CAUTION:
6) Remove the shock absorber lower bolt. • Before handling the shock absorber, be sure
7) Disconnect the rear lateral link. 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.
RS-00260
8) Remove the shock absorber mount nut.
(1)
RS-00135
RS-00261 (1) 40 mm (1.57 in)
9) Remove the shock absorber.

B: INSTALLATION
CAUTION:
Tightening torque:
Refer to “COMPONENT” of “General Descrip-
tion” for the tightening torque. <Ref. to RS-3,
COMPONENT, General Description.>
2) Check the wheel alignment and adjust it if nec-
essary.
C: DISASSEMBLY
Refer to “Front Strut” for disassembly procedure.
<Ref. to FS-25, DISASSEMBLY, Front Strut.>
RS-14
Front Lateral Link

REAR SUSPENSION
7. Front Lateral Link B: INSTALLATION

A: REMOVAL CAUTION:
1) Lift up the vehicle, and then remove the rear • Always tighten the bushing in the state where
wheels. the vehicle is at curb weight and the wheels are
2) Remove the rear trailing link. <Ref. to RS-10, in full contact with the ground.
REMOVAL, Rear Trailing Link.> 1) Install each part in the reverse order of removal.
3) Remove the snap pin and nut.
Tightening torque:
(1)
Front lateral link — Sub frame
100 N·m (10.2 kgf-m, 73.8 ft-lb)
Front lateral link — Rear axle housing
(2) 60 N·m (6.1 kgf-m, 44.3 ft-lb)
sary.
C: INSPECTION
Visually check the front lateral link for damage and
RS-00189 deformation.
(1) Snap pin D: DISASSEMBLY
(2) Nut Using the ST A and ST B, press the bushing out.
ST A 20099AE000 INSTALLER & REMOVER
4) Using a puller, remove the ball joint.
ST B 20099AE000 INSTALLER & REMOVER
ST-A
ST-B
RS-00190
RS-00192
5) Scribe an alignment mark on the front lateral link
adjusting bolt and rear sub frame. E: ASSEMBLY
6) Remove the adjusting bolt, and remove the front Using the ST A and ST B, press-fit the bushing.
lateral link.
CAUTION:
CAUTION: Make sure to press the bushing straight in.
When removing the adjusting bolt, make sure ST A 20099AE000 INSTALLER & REMOVER
to fix the bolt head in place when loosening the ST B 20099AE000 INSTALLER & REMOVER
nut.
RS-00262
RS-15
Rear Lateral Link

REAR SUSPENSION
8. Rear Lateral Link D: ASSEMBLY

Using the ST A and ST B, press-fit the bushing.
A: REMOVAL ST A 20099AE010 INSTALLER & REMOVER
1) Lift up the vehicle, and then remove the rear ST B 20099AE010 INSTALLER & REMOVER
wheels.
2) Remove the nut and disconnect the stabilizer
link.
ST-A
3) Remove the shock absorber lower bolt.
4) Remove the bolt, and remove rear lateral link.
ST-B
RS-00083
E: INSPECTION
Visually check the rear lateral link for damage and
deformation.
RS-00263
B: INSTALLATION
CAUTION:
Tightening torque:
Rear lateral link
80 N·m (8.2 kgf-m, 59.0 ft-lb)
Shock absorber
80 N·m (8.2 kgf-m, 59.0 ft-lb)
Stabilizer link
38 N·m (3.9 kgf-m, 28 ft-lb)
sary.
C: DISASSEMBLY
Using the ST A and ST B, press the bushing out.
ST A 20099AE010 INSTALLER & REMOVER
ST B 20099AE010 INSTALLER & REMOVER
ST-A
ST-B
RS-00083
RS-16
Rear Sub Frame

REAR SUSPENSION
9. Rear Sub Frame 9) Disconnect the ABS wheel speed sensor con-
nector.
A: REMOVAL
1) Lift up the vehicle, and then remove the rear
wheels.
2) Separate the front exhaust pipe and rear ex-
haust pipe.
5) Remove the rear ABS wheel speed sensor from
the rear housing. RS-00266
10) Remove the shock absorber lower bolt.
FU-03357
6) Remove the brake hose bracket from rear hous- RS-00267

ing.
11) Support the sub frame using a jack.
12) Remove the support plate.
RS-00264
7) Remove the rear disc brake caliper, and sus- RS-00268

pend it from the shock absorber. (Disc brake mod-
el) 13) Remove the rear sub frame.
RS-00269
FU-03358
8) Remove the rear parking brake cable from the

parking brake assembly. <Ref. to PB-6, REMOV-
AL, Parking Brake Assembly (Rear Disc Brake).>
RS-17
Rear Sub Frame

REAR SUSPENSION
B: INSTALLATION
CAUTION:
Tightening torque:
Refer to “COMPONENT” of “General Descrip-
tion” for the tightening torque. <Ref. to RS-3,
COMPONENT, General Description.>
sary.
C: INSPECTION
Check the removed parts for wear, damage and
crack, and repair or replace them if faulty.
RS-18

REAR SUSPENSION

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
(1) Permanent distortion or damaged coil spring Replace.
(2) Rough operation of 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. 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
(2) Overinflation of tires Adjust.
(3) Improper wheel arch height Replace the coil springs with new parts.
(4) Fault in operation of strut or shock absorber Replace.
(5) Damage or deformation of strut mount or shock absorber mount Replace.
(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 strut or shock absorber Replace.
3. NOISE
(1) Wear or damage of strut or shock absorber component parts Replace.
(2) Loosening of the suspension link installing bolt Tighten to the specified torque.
(3) Deformation or loss of bushing Replace.
(6) Wear or damage of the ball joint Replace.
(7) Deformation of the stabilizer clamp Replace.
RS-19
WHEEL AND TIRE SYSTEM
WT
Page
2. Tire and Wheel ...........................................................................................4
3. “T-type” Tire ...............................................................................................7
4. Tire Pressure Monitoring System ...............................................................8
General Description
A: SPECIFICATION
WT-00001
(1) Inset
(2) P.C.D.
Tire inflation pressure

Inset P.C.D. kPa (kgf/cm2, psi)
Model Tire size Wheel size
mm (in) mm (in)
Front wheel Rear wheel
Standard type 245/40R18 93W 18 × 81/2J 55 (2.17)
STI model 114.3 (4.50)
“T-type” Tire T135/70D17 102M 17 × 4T 30 (1.18) *1
Except for STI Standard type 235/45R17 94W 17 × 8J 53 (2.09)
100 (3.94)
model “T-type” Tire T135/70D17 102M 17 × 4T 30 (1.18)
*1: Size and inflation pressure of the standard equipment tire, spare tire for emergency and appropriate tire for equipment are de-
scribed on the “Tire inflation pressure” label attached to the body side of the driver’s door.
NOTE:
“T-type” tire for temporary use is equipped as a spare tire.
1. SERVICE DATA
Part Axial runout Radial runout
Steel wheel 1.5 mm (0.059 in)
Aluminum wheel 1.0 mm (0.039 in)
WT-2
General Description
B: COMPONENT
(1)
T1
(3)
T2 (2)
(4)
WT-00168
(1) TPMS & keyless entry control (3) Transmitter (snap in type) Tightening torque: N·m (kgf-m, ft-lb)
module
(2) Screw (4) Valve T1: 1.4 (0.14, 1)
T2: 7.5 (0.76, 5.5)
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME REMARKS
Air pressure gauge Used for measuring tire air pressure.
Dial gauge Used for measuring wheel runout.
WT-3
Tire and Wheel

2. Tire and Wheel

A: REMOVAL
2) Remove the wheel nut.
3) Remove the wheels.
NOTE:
When removing the wheels, be careful not to damage the hub bolts.
B: INSTALLATION
1) Install the wheels to vehicle.
2) Tighten the wheel nuts to the specified torque.
Tightening torque:
100 N·m (10.2 kgf-m, 73.8 ft-lb)
C: INSPECTION
1. TIRES
CAUTION:
When replacing a tire, make sure to use only tires of the same size, construction and load range as
originally installed.
1) Tire size and tire inflation pressure check <Ref. to WT-2, SPECIFICATION, General Description.>
2) Cracks, damage and wear check
3) Tire runout check
(1) Lift up the vehicle.
(2) Slowly rotate the wheel to check rim “runout” using a dial gauge.
WT-00004
• Aluminum wheel
Axial runout limit Radial runout limit
1.0 mm (0.039 in)
• Steel wheel
Axial runout limit Radial runout limit
1.5 mm (0.059 in)
(3) If the rim runout exceeds service limit, replace the wheel.
WT-4
Tire and Wheel

2. TIRE ROTATION
NOTE:
Rotate tires periodically (12,500 km/7,500 miles) in order to prolong life and to prevent uneven wear.
Rotate tires as shown in the figure depending on whether or not the direction of the tire rotation is specified.
• When the direction of tire rotation is not specified
WT-00113
• When the direction of tire rotation is specified
WT-00115
WT-5
Tire and Wheel

3. WHEEL BALANCING
1) Using the wheel balancer, measure wheel balance.
2) Adjust the wheel balancing.
NOTE:
• Unbalance after adjusting the wheel balancing should be 5 g (0.18 oz) or less.
• When using the adhesive type weight, degrease the surface where the adhesive type weight will be ap-
plied securely.
• After applying the adhesive type weight, apply a force to the weight and attain full adhesion.
• Using the knock-on type weight, check the size of the knock-on part.
A
A
(1) (2)
WT-00107
(1) Knock-on type weight for aluminum wheel

(2) Knock-on type weight for steel wheel
Service limit A:
Knock-on type weight for steel wheel:
2.0 mm (0.079 in)
Knock-on type weight for aluminum wheel:
5.0 mm (0.197 in)
WT-6
“T-type” Tire
3. “T-type” Tire
A: NOTE
CAUTION:
• The “T-type” tire is only for temporary use.
Replace with a conventional tire as soon as
possible.
• Do not use tire chains for “T-type” tires. Be-
cause tire size is small, tire chains can not be
installed and will damage the vehicle and tires.
• Do not drive at a speed greater than 80 km/h
(50 MPH).
• Drive the vehicle as slowly as possible and
avoid bumps on the road.
“T-type” tire for temporary use is prepared as a
spare tire.
B: REPLACEMENT
CAUTION:
The “T-type” tire is only for temporary use. Re-
place with a conventional tire as soon as possi-
ble.
Refer to “Tire & Wheel” for removal and installation
of the “T-type” tire. <Ref. to WT-4, Tire and
Wheel.>
C: INSPECTION
Refer to “Tire & Wheel” for inspection of the “T-
type” tire. <Ref. to WT-4, TIRES, INSPECTION,
Tire and Wheel.>
WT-7
Tire Pressure Monitoring System

4. Tire Pressure Monitoring 5) Remove the bolt and then remove the TPMS &
keyless entry control module.
System • 5 door model
A: REMOVAL
1. TRANSMITTER (SNAP IN TYPE)
1) Remove the wheels from the vehicle. <Ref. to
WT-4, REMOVAL, Tire and 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 SL-00747
the valve stem. • 4 door model
NOTE:
Replace the valve and screw with a new part when
reusing transmitter.
(3) (4)
(2)
(1)
SL-00800
B: INSTALLATION
WT-00125 1. TRANSMITTER (SNAP IN TYPE)
(1) Wheel CAUTION:
(2) Transmitter Use the new transmitter assembly or replace
(3) Screw
the new valve and screw, when installing.
1) Replace the valve and screw with a new part
(4) Valve
when reusing transmitter.
4) Remove the valve from the wheel.
(1) (2)
2. TPMS & KEYLESS ENTRY CONTROL
MODULE
NOTE: (3)
TPMS control module is integrated into keyless en-
try control module.
2) Remove the left rear quarter trim. (5 door model)
<Ref. to EI-60, REMOVAL, Rear Quarter Trim.> WT-00167
3) Remove the rear shelf trim. (4 door model) <Ref.
to EI-62, REMOVAL, Rear Shelf Trim.> (1) Screw
4) Disconnect the harness connector. (2) Transmitter
(3) Valve
Tightening torque:
1.4 N·m (0.14 kgf-m, 1 ft-lb)
WT-8
Tire Pressure Monitoring System

2) Install the transmitter to the wheel by aligning it

with valve hole.
NOTE:
When using the jig that pulls the valve cap by hook-
ing its neck part, use another short-type cap.
3) Install the tires to wheels.
CAUTION:
• Use a tire changer when installing tire to
wheel.
• To prevent damaging the transmitter, set the
tire changer boom in the position as shown in
the figure.
(4)
(3)
(2) (5)
(6)
(1)
WT-00130
(1) Transmitter
(2) Direction of turn table rotation
(3) 135°
(4) Tire changer boom
(5) 90°
(6) Starting point for fitting the bead to the rim
4) Install the wheels to vehicle. <Ref. to WT-4, IN-

STALLATION, Tire and Wheel.>
5) Register the transmitter ID to the TPMS & key-
less entry control module. <Ref. to TPM(diag)-9,
REGISTER TRANSMITTER ID, OPERATION,
Subaru Select Monitor.>
2. TPMS & KEYLESS ENTRY CONTROL
MODULE
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
C: ADJUSTMENT
Re-register the transmitter ID when transmitter has
been replaced. <Ref. to TPM(diag)-9, REGISTER
TRANSMITTER ID, OPERATION, Subaru Select
Monitor.>
Re-register the keyless transmitter when TPMS &
keyless entry control module has been replaced.
<Ref. to SL-49, REGISTRATION OF KEYLESS
TRANSMITTER WITH SUBARU SELECT MONI-
TOR, REPLACEMENT, Transmitter.>
WT-9


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
Rear wheel alignment Check the rear wheel alignment. <Ref. to RS-
8, INSPECTION, Wheel Alignment.>
Front strut Check the front strut. <Ref. to FS-26,
INSPECTION, Front Strut.>
Rear shock absorber Check the rear shock absorber. <Ref. to RS-
14, INSPECTION, Rear Shock Absorber.>
Front axle Check the front axle. <Ref. to DS-17,
INSPECTION, Front Axle.>
Front hub unit bearing Check the front hub unit bearing. <Ref. to
DS-19, INSPECTION, Front Hub Unit Bear-
ing.>
Rear hub unit bearing Check the rear hub unit bearing. <Ref. to DS-
26, INSPECTION, Rear Hub Unit Bearing.>
Vehicle is abnormally out of Improperly inflated tire. Adjust the tire pressure.
balance. Uneven wear Check the tire referring to Abnormal tire wear
replace the tire.
Front stabilizer Inspect the front stabilizer. <Ref. to FS-17,
INSPECTION, Front Stabilizer.>
Abnormal wheel vibration Improperly inflated tire. Adjust the tire pressure.
Uneven wear Check the tire referring to Abnormal tire wear
replace the tire.
Improper wheel balancing Check the wheel balance. <Ref. to WT-6,
WHEEL BALANCING, INSPECTION, Tire
and Wheel.>
Front axle Check the front axle. <Ref. to DS-17,
INSPECTION, Front Axle.>
Front hub unit bearing Check the front hub unit bearing. <Ref. to
DS-19, INSPECTION, Front Hub Unit Bear-
ing.>
Rear hub unit bearing Check the rear hub unit bearing. <Ref. to DS-
26, INSPECTION, Rear Hub Unit Bearing.>
Abnormal tire wear Improperly inflated tire. Adjust the tire pressure.
Improper wheel balancing Check the wheel balance. <Ref. to WT-6,
WHEEL BALANCING, INSPECTION, Tire
and Wheel.>
WT-10
TIRE PRESSURE MONITORING SYSTEM

(DIAGNOSTICS)
TPM(diag)
Page
3. Electrical Component Location ..................................................................5
4. Control Module I/O Signal ..........................................................................6
5. Subaru Select Monitor ................................................................................7
7. Inspection Mode .......................................................................................13
9. Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern ...15

TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

A: PROCEDURE
CAUTION:
Remove foreign matter (dust, water, oil etc.) from the TPMS & keyless entry control module connec-
tor when removing and installing.
NOTE:
To check harness for open or short circuits, shake the suspected trouble spot or connector.
Step Check Yes No
1 CHECK PRE-INSPECTION. Is the component that might Go to step 2. Repair or replace
1) Check with the user regarding when the affect the tire pressure monitor each component.
warning light lit or started blinking. system normal?
2) Before performing diagnostics, check all
components which may adversely affect the tire
pressure monitor system. <Ref. to TPM(diag)-
3, INSPECTION, General Description.>
2 CHECK DIAGNOSTIC TROUBLE CODE Is DTC displayed? Go to step 4. Go to step 3.
(DTC).
2) Connect the Subaru Select Monitor to data
link connector.
3) Turn the ignition switch to ON and run the
NOTE:
If the communication function of the Subaru Se-
lect Monitor cannot be executed normally,
check the communication circuit. <Ref. to
TPM(diag)-10, COMMUNICATION FOR INI-
TIALIZING IMPOSSIBLE, INSPECTION, Sub-
aru Select Monitor.>
4) Read the DTC. <Ref. to TPM(diag)-12,
OPERATION, Read Diagnostic Trouble Code
(DTC).>
3 PERFORM GENERAL DIAGNOSTICS. Does the tire pressure warning Finish the diagno- Check the tire infla-
1) Perform the inspection by referring to “Gen- light illuminates for about 2 sec- sis. tion pressure
eral Diagnostic Table”. <Ref. to TPM(diag)-32, onds and then foes off after warning light blink-
General Diagnostic Table.> turning on the ignition switch, ing patterns. <Ref.
2) Perform the Clear Memory Mode. <Ref. to and then go out? to TPM(diag)-15,
TPM(diag)-8, CLEAR MEMORY, OPERATION, INSPECTION, Tire
Subaru Select Monitor.> Pressure Warning
3) Perform the Inspection Mode. <Ref. to Light / Trouble Indi-
TPM(diag)-13, Inspection Mode.> cator Light Illumi-
4) Read the DTC. <Ref. to TPM(diag)-7, READ nation Pattern.>
DIAGNOSTIC TROUBLE CODE (DTC),
OPERATION, Subaru Select Monitor.>
Check the DTC is not displayed.
4 PERFORM DIAGNOSIS. Is DTC displayed? Repeat steps 1 to 4 Finish the diagno-
1) Refer to “List of Diagnostic Trouble Code until DTC is not sis.
(DTC)”. shown.
2) Correct the cause of trouble.
3) Perform the Clear Memory Mode. <Ref. to
TPM(diag)-8, CLEAR MEMORY, OPERATION,
4) Perform the drive test.
Drive the vehicle at 40 km/h (25 MPH) or faster
for at least 10 minutes.
5) Read the DTC. <Ref. to TPM(diag)-7, READ
DIAGNOSTIC TROUBLE CODE (DTC),
TPM(diag)-2
General Description
2. General Description B: INSPECTION

Before performing diagnosis, check the following
A: CAUTION item which might affect the quality of the tire pres-
1. SRS AIRBAG SYSTEM sure monitoring system.
Airbag system wiring harness is routed near the 1. TIRES
TPM control module. • Inspect that the tire pressure is within the speci-
CAUTION: fication while the tire is cool. (Refer to Tire Caution
• Do not use electrical test equipment on any Label.)
of the airbag system wiring harness circuits. • Check the tires for damage or the insertion of for-
• Be careful not to damage the wiring harness eign matters.
of the airbag system when servicing the TPMS
& keyless entry control module. 2. BATTERY
Check that amount of battery fluid, gravity and volt-
2. TPMS & KEYLESS ENTRY CONTROL age are within the specifications.
MODULE
Standard voltage: 12 V or more
• If the transmitter is replaced, ID registration for
the transmitter is required. <Ref. to TPM(diag)-9, Specific gravity: 1.260 or more
REGISTER TRANSMITTER ID, OPERATION,
• 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.
235/45R17, 245/40R18
Indoor
15.5 (60)
Temperature temperature
°C (°F) Ambient
–1 (30) –12 (10) –23 (–10)
temperature
Air pressure Front 250 (36) 265 (38) 280 (40)
kPa (psi) Rear 240 (35) 255 (37) 270 (39)
TPM(diag)-3
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
1B022XU0 SUBARU SELECT Used for troubleshooting the electrical system.
MONITOR III KIT
ST1B022XU0
2. GENERAL TOOL
TOOL NAME REMARKS
Transmitter registration tool Used to register the transmitter ID. Manufacturer: Kent-Moore
Item number: J45295
TPM(diag)-4


A: LOCATION
(1)
(2)
(1)
(3)
(3)
TPM00075
(1) TPMS & keyless entry control (2) Tire pressure warning light (3) Snap-in type transmitter
module
• 5 DOOR MODEL • 4 DOOR MODEL
(1)
(1)
TPM00076 TPM00077
(3)
(2)
TPM00048 TPM00049
TPM(diag)-5
Control Module I/O Signal

4. Control Module I/O Signal

6 5 4 3 2 1
12 11 10 9 8 7
TO R221
TPM00081
Terminal Measured value and measuring

Content Remarks
No. conditions
1 — — —
Illuminate when malfunction System failure: blinks 25 times → illuminates
2 Tire pressure warning light output
occurs, or tire pressure decreases Tire pressure decreases: turns on
3 Speed sensor signal While driving (Pulse signal) Change according to vehicle speed
4 Ignition power supply IG switch ON (Battery voltage) —
5 GND 0 V (Always) —
6 Battery power supply Battery voltage (Always) —
7 — — —
8 — — —
9 — — —
10 — — —
11 Body integrated unit — —
12 Select monitor communication Serial communication —
B: WIRING DIAGRAM
<Ref. to WI-71, WIRING DIAGRAM, Tire Pressure Monitoring System.>
TPM(diag)-6

5. Subaru Select Monitor 8) If TPMS & keyless entry control module and
Subaru Select Monitor cannot communicate, check
A: OPERATION the communication circuit. <Ref. to TPM(diag)-10,
COMMUNICATION FOR INITIALIZING IMPOSSI-
1. READ DIAGNOSTIC TROUBLE CODE BLE, INSPECTION, Subaru Select Monitor.>
(DTC) 9) When DTC is not displayed, check the tire infla-
1) Prepare the Subaru Select Monitor kit. <Ref. to tion pressure warning light blinking patterns. <Ref.
TPM(diag)-4, SPECIAL TOOL, PREPARATION to TPM(diag)-15, INSPECTION, Tire Pressure
TOOL, General Description.> Warning Light / Trouble Indicator Light Illumination
2) Connect the diagnosis cable to Subaru Select Pattern.>
Monitor.
3) Connect the Subaru Select Monitor to data link
connector.
(1) Data link connector is located in the lower
portion of instrument panel (on the driver’s
side).
IM-00275
(2) Connect the diagnosis cable to data link

connector.
CAUTION:
Do not connect scan tools other than the Suba-
ru Select Monitor.
4) Turn the ignition switch to ON and run the Suba-
ru Select Monitor.
5) On «Main Menu» display, select {Each System
Check}.
{Tire pressure monitor}.
7) On «Tire pressure monitor diagnosis» display,
select {Diagnostic Code(s) Display}.
NOTE:
• For details concerning DTCs, refer to List of Di-
agnostic Trouble Code (DTC). <Ref. to TPM(diag)-
20, List of Diagnostic Trouble Code (DTC).>
• All DTCs detected will be displayed.
• If a particular DTC is not properly stored in mem-
ory (due to a voltage drop of the TPMS & keyless
entry 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.
TPM(diag)-7

2. DATA DISPLAY
1) On «Main Menu» display, select {Each System Check}.
2) On «System Selection Menu» display, select {Tire pressure monitor}.
3) After the {Tire pressure monitor} is displayed, select [OK].
4) On «Tire pressure monitor diagnosis» display, select {Data Display}, and then necessary data will be dis-
played.
1. Data monitor (Analog)
Display Contents to be displayed Unit of measure
Tire 1 FN code LEARN: Transmitted transmitter ID using the transmitter
Tire 2 FN code registration tool
LOW BAT: Transmitter battery voltage running low
Tire 3 FN code
LEARN, LOW BAT, OFF, WAKE, RE ME, OFF: Transmitter function stops (no data transmission)
NORMAL RE ME: Tire air changes ±8.4 kPa
Tire 4 FN code WAKE: When data transmission is started from a
stopped state.
NORMAL: Conditions other than above
Tire 1 air pressure Value converted to tire pressure from data kPa, psig, mmHg, inHg
Tire 2 air pressure delivered from transmitter is displayed. kPa, psig, mmHg, inHg
Tire 3 air pressure (The figure may differ from the actual kPa, psig, mmHg, inHg
Tire 4 air pressure measured values.) kPa, psig, mmHg, inHg
Vehicle speed signal which is input in con-
Vehicle Speed km/h, MPH
trol module
Threshold where tire pressure warning
Pressure warning kPa, psig, mmHg, inHg
light illuminates
Threshold where tire pressure warning
Return pressure kPa, psig, mmHg, inHg
light goes out
3. CLEAR MEMORY
Check}.
{Tire pressure monitor}.
3) After the {Tire pressure monitor} is displayed,
select [OK].
select {Clear Memory}.
5) When “Done” and “Turn off the ignition switch.”
are shown on the display screen, turn the Subaru
Select Monitor and the ignition switch to OFF.
NOTE:
For details concerning the operation procedure, re-
fer to “PC application help for Subaru Select Moni-
tor”.
TPM(diag)-8

4. REGISTER TRANSMITTER ID NOTE:

Perform the registration procedure of the transmit- • The registration order of transmitter ID is not
ter in the following cases: specified.
• Transmitter replaced. • The transmitter registration tool is used by touch-
• TPMS & keyless entry control module replaced. ing the side wall area near the transmitter.
• If registration procedure stop in the halfway
NOTE: (turning ignition switch to OFF, wrong registration
• If registration of the transmitter ID is not possible order, etc), proceed from step 5).
after 2 attempts, replace TPMS & keyless entry 8) When ID registration is completed, the tire pres-
control module. <Ref. to WT-8, TPMS & KEYLESS sure warning light remains lit for approximately 2
ENTRY CONTROL MODULE, REMOVAL, Tire seconds, to end the registration. Switch to the
Pressure Monitoring System.> <Ref. to WT-9, screen displaying the transmitter ID on the Subaru
TPMS & KEYLESS ENTRY CONTROL MODULE, Select Monitor display. <Ref. to TPM(diag)-9, DIS-
INSTALLATION, Tire Pressure Monitoring Sys- PLAY TRANSMITTER (ID), OPERATION, Subaru
tem.> Select Monitor.>
• During the registration, turn the ignition switch to 9) Check the transmitter ID that was registered,
OFF and end the Subaru Select Monitor. Or if the then perform a driving test. <Ref. to TPM(diag)-13,
registration is not performed for 5 minutes or more, PROCEDURE, Inspection Mode.>
the registration mode is cancelled.
• When rotating tires, there is no affect on the per- 5. DISPLAY TRANSMITTER (ID)
formance or functions of the tire pressure monitor- 1) On «Main Menu» display, select {Each System
ing control module even if the transmitter (ID) is not Check}.
registered, however, the tire position displayed on 2) On «System Selection Menu» display, select
the Subaru Select Monitor will be incorrect. {Tire pressure monitor}.
1) Adjust all tire pressures to the specifications. 3) After the {Tire pressure monitor} is displayed,
2) Connect Subaru Select Monitor and select the select [OK].
{Each System Check} on the «Main Menu». 4) On «Tire pressure monitor diagnosis» display,
3) On «System Selection Menu» display, select select {Transmitter ID regist confirm}.
{Tire pressure monitor}. 5) Select the {Transmitter ID monitor} and then se-
4) After the {Tire pressure monitor} is displayed, lect [OK] to display the transmitter ID.
select [OK].
select {Transmitter ID regist confirm}.
6) {ID registration mode When execute Registered
ID is deleted. Continue?} is displayed, select [OK].
7) Contact 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 TPMS & keyless entry control module. (At this
time, the tire pressure warning light blinks to con-
firm that the registration has started.)
(1)
(2)
TPM00006
(1) Air valve (transmitter)

(2) Transmitter registration tool
TPM(diag)-9

B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DETECTING CONDITION:
TROUBLE SYMPTOM:
Communication is impossible between the TPMS & keyless entry control module and the Subaru Select
Monitor.
WIRING DIAGRAM:
Tire Pressure Monitoring System <Ref. to WI-71, WIRING DIAGRAM, Tire Pressure Monitoring System.>
TO POWER SUPPLY CIRCUIT R221

FB-48 FB-11 MB-27
F/B FUSE NO. 4 M/B FUSE NO. 8 M/B FUSE NO. 13 1 2 3 4 5 6
(IG) (B) (B) 7 8 9 10 11 12
B40
B40 1 2 3 4 5 6 7 8
B435 B440 9 10 11 12 13 14 15 16
16
3 2 7
MULTI JOINT DATA LINK
CONNECTOR B99
B99 CONNECTOR
8
1 2 3 4 5
R3 6 7 8 9 10 11 12
12
4
B435
B440
R221
1 2 3 4 5
TPMS & KEYLESS ENTRY CM
TPM00078
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 Repair or tighten Go to step 4.
terminal? the battery termi-
nal.
4 CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Go to step 8. Go to step 5.
MUNICATION. on Subaru Select Monitor?
2) Using the Subaru Select Monitor, check
whether communication to other systems can
be executed normally.
5 CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Replace the TPMS Go to step 6.
MUNICATION. on Subaru Select Monitor? & keyless entry
1) Turn the ignition switch to OFF. control module.
2) Disconnect the TPMS & keyless entry con- <Ref. to WT-8,
trol module. TPMS & KEY-
3) Turn the ignition switch to ON. LESS ENTRY
4) Check whether communication to other sys- CONTROL MOD-
tems can be executed normally. ULE, REMOVAL,
Tire Pressure
Monitoring Sys-
tem.>
TPM(diag)-10

Step Check Yes No

6 CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or Go to step 7. Repair the harness
2) Disconnect the TPMS & keyless entry con- data link connec-
trol module. tor.
7 CHECK OUTPUT SIGNAL TO TPMS & KEY- Is the voltage less than 1 V? Go to step 8. Repair the harness
LESS ENTRY CONTROL MODULE. and connector
1) Turn the ignition switch to ON. between each con-
2) Measure the voltage between TPMS & key- trol module and
less entry control module and chassis ground. data link connec-
8 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 9. Repair the harness
TPMS & KEYLESS ENTRY CONTROL MOD- Ω? and connector
ULE AND DATA LINK CONNECTOR. between TPMS &
1) Turn the ignition switch to OFF. keyless entry con-
2) Measure the resistance between the TPMS trol module and
& keyless entry control module connector and data link connec-
the data link connector. tor.
(R221) No. 12 — (B40) No. 7:
9 CHECK TPMS & KEYLESS ENTRY CON- Is TPMS & keyless entry control Go to step 10. Insert the connec-
TROL MODULE CONNECTOR. module connector inserted until tor into the TPMS
it locks? & keyless entry
control module.
10 CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 — 15 V? Go to step 11. Repair open circuit
1) Turn the ignition switch to ON. of the harness
2) Measure the ignition power supply voltage between TPMS &
between TPMS & keyless entry control module keyless entry con-
connector and chassis ground. trol module and
Connector & terminal battery.
11 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 12. Repair open circuit
TPMS & KEYLESS ENTRY CONTROL MOD- Ω? of the harness of
ULE AND CHASSIS GROUND. the TPMS & key-
1) Turn the ignition switch to OFF. less entry control
2) Disconnect the connector from the TPMS & module.
keyless entry control module.
TPMS & keyless entry control module and
chassis ground.
12 CHECK POOR CONTACT OF CONNECTOR. Is there poor contact of TPMS & Repair the connec- Replace the TPMS
keyless entry control module tor. & keyless entry
power supply, ground circuit control module.
and data link connector? <Ref. to WT-8,
TPMS & KEY-
LESS ENTRY
CONTROL MOD-
ULE, REMOVAL,
Tire Pressure
Monitoring Sys-
tem.>
TPM(diag)-11


Code (DTC)
A: OPERATION
For details about reading of DTCs, refer to “Subaru
Select Monitor”. <Ref. to TPM(diag)-7, Subaru Se-
lect Monitor.>
TPM(diag)-12
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)-13
Clear Memory Mode


A: OPERATION
For details concerning DTC clear operation, refer to
“Subaru Select Monitor”. <Ref. to TPM(diag)-7,
TPM(diag)-14
Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern

9. Tire Pressure Warning Light / Trouble Indicator Light Illumination

Pattern
A: INSPECTION
(4)
(3) (3)
(2) (2)
(1)
(6)
(5)
(7)
(10)
(10)
(9) (9)
(8)
(19)
(13)
(12)
(11)
(10)
(16)
(19)
(15)
(14)
(17) (18)
(19)
TPM00071
(1) Ignition switch (8) Tire inflation pressure warning (15) Light OFF
light (pressure condition)
(2) OFF (9) Light OFF (16) Blink
(3) ON (10) Light ON (17) 1 second
(4) Start (11) System status (18) Blinks 25 times
(5) Tire inflation pressure (12) Normal (19) 2 seconds
(6) Meet the specification (13) Malfunction
(7) Less than standard value (For the (14) Tire inflation pressure warning
pressure warning level, refer to light (system condition)
CURRENT DATA.) <Ref. to
TPM(diag)-8, DATA DISPLAY,
OPERATION, Subaru Select Mon-
itor.>
TPM(diag)-15

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 TPMS & keyless entry control module/warning
light circuit and the combination meter circuit. <Ref. to TPM(diag)-17, 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.)
B: TIRE PRESSURE WARNING LIGHT DOES NOT COME ON
Defective combination meter
TROUBLE SYMPTOM:
When the ignition switch is turned to ON, the tire pressure warning light does not turn on (for approx. 2 sec-
onds).
Step Check Yes No
1 CHECK DIAGNOSTIC TROUBLE CODE Is diagnostics code (DTC) dis- Perform the diag- Replace the com-
(DTC). played? nosis according to bination meter.
Connect the Subaru Select Monitor, and read the DTC. <Ref. to <Ref. to IDI-18,
the Diagnostic Trouble Code. <Ref. to TPM(diag)-20, List REMOVAL, Com-
TPM(diag)-7, READ DIAGNOSTIC TROUBLE of Diagnostic Trou- bination Meter.>
CODE (DTC), OPERATION, Subaru Select ble Code (DTC).>
Monitor.>
TPM(diag)-16

C: TIRE PRESSURE WARNING LIGHT DOES NOT COME OFF

• Defective combination meter
• Tires pressure drop
• Transmitter ID not registered
TROUBLE SYMPTOM:
Tire pressure warning light remains illuminating after engine starts.
Step Check Yes No
1 CHECK DTC. Is a DTC displayed? Perform the diag- Go to step 2.
Connect the Subaru Select Monitor, and read nosis according to
the Diagnostic Trouble Code. <Ref. to the DTC. <Ref. to
TPM(diag)-7, READ DIAGNOSTIC TROUBLE TPM(diag)-20, List
CODE (DTC), OPERATION, Subaru Select of Diagnostic Trou-
Monitor.> ble Code (DTC).>
2 CHECK TRANSMITTER (ID). Is the transmitter ID registered?Go to step 3. Register the trans-
Display the transmitter ID of the tire pressure mitter ID. <Ref. to
monitor system. TPM(diag)-9,
REGISTER
TRANSMITTER
ID, OPERATION,
Subaru Select
Monitor.>
3 CHECK TRANSMITTER DATA OUTPUT. Is the warning light output ON? Replace the TPMS Replace the com-
1) Select data display of the tire pressure mon- & keyless entry bination meter.
itoring. control module. <Ref. to IDI-18,
2) Start the engine and check the tire pressure <Ref. to WT-8, REMOVAL, Com-
warning light output. TPMS & KEY- bination Meter.>
LESS ENTRY
CONTROL MOD-
ULE, REMOVAL,
Tire Pressure
Monitoring Sys-
tem.>
TPM(diag)-17

D: TIRE PRESSURE WARNING LIGHT IS 25 TIMES BLINKING AND TURN ON

• Defective TPMS & keyless entry control module
• 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-11 FB-48 FB-36

M/B FUSE NO. 8 F/B FUSE NO. 4 F/B FUSE NO. 5
i10
(B) (IG) (IG)
1 2 3 4 5 6 7 8 9 10 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
2
I/F
TIRE INFLATION COMBINATION
PRESSURE
WARNING LIGHT METER i102
i10
MICRO COMPUTER DRIVE 1 2 3 4 5 6 7
CIRCUIT
8 9 10 11 12 13 14 15 16
I/F
34
i102
15
R167 R221
1 2 3 4 5 6
6
7 8 9 10 11 12
R221
TPMS & KEYLESS ENTRY CM
TPM00079
Step Check Yes No

1 CHECK DTC. Is diagnostics code (DTC) dis- Perform the diag- Go to step 2.
Connect the Subaru Select Monitor, and read played? nosis according to
the Diagnostic Trouble Code. <Ref. to the DTC. <Ref. to
TPM(diag)-7, READ DIAGNOSTIC TROUBLE TPM(diag)-20, List
CODE (DTC), OPERATION, Subaru Select of Diagnostic Trou-
Monitor.> ble Code (DTC).>
2 CHECK HARNESS. Is the voltage 10 V or more? Go to step 3. Go to step 4.
1) Connect the Subaru Select Monitor to the
terminal No. 2 of the TPMS & keyless entry con-
trol module connector (R221).
2) Turn the ignition switch to ON, and select
“Oscilloscope” from the Main Menu of Subaru
Select Monitor.
3) Check the voltage displayed.
TPM(diag)-18

Step Check Yes No

3 CHECK HARNESS. Is the pattern the same output Check the combi- Replace the TPMS
1) Check the output waveform displayed in the waveform as shown in the fig- nation meter. <Ref. & keyless entry
oscilloscope of Subaru Select Monitor. ure? to IDI-5, INSPEC- control module.
(1) 400±9 ms Duty 50% TION, Combina- <Ref. to WT-8,
High: Battery voltage tion Meter REMOVAL, Tire
Low: 1.5 V or less System.> Pressure Monitor-
High ing System.>
Low
(1)
TPM00044
4 CHECK HARNESS. Is the voltage 10 V or more? Replace the TPMS The harness
1) Disconnect the TPMS & keyless entry con- & keyless entry between the com-
trol module connector. control module. bination meter
2) Connect the Subaru Select Monitor to the <Ref. to WT-8, connector and the
terminal No. 2 of the TPMS & keyless entry con- REMOVAL, Tire TPMS & keyless
trol module connector (R221). Pressure Monitor- entry control mod-
Connector & terminal ing System.> ule connector is
(R221) No. 2 (+) — Chassis ground (–): shorted or open.
3) Turn the ignition switch to ON, and select Repair or replace
“Oscilloscope” from the Main Menu of Subaru the harness.
Select Monitor.
4) Check the voltage displayed.
TPM(diag)-19


A: LIST
DTC Item Contents of diagnosis Remarks
Tire 1 Air Pressure Decrease Tire pressure of tire 1 is reduced. <Ref. to TPM(diag)-22, DTC 11 TIRE 1 AIR PRES-
11 SURE DECREASE, Diagnostic Procedure with
Transmitter 1 No Data Data cannot be received from <Ref. to TPM(diag)-23, DTC 21 TRANSMITTER 1
21 transmitter 1. NO DATA, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
Transmitter 1 Pressure Data Transmitter 1 data contents are <Ref. to TPM(diag)-25, DTC 31 TRANSMITTER 1
31 Abnormal abnormal. PRESSURE DATA ABNORMAL, Diagnostic Proce-
Transmitter 1 Function Code Function code has error. <Ref. to TPM(diag)-27, DTC 41 TRANSMITTER 1
41 Abnormal FUNCTION CODE ABNORMAL, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
Transmitter 1 Battery Voltage Transmitter battery voltage is low. <Ref. to TPM(diag)-29, DTC 51 TRANSMITTER 1
51 Decrease BATTERY VOLTAGE DECREASE, Diagnostic Pro-
TPM(diag)-20

DTC Item Contents of diagnosis Remarks

Vehicle Speed is Abnormal Vehicle speed signal is not input to
<Ref. to TPM(diag)-31, DTC 61 VEHICLE SPEED
the control module when the vehi-
61 IS ABNORMAL, Diagnostic Procedure with Diag-
cle speed is 6 km/h (3.7 MPH) or
nostic Trouble Code (DTC).>
more.
TPM(diag)-21


A: DTC 11 TIRE 1 AIR PRESSURE DECREASE
NOTE:
Refer to DTC 14 for diagnostic procedure. <Ref. to TPM(diag)-23, 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:
TPM(diag)-22

D: DTC 14 TIRE 4 AIR PRESSURE DECREASE

Inflation pressure of tires dropped below the specified value.
NOTE:
For the specifications, refer to CURRENT DATA. <Ref. to TPM(diag)-8, DATA DISPLAY, OPERATION, Sub-
TROUBLE SYMPTOM:
Tire pressure warning light illuminates.
Step Check Yes No
1 CHECK TIRES. Are there cracks or damage? Replace the tire. Go to step 2.
Lift up the vehicle and check for damage in the
tires.
2 CHECK TIRES. Is the tire pressure in the speci- Go to step 3. Adjust the air pres-
Check the tire air pressure. fications? sure.
3 CHECK TRANSMITTER. Is there a transmitter with differ- Replace the trans- Go to step 4.
Drive the vehicle at 40 km/h (25 MPH) or fasterent data? mitter (tire pres-
and compare the data from the transmitter on sure sensor). <Ref.
the four wheels. to WT-8, Tire Pres-
sure Monitoring
System.>
4 PERFORM DRIVING TEST. Is DTC displayed? Inspect by referring Finish the diagno-
1) Perform the Clear Memory Mode. <Ref. to to “Diagnostic Pro- sis.
TPM(diag)-8, CLEAR MEMORY, OPERATION, cedure with Diag-
Subaru Select Monitor.> nostic Trouble
2) Perform a driving test. <Ref. to TPM(diag)- Code (DTC)”.
13, PROCEDURE, Inspection Mode.> <Ref. to
3) Read the DTC. <Ref. to TPM(diag)-7, READ TPM(diag)-22,
DIAGNOSTIC TROUBLE CODE (DTC), Diagnostic Proce-
OPERATION, Subaru Select Monitor.> dure with Diagnos-
tic Trouble Code
(DTC).>
CAUTION:
When driving vehicle to perform driving test, there should be always 2 persons (driver and checker)
to check.
E: DTC 21 TRANSMITTER 1 NO DATA
NOTE:
Refer to DTC 24 for diagnostic procedure. <Ref. to TPM(diag)-24, DTC 24 TRANSMITTER 4 NO DATA, Di-
agnostic Procedure with Diagnostic Trouble Code (DTC).>
F: DTC 22 TRANSMITTER 2 NO DATA
NOTE:
G: DTC 23 TRANSMITTER 3 NO DATA
NOTE:
TPM(diag)-23

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.
Step Check Yes No
1 START FL TRANSMITTER. Is “Latest reception ID” Go to step 2. Replace front left
1) Connect the Subaru Select Monitor and updated? transmitter.
then turn the ignition switch to ON.
2) Select “Transmit ID data monitor”. <Ref. to
TPM(diag)-9, DISPLAY TRANSMITTER (ID),
3) Use the transmitter registration tool and
transmit the ID from the FL transmitter to check
“Latest reception ID”.
2 CHECK FL TRANSMITTER ID. Are the two IDs same? Go to step 3. Record the
Check the ID displayed in the updated ID dis- received ID update
play and the tire 1 registered ID. as the FL transmit-
ter. Go to step 3.
3 START FR TRANSMITTER. Is “Latest reception ID” Go to step 4. Replace the front
Use the transmitter registration tool and trans- updated? right transmitter.
mit the ID from the FR transmitter to check “Lat-
est reception ID”.
4 CHECK FR TRANSMITTER ID. Are the two IDs same? Go to step 5. Record the
play and the tire 2 registered ID. as the FR transmit-
ter. Go to step 5.
5 START RR TRANSMITTER. Is “Latest reception ID” Go to step 6. Replace the RR
Use the transmitter registration tool and trans- updated? transmitter.
mit the ID from the RR transmitter to check “Lat-
6 CHECK RR TRANSMITTER ID. Are the two IDs same? Go to step 7. Record the
play and the tire 3 registered ID. as the RR transmit-
ter. Go to step 7.
7 START RL TRANSMITTER. Is “Latest reception ID” Go to step 8. Replace the RL
mit the ID from the RL transmitter to check “Lat-
8 CHECK RL TRANSMITTER ID. Are the two IDs same? Go to step 9. Record the
play and the tire 4 registered ID. as the RL transmit-
ter. Go to step 9.
9 CHECK MALFUNCTION TRANSMITTER. Is ID recorded by this proce- Go to step 10. Go to step 1.
dure?
10 CHECK MALFUNCTION TRANSMITTER. Is there checked ID in the Replace the trans- Replace the trans-
Check the registered ID of the transmitter indi- record? mitter of the mitter showing the
cated by DTC. recorded position. latest ID that is not
included in the reg-
istered IDs.
CAUTION:
When driving vehicle to perform driving test, there should be always 2 persons (driver and checker)
to check.
TPM(diag)-24

I: DTC 31 TRANSMITTER 1 PRESSURE DATA ABNORMAL

NOTE:
Refer to DTC 34 for diagnostic procedure. <Ref. to TPM(diag)-26, DTC 34 TRANSMITTER 4 PRESSURE
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)-25

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
ter. Go to step 3.
ter. Go to step 5.
ter. Go to step 7.
ter. Go to step 9.
9 CHECK MALFUNCTION TRANSMITTER. Is ID recorded by this proce- Go to step 10. Go to step 1.
dure?
istered IDs.
TPM(diag)-26

M: DTC 41 TRANSMITTER 1 FUNCTION CODE ABNORMAL

NOTE:
Refer to DTC 44 for diagnostic procedure. <Ref. to TPM(diag)-28, 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)-27

P: DTC 44 TRANSMITTER 4 FUNCTION CODE ABNORMAL

Unexpected function codes received from each transmitter.
TROUBLE SYMPTOM:
Step Check Yes No
ter. Go to step 3.
ter. Go to step 5.
ter. Go to step 7.
ter. Go to step 9.
9 CHECK MALFUNCTION TRANSMITTER. Is ID recorded by this proce- Go to step 10. Check again. Go to
dure? step 1.
istered IDs.
TPM(diag)-28

Q: DTC 51 TRANSMITTER 1 BATTERY VOLTAGE DECREASE

NOTE:
Refer to DTC 54 for diagnostic procedure. <Ref. to TPM(diag)-30, 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:
TPM(diag)-29

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. Is the fault eliminated? Internal battery of Replace the TPMS
1) Replace all transmitters and register their the transmitter had & keyless entry
IDs. <Ref. to TPM(diag)-9, REGISTER TRANS- worn out. control module.
MITTER ID, OPERATION, Subaru Select Moni- <Ref. to WT-8,
tor.> TPMS & KEY-
2) Perform the Clear Memory Mode, and per- LESS ENTRY
form driving test. CONTROL MOD-
ULE, REMOVAL,
Tire Pressure
Monitoring Sys-
tem.>
TPM(diag)-30

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:
TO POWER SUPPLY i10

CIRCUIT
FB-36 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F/B FUSE NO. 5 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
(IG)
i1
1 2 3 4
i10 i1
5 6 7 8 9 10
31
2
2
11 12 13 14 15 16
B36
17 18 19 20 21 22
23 24 25 26 27 28
SPEEDO-
METER
POWER
I/F SUPPLY I/F
CIRCUIT
B310
MICRO COMPUTER
B99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
12
22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
COMBINATION METER R3
B310
B99 R221
33
5
1 2 3 4 5 1 2 3 4 5 6
6 7 8 9 10 11 12 7 8 9 10 11 12
R221
TPMS & VDC CM

KEYLESS ENTRY CM
TPM00080
Step Check Yes No

1 CHECK TPMS & KEYLESS ENTRY CON- Is the vehicle speed being Replace the TPMS Go to step 2.
TROL MODULE. input? & keyless entry
1) Connect an oscilloscope to the terminal No. control module.
3 of the TPMS & keyless entry control module <Ref. to WT-8,
connector (R221). TPMS & KEY-
Connector & terminal LESS ENTRY
(R221) No. 3 (+) — Chassis ground (–): CONTROL MOD-
2) Lift up the vehicle and then drive the vehicle ULE, REMOVAL,
at 40 km/h (25 MPH) and check the vehicle Tire Pressure
speed signal at that time. Monitoring Sys-
tem.>
2 CHECK HARNESS. Is the resistance less than 0.5 Replace the com- Repair or replace
1) Disconnect the combination meter connec- Ω? bination meter. the open circuit of
tor (i10). <Ref. to IDI-18, the harness.
2) Connect the tester to the TPMS & keyless REMOVAL, Com-
entry control module connector (R221) and bination Meter.>
combination meter connector (i10), and mea-
sure the resistance.
(R221) No. 3 — (i10) No. 31:
TPM(diag)-31


A: INSPECTION
Tire pressure warning light illumi- • Improper tire pressure adjustment.
Tire pressure is reduced.
nates. • Punctured tire
• Air pressure sensor malfunction
• Air pressure sensor is out of battery.
Tire pressure warning light blinks Tire pressure monitoring system
25 times and then illuminates. has malfunction.
• Defective vehicle harness
• Air pressure sensor malfunction
Tire pressure is dropping but the Tire pressure warning light does
warning light does not illuminate. not illuminate.
TPM(diag)-32
DIFFERENTIALS
DI
Page
2. Differential Gear Oil ..................................................................................19
3. Front Differential Assembly ......................................................................22
4. Rear Differential (T-type) ..........................................................................23
5. Rear Differential Front Oil Seal ................................................................54
6. Rear Differential Side Oil Seal .................................................................56
7. Rear Differential Front Member ................................................................57
8. Rear Differential Mount Bushing ..............................................................58
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.
2.5 L high power turbo 2.5 L turbo
Model
6MT 5MT
Rear differential type T-type
Identification H3 B2
LSD type Torsen —
Type of gear Hypoid gear
Gear ratio (Number of gear teeth) 3.545 (39/11) 3.900 (39/10)
Oil capacity 1.0 L (1.1 US qt, 0.9 Imp qt) 0.8 L (0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5
2. IDENTIFICATION 3. REAR DIFFERENTIAL GEAR OIL

Identification positions are shown in the following Recommended gear oil:
figures. For details concerning identification, refer GL-5 (75W-90) or equivalent
to the “ID” section.
CAUTION:
Each oil manufacturer has its base oil and addi-
(1) tives. Thus, do not mix two or more brands.
(1)
(2)
(3)
GL-5
(4)
( C) -30 -26 -15 -5 0 15 25 30
( F) -22 -15 5 23 32 59 77 86
90
DI-00502 85W
80W
75W -90
(1) Identification
MT-00001
(1) Item
(2) Rear differential gear oil
(3) API classification
(4) SAE viscosity No. and applicable temperature
DI-2
General Description
DIFFERENTIALS
4. SERVICE DATA
Measured with spring measurement (Measured at T-type (B2) 18.1 — 38.8 (1.8 — 4.0, 4.1 — 8.7)
Drive pinion bearing companion flange bolt hole) N (kgf, lbf) T-type (H3) 24.1 — 38.6 (2.5 — 3.9, 5.4 — 8.7)
preload (For new
bearing) T-type (B2) 0.69 — 1.47 (0.07 — 0.15, 0.51 — 1.08)
Measured with torque wrench N·m (kgf-m, ft-lb)
T-type (H3) 0.98 — 1.57 (0.10 — 0.16, 0.72 — 1.16)
Side gear backlash mm (in) T-type (B2) 0.10 — 0.20 (0.004 — 0.008)
Side bearing standard width mm (in) 20.00 (0.7874)
Hypoid driven gear to drive pinion backlash mm (in) 0.10 — 0.20 (0.004 — 0.008)
Hypoid driven gear runout on its back surface mm (in) 0.05 (0.002)
Companion flange mating surface runout mm (in) 0.08 (0.003)
Companion flange runout on its inner surface mm (in) 0.08 (0.003)
Total preload (Measured from the companion flange bolt T-type (B2) 20.7 — 54.4 (2.1 — 5.5, 4.7 — 12.2)
N (kgf, lbf)
hole) T-type (H3) 26.5 — 53 (2.7 — 5.4, 6.0 — 11.9)
DI-3
General Description
DIFFERENTIALS
5. ADJUSTING PARTS
• T-type (B2)
Part No. Length mm (in)
383695201 56.2 (2.213)
383695202 56.4 (2.220)
383695203 56.6 (2.228)
Preload adjusting spacer
383695204 56.8 (2.236)
383695205 57.0 (2.244)
383695206 57.2 (2.252)
DI-4
General Description
DIFFERENTIALS

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)
Preload adjusting washer 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)
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)
Pinion height adjusting washer
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)
383445201 0.75 — 0.80 (0.0295 — 0.0315)
Side gear thrust washer 383445202 0.80 — 0.85 (0.0315 — 0.0335)
383445203 0.85 — 0.90 (0.0335 — 0.0354)
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
Side retainer shim 383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
DI-5
General Description
DIFFERENTIALS
• T-type (H3)
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)
Preload adjusting washer 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)
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
Side retainer shim 383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
DI-6
General Description
DIFFERENTIALS
B: COMPONENT
1. REAR DIFFERENTIAL (T-TYPE (B2))
(1) (18)
(19) (21)
(2) (20)
(3)
(4)
(5) (19)
(20) (18)
(21)
(23) (1)
(22) (25)
T4 (26)
(27) T3
T1
(16) (28)
T3
(15)
(14) (24)
(23) T2
(13) (30)
(17)
(31)
(29)
(6)
(7)
T1
(13)
(14)
(15)
(8) (16)
(9) (17)
(10)
(11)
(12) T5
DI-00956
(1) Hypoid driven gear and drive pin- (14) O-ring (27) Filler plug
ion set
(2) Pinion height adjusting washer (15) Side retainer shim (28) Drain plug
(3) Rear bearing (16) Side retainer (29) Rear cover
(4) Preload adjusting spacer (17) Side oil seal (30) Differential case
(5) Preload adjusting washer (18) Side gear thrust washer (31) Gasket
(6) Differential carrier (19) Side gear
(7) Front bearing (20) Pinion mate gear Tightening torque: N·m (kgf-m, ft-lb)
(8) Spacer (21) Pinion mate gear washer T1: 10.5 (1.1, 7.7)
(9) Pilot bearing (22) Pinion shaft lock pin T2: 29.5 (3.0, 21.8)
(10) Front oil seal (23) Snap ring T3: 49 (5.0, 36.1)
(11) Companion flange (24) Pinion mate shaft T4: 103 (10.5, 76.0)
(12) Self-locking nut (25) Air breather cap T5: 181.5 (18.5, 133.9)
(13) Side bearing (26) Stud bolt
DI-7
General Description
DIFFERENTIALS
2. REAR DIFFERENTIAL (T-TYPE (H3))
(1)
(2)
(3)
(4)
(5)
(26)
(1)
(21)
(23)
(22) (25)
T4 T3
T1 (20)
(24)
(15) (25)
(19)
(13)
(17)
(18) T2
(16) (6)
(14)
(14)
(15)
(7)
(13)
T1
(16)
(8) (17)
(9)
(10)
T5
(12) (11)
DI-00957
(1) Hypoid driven gear and drive pin- (12) Self-locking nut (23) Oil temperature switch
ion set
(2) Pinion height adjusting washer (13) Side bearing (24) Drain plug
(3) Rear bearing (14) O-ring (25) Gasket
(4) Preload adjusting spacer (15) Side retainer shim (26) Stay ground
(5) Preload adjusting washer (16) Side retainer
(6) Differential carrier (17) Side oil seal Tightening torque: N·m (kgf-m, ft-lb)
(7) Front bearing (18) Gasket T1: 10.5 (1.1, 7.7)
(8) Spacer (19) Differential case ASSY T2: 44 (4.5, 32.5)
(9) Pilot bearing (20) Rear cover T3: 60 (6.1, 44.3)
(10) Front oil seal (21) Air breather cap T4: 103 (10.5, 76.0)
(11) Companion flange (22) Stud bolt T5: 181.5 (18.5, 133.9)
DI-8
General Description
DIFFERENTIALS
3. REAR DIFFERENTIAL MOUNTING SYSTEM
T2
(4) (6)
(5)
(6)
(3)
(2)
(5)
T3
(1)
(5)
T1
DI-00649
(1) Rear differential front member (4) Sub frame Tightening torque: N·m (kgf-m, ft-lb)
(2) Rear differential member plate (5) Self-locking nut T1: 50 (5.1, 36.9)
(3) Rear differential ASSY (6) Rear differential mounting bushing T2: 70 (7.1, 51.6)
T3: 110 (11.2, 81.1)
DI-9
General Description
DIFFERENTIALS
C: CAUTION
any work.
• Use SUBARU genuine gear oil, grease. Do not mix gear oil, grease, etc. of different grades or manufac-
turers.
• Apply gear oil onto sliding or revolving surfaces before installation.
• Before installing the O-ring or snap ring, apply a sufficient amount of gear oil to avoid damage and defor-
mation.
D: PREPARATION TOOL
1. SPECIAL TOOL
398477702 DRIFT Used for installing the front bearing race.
ST-398477702
398217700 ATTACHMENT SET Stand for rear differential carrier disassembly
and assembly.
ST-398217700
498447120 INSTALLER Used for installing the front oil seal.
ST-498447120
DI-10
General Description
DIFFERENTIALS

398467700 DRIFT Used for removing drive pinion shaft, pilot bear-
ing and front bearing cone.
ST-398467700
399780104 WEIGHT • Used for installing the pilot bearing companion
flange.
• Used for installing the front bearing cone. (T-
type (B2))
ST-399780104
899580100 INSTALLER • Used for installing the pilot bearing.
• Used for installing the front bearing cone. (T-
type (B2))
ST-899580100
899904100 STRAIGHT PIN Used for removing and installing the pinion mate
REMOVER shaft lock pin. (T-type (B2))
ST-899904100
498247001 MAGNET BASE • Used for measuring the backlash of hypoid
gear.
• Used together with DIAL GAUGE
(498247100).
ST-498247001
DI-11
General Description
DIFFERENTIALS

498247100 DIAL GAUGE • Used for measuring the backlash of hypoid
gear.
• Used together with MAGNET BASE
(498247001).
ST-498247100
398507704 BLOCK Used for adjusting pinion height and preload. (T-
type (B2))
ST-398507704
398457700 ATTACHMENT Used for removing the side retainer.
ST-398457700
398437700 DRIFT Used for installing the side oil seal.
ST-398437700
398507703 DUMMY COLLAR • Used for adjusting pinion height and preload.
• Used for installing the front bearing cone.
ST-398507703
DI-12
General Description
DIFFERENTIALS

398517700 REPLACER Used for removing rear bearing cone.
ST-398517700
398487700 DRIFT Used for installing side bearing cone.
ST-398487700
398527700 PULLER ASSY • Used for removing front oil seal.
• Used for removing the side bearing race.
ST-398527700
28099PA090 OIL SEAL PROTEC- Used for installing the rear drive shaft to the rear
TOR differential. (For oil seal protection)
ST28099PA090
28099PA100 DRIVE SHAFT Used for removing the rear drive shaft from rear
REMOVER differential.
ST28099PA100
DI-13
General Description
DIFFERENTIALS

399703600 PULLER ASSY Used for removing companion flange.
ST-399703600
899874100 INSTALLER Used for installing the companion flange.
ST-899874100
18759AA000 PULLER ASSY Used for removing the side bearing cone.
ST18759AA000
398417700 DRIFT Used for installing side bearing race.
ST-398417700
498937110 HOLDER DRIVE Used for installing the pilot bearing and the com-
PINION panion flange. (T-type (H3))
ST-498937110
DI-14
General Description
DIFFERENTIALS

18674AA000 INSTALLER Used for installing the rear bearing cone. (T-type
(H3))
ST18674AA000
398177700 INSTALLER Used for installing the rear bearing cone. (T-type
(B2))
ST-398177700
398477701 HANDLE Used for installing the front and rear bearing
races. (T-type (B2))
ST-398477701
398477703 DRIFT 2 Used for installing the rear bearing race. (T-type
(B2))
ST-398477703
498427200 FLANGE WRENCH Used for preventing rotation of companion flange
when loosening and tightening self-lock nut. (T-
type (B2))
ST-498427200
DI-15
General Description
DIFFERENTIALS

18633AA000 WRENCH COMPL Used for preventing rotation of companion flange
when loosening and tightening self-lock nut. (T-
type (H3))
ST18633AA000
398507702 DUMMY SHAFT Used for adjusting pinion height and preload. (T-
type (B2))
ST-398507702
398507701 DIFFERENTIAL Used for adjusting pinion height. (T-type (B2))
CARRIER GAUGE
ST-398507701
(6) 41399FG001 SPECIAL TOOL • Used for removing and installing the rear dif-
ASSY ferential mount bushing.
(2) • Use (1), (3), (5), (6), (7), (8) and (9) for
(5) removal.
• Use (2), (4), (5), (6), (7), (8) and (9) for installa-
(7)
tion.
(1) SPECIAL TOOL A (41399FG010)
(4)
(3) (2) SPECIAL TOOL B (41399FG020)
(3) SPECIAL TOOL C (41399FG031)
(1) (4) SPECIAL TOOL D (41399FG041)
(8)
(9) (5) SPECIAL TOOL SLEEVE (41399FG050)
ST41399FG001 (6) SPECIAL TOOL RING (41399FG061)
(7) SPECIAL TOOL NUT (41399FG070)
(8) SPECIAL TOOL BEARING (41399FG080)
(9) SPECIAL TOOL SHAFT (41399FG091)
DI-16
General Description
DIFFERENTIALS

41399FG010 SPECIAL TOOL A • Used for removing the rear differential mount
bushing.
• For combination of tools for removal, refer to
“SPECIAL TOOL ASSY (41399FG001)”.
ST41399FG010
41399FG020 SPECIAL TOOL B • Used for installing the rear differential mount
bushing.
• For combination of tools for installation, refer
to “SPECIAL TOOL ASSY (41399FG001)”.
ST41399FG020
41399FG031 SPECIAL TOOL C • Used for removing the rear differential mount
bushing.
• For combination of tools for removal, refer to
“SPECIAL TOOL ASSY (41399FG001)”.
ST41399FG031
41399FG041 SPECIAL TOOL D • Used for installing the rear differential mount
bushing.
• For combination of tools for installation, refer
to “SPECIAL TOOL ASSY (41399FG001)”.
ST41399FG041
41399FG050 SPECIAL TOOL • Used for removing and installing the rear dif-
SLEEVE ferential mount bushing.
• For combination of tools for removal and instal-
lation, refer to “SPECIAL TOOL ASSY
(41399FG001)”.
ST41399FG050
DI-17
General Description
DIFFERENTIALS

RING ferential mount bushing.
(41399FG001)”.
ST41399FG061
NUT ferential mount bushing.
(41399FG001)”.
ST41399FG070
BEARING ferential mount bushing.
(41399FG001)”.
ST41399FG080
SHAFT ferential mount bushing.
(41399FG001)”.
ST41399FG091
2. GENERAL TOOL
TOOL NAME REMARKS
Transmission jack Used for removing and installing the rear differential.
Puller Used for removing the side retainer.
Thickness gauge Used for measuring clearance.
DI-18
Differential Gear Oil

DIFFERENTIALS
2. Differential Gear Oil • T-type (H3)
A: INSPECTION (A)
3) Disconnect the oil temperature switch connec-
tor. (T-type (H3))
DI-00750
(A) (A) Oil temperature switch
6) Install the filler plug or the oil temperature switch.

NOTE:
DI-00749
• For the T-type (B2), apply liquid gasket to the
drain plug.
(A) Oil temperature switch connector • For T-type (H3), use a new gasket.
• Install the oil temperature switch and adapter as
4) Remove the filler plug or the oil temperature a unit.
switch, and then check the gear oil. Replace the
gear oil if it is contaminated, deteriorated or cloudy. Liquid gasket:
<Ref. to DI-20, REPLACEMENT, Differential Gear THREE BOND 1105 (Part No. 004403010) or
Oil.> equivalent
Remove the oil temperature switch and adapter as T-type (B2)
a unit. 49 N·m (5.0 kgf-m, 36.1 ft-lb)
5) Check that the gear oil level is within –5 mm (–0.2 T-type (H3)
in) from the bottom of the filler plug hole or of the oil 60 N·m (6.1 kgf-m, 44.3 ft-lb)
temperature switch hole. If the level is low, confirm 7) Connect the oil temperature switch connector.
that there is no oil leakage and refill up to the bottom (T-type (H3))
of filler plug hole or the oil temperature switch hole.
• T-type (B2)
(A)
(A)
DI-00749
(A) Oil temperature switch connector

DI-00711
(A) Filler plug 8) Lower the vehicle.

DI-19

DIFFERENTIALS
B: REPLACEMENT • T-type (H3)

CAUTION:
• Gear oil is extremely hot just after driving. Be
wary of receiving burns.
• Be careful not to spill the differential gear oil
on exhaust pipe. If gear oil is spilled, wipe it off
completely. (A)
1) Disconnect the ground cable from battery. (B)
3) Disconnect the oil temperature switch connec-
tor. (T-type (H3)) DI-00593
(A) Oil temperature switch

(B) Drain plug
5) Tighten the drain plug.

(A) NOTE:
drain plug.
• For T-type (H3), use a new gasket.
DI-00749 Liquid gasket:
(A) Oil temperature switch connector equivalent
4) Remove the drain plug and filler plug or the oil Tightening torque:
temperature switch, and drain the gear oil. T-type (B2)
49 N·m (5.0 kgf-m, 36.1 ft-lb)
NOTE:
T-type (H3)
Remove the oil temperature switch and adapter as
60 N·m (6.1 kgf-m, 44.3 ft-lb)
a unit.
6) Fill the differential carrier with gear oil to the bot-
• T-type (B2)
tom of filler plug hole or the oil temperature switch
hole.
(A) NOTE:
Carefully refill gear oil while watching the level. Ex-
cessive or insufficient oil must be avoided.
Recommended gear oil:
(B) <Ref. to DI-2, SPECIFICATION, General De-
scription.>
DI-00522 Oil capacity:
6MT model
(A) Filler plug 1.0 L (1.1 US qt, 0.9 Imp qt)
(B) Drain plug 5MT model
0.8 L (0.8 US qt, 0.7 Imp qt)
DI-20

DIFFERENTIALS
• T-type (B2) 8) Connect the oil temperature switch connector.

(T-type (H3))
(A)
(A)
(B)
DI-00521
DI-00749
(A) Filler plug
(B) Drain plug (A) Oil temperature switch connector
• T-type (H3) 9) Lower the vehicle.

(A)
(B)
DI-00531
(A) Oil temperature switch

(B) Drain plug
7) Install the filler plug or the oil temperature switch.

NOTE:
drain plug.
a unit.
Liquid gasket:
equivalent
Tightening torque:
T-type (B2)
49 N·m (5.0 kgf-m, 36.1 ft-lb)
T-type (H3)
60 N·m (6.1 kgf-m, 44.3 ft-lb)
DI-21

DIFFERENTIALS
3. Front Differential Assembly

A: NOTE
• 6MT
For front differential for the 6MT, refer to the “6MT”
section. <Ref. to 6MT-100, Front Differential As-
sembly.>
• 5MT
For front differential for the 5MT, refer to the “5MT”
section. <Ref. to 5MT-68, Front Differential Assem-
bly.>
DI-22
Rear Differential (T-type)

DIFFERENTIALS
4. Rear Differential (T-type) 12) Remove the DOJ of rear drive shaft from rear
differential.
A: REMOVAL (1) Remove the ABS wheel speed sensor cable
1) Disconnect the ground cable from battery. from the clamp.
2) Place the gear shift lever in neutral.
3) Release the parking brake. (A)
4) Loosen the wheel nuts.

6) Remove the wheels.
7) Disconnect the oil temperature switch connector
and ground connector. (H3)
(B)
DI-00507
(A) ABS wheel speed sensor cable

(A)
(2) Remove the bolts which secure the rear sta-
bilizer link to the rear lateral link.
DI-00536
(A) Oil temperature switch connector

(B) Ground connector
8) Drain differential gear oil. <Ref. to DI-20, RE-

PLACEMENT, Differential Gear Oil.>
<Ref. to EX(w/o STI)-2, General Description.> DI-00508
<Ref. to EX(STI)-13, REMOVAL, Rear Exhaust (3) Remove the bolts which secure the shock
Pipe.> <Ref. to EX(w/o STI)-2, General Descrip- absorber to the rear lateral link.
tion.> <Ref. to EX(STI)-15, REMOVAL, Muffler.>
FU-03359
MT-01660
(4) Remove the bolts which secure the rear lat-
eral link to the housing.
DI-00509
DI-23

DIFFERENTIALS
(5) Remove the bolts which secure the trailing 14) Support the rear differential with the transmis-
link to the housing. sion jack.
DI-00510 DI-00745
(6) Remove the DOJ from the rear differential 15) Remove the rear differential front member.
by using ST.
NOTE:
When removing the DOJ from the rear differential,
fit the ST to the bolts as shown in the figure so as
not to damage the side retainer.
ST 28099PA100 DRIVE SHAFT REMOVER
ST
DI-00742
16) Remove the self-lock nuts which hold the rear

differential to the rear crossmember.
(A) DI-00270
(A) Bolt
13) Suspend the rear drive shaft to the rear cross-

member using wire.
DI-00602
17) While slowly lowering the transmission jack,

move the rear differential forward, and remove the
rear differential from the vehicle.
DI-00583
DI-00614
DI-24

DIFFERENTIALS
18) Remove the rear differential member plate from 4) After inserting the rear differential stud bolt into
the rear differential. the rear crossmember bushing, lift up the transmis-
sion jack and align the rear differential to its attach-
(A)
ment position.
DI-00359
(A) Rear differential member plate DI-00613
5) Tighten a new self-locking nut temporarily to rear

B: INSTALLATION crossmember.
1) Attach the rear differential member plate to the
rear differential.
(A)
DI-00602
DI-00359
6) Install the rear differential front member with a
new self-locking nut.
(A) Rear differential member plate Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
2) Set the rear differential to transmission jack.
T2: 110 N·m (11.2 kgf-m, 81.1 ft-lb)
3) Adjust the transmission jack and properly insert
the rear differential stud bolt into rear crossmember
bushing.
T2
T1
DI-00541
DI-00614
DI-25

DIFFERENTIALS
7) Tighten the self-locking nut. 13) Installing procedure hereafter is in the reverse
order of removal.
Tightening torque:
14) After installing, fill the differential carrier with
70 N·m (7.1 kgf-m, 51.6 ft-lb)
gear oil up to the bottom of the filler plug or the oil
temperature switch hole. <Ref. to DI-20, RE-
15) Inspect the wheel alignment and adjust if nec-
essary.
C: DISASSEMBLY
1. T-TYPE (B2)
To detect the real cause of trouble, inspect the fol-
lowing items before disassembling.
DI-00602
• Tooth contact and backlash between hypoid
8) Attach the ST to rear differential. driven gear and drive pinion
ST 28099PA090 OIL SEAL PROTECTOR • 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 ST 398217700 ATTACHMENT SET
DI-00279
9) Insert the spline shaft until the spline portion

comes inside the side oil seal.
ST
DI-00061
2) Remove the air breather cap.

NOTE:
• Do not attempt to remove the air breather cap
unless necessary.
• Whenever the air breather cap is removed, re-
place it with a new part.
DI-00280 (A)
10) Remove ST from rear differential.

11) Push the housing to fully insert the DOJ into the
rear differential.
(B)
DI-00672
(A) Air breather cap

(B) Rear cover
3) Remove the drain plug and filler plug.

DI-00518
4) Remove the bolts, and then remove the rear
12) Lower the transmission jack. cover.
DI-26

DIFFERENTIALS
5) Remove the side retainer attachment bolts, set 9) Using the ST, remove the bearing cone.
the ST to differential case, and extract the side re- NOTE:
tainers RH and LH with a puller.
• Do not attempt to disassemble the parts unless
NOTE: necessary.
• Side retainer shim of each side should be kept • Set the puller so that its claws catch the edge of
together with its mating retainer. the bearing cone.
• Keep the side retainers separate by attaching • Never mix up the RH and LH bearing races and
tags or in similar ways to make it possible to identify cones.
RH and LH sides during reassembly. ST 18759AA000 PULLER ASSY
ST 398457700 ATTACHMENT
ST
ST
DI-00316
DI-00064
10) Remove the hypoid driven gear by loosening
6) Pull out the differential case assembly from the hypoid driven gear bolts.
differential carrier.
NOTE:
Be careful not to hit the teeth of hypoid driven gear
against the differential carrier.
DI-00068
11) Remove the pinion shaft lock pin from driven

gear side using ST.
DI-00065
7) Remove the oil seal and O-ring from the side re-
tainer.
ST
8) When replacing the side bearing, remove the
bearing cup from the side retainer using ST.
DI-00701
ST
DI-00066
DI-27

DIFFERENTIALS
12) Draw out the pinion mate shaft, and remove 15) Press the end of drive pinion shaft by using the
pinion mate gears, pinion mate gear washers, side ST, and remove the drive pinion shaft, rear bearing
gears, and side gear thrust washers. cone, preload adjusting spacer and washer.
NOTE: NOTE:
The gears and washers should be marked or kept Hold the drive pinion so as not to drop it.
separately right and left, and front and rear. ST 398467700 DRIFT
(A)
(F)
(C) (B)
(A) ST
(C)
(F)
(E)
(D)
DI-00685 DI-00073
(A) Side gear 16) Remove the rear bearing cone from drive pin-
ion while supporting the cone with ST.
(B) Pinion mate gear
(C) Side gear thrust washer NOTE:
(D) Differential case Place the replacer so that its center-recessed side
(E) Pinion mate shaft
faces the bearing cone.
ST 398517700 REPLACER
(F) Pinion mate gear washer
13) Remove the self-locking nut while securing the

companion flange with ST.
ST 498427200 FLANGE WRENCH
ST
DI-00074
17) Remove the front oil seal from differential carri-

er using ST.
ST ST 398527700 PULLER ASSY
DI-00071
(A)
14) Extract the companion flange with a puller.
(A)
(B)
DI-00145
(B) (A) Differential carrier

DI-00142
(B) Front oil seal
(A) Companion flange
(B) Puller
DI-28

DIFFERENTIALS
18) Remove the pilot bearing together with the front 2. T-TYPE (H3)
bearing cone and spacer using the ST. To detect the real cause of trouble, inspect the fol-
ST 398467700 DRIFT lowing items before disassembling.
• Tooth contact and backlash between hypoid
ST 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
(D) (B)
(C) (A)
DI-00076
(A) Pilot bearing

(B) Spacer
(C) Front bearing
(D) Rear bearing cup
ST
19) When replacing the bearings, hit out the front
DI-00061
bearing race and rear bearing race in this order us-
ing a brass bar. 2) Remove the drain plug and oil temperature
switch, and drain the gear oil.
(A) NOTE:
Remove the oil temperature switch and adapter as
a unit.
3) Remove the air breather cap.
NOTE:
• Do not attempt to remove the air breather cap
unless necessary.
(B) • Whenever the air breather cap is removed, re-
DI-00077 place it with a new part.
(A) 2 cutout portions along diagonal lines (A)
(B) Tap alternately with brass bar.
(B)
(C)
(D)
DI-00678
(A) Air breather cap

(B) Rear cover
(C) Oil temperature switch
(D) Drain plug
4) Remove the bolts, and then remove the rear

cover.
DI-29

DIFFERENTIALS
5) Remove the side retainer attachment bolts, set 9) Using the ST, remove the bearing cone.
the ST to differential case, and extract the side re- NOTE:
tainers RH and LH with a puller.
• Do not attempt to disassemble the parts unless
NOTE: necessary.
• Side retainer shim of each side should be kept • Set the puller so that its claws catch the edge of
together with its mating retainer. the bearing cone.
• Keep the side retainers separate by attaching • Never mix up the RH and LH bearing races and
tags or in similar ways to make it possible to identify cones.
RH and LH sides during reassembly. ST 18759AA000 PULLER ASSY
ST 398457700 ATTACHMENT
ST
ST
DI-00316
DI-00064
10) Remove the hypoid driven gear by loosening
6) Pull out the differential case assembly from the hypoid driven gear bolts.
differential carrier.
NOTE:
NOTE: Do not disassemble the differential case assembly.
DI-00068
11) Remove the self-locking nut while securing the

DI-00065
companion flange with ST.
7) Remove the oil seal and O-ring from the side re- ST 18633AA000 WRENCH COMPL
tainer.
8) When replacing the side bearing, remove the
bearing cup from the side retainer using ST.
ST ST
DI-00071
DI-00066
DI-30

DIFFERENTIALS
12) Extract the companion flange with a puller. 15) Remove the front oil seal from differential carri-
er using ST.
(A)
(A)
(B)
DI-00142
(B)
(A) Companion flange DI-00145
(B) Puller
(A) Differential carrier
13) Press the end of drive pinion shaft by using the (B) Front oil seal
ST, and remove the drive pinion shaft, rear bearing
cone, preload adjusting spacer and washer. 16) Remove the pilot bearing together with the front
NOTE: bearing cone and spacer using the ST.
Hold the drive pinion so as not to drop it. ST 398467700 DRIFT
ST 398467700 DRIFT
ST
ST
(D) (B)
(C) (A)
DI-00076
DI-00073
(A) Pilot bearing
14) Remove the rear bearing cone from drive pin- (B) Spacer
ion by supporting the cone with ST. (C) Front bearing
NOTE: (D) Rear bearing cup
Place the replacer so that its center-recessed side
faces the bearing cone. 17) When replacing the bearings, use a brass bar
ST 398517700 REPLACER to tap out the front bearing race and rear bearing
race in this order to remove them.
(A)
ST
DI-00074 (B)
DI-00077
(A) 2 cutout portions along diagonal lines

(B) Tap alternately with brass bar.
DI-31

DIFFERENTIALS
D: ASSEMBLY (2) Install the front bearing race to the differen-

tial carrier using ST1 and ST2.
1. T-TYPE (B2)
NOTE:
NOTE: Use a new front bearing race.
• Assemble in the reverse order of disassembly. ST1 398477701 HANDLE
• Check and adjust each part during assembly. ST2 398477702 DRIFT
• Keep the shims and washers in order, so that (3) Insert the ST1 (DUMMY SHAFT) into carrier
they are not improperly installed. with the pinion height adjusting washer and rear
• Thoroughly clean the surfaces on which the bearing cone fitted onto it.
shims, washers and bearings are to be installed.
NOTE:
• Apply gear oil when installing the bearings and
thrust washers. If tooth contact (drive pinion, hypoid driven gear) is
normal in the inspection before disassembling, ver-
• Be careful not to mix up the RH and LH bearing
ify that the washer is not deformed, and then re-use
races.
the used washer.
• Use a new O-ring and gasket.
(4) Install the preload adjusting spacer and
• Replace the oil seal with a new part at every dis-
washer, front bearing cone, ST2, companion
assembly.
flange and self-locking nut.
• Be careful not to mix up the oil seal RH and LH.
ST1 398507702 DUMMY SHAFT
• Apply differential gear oil to the lips when install-
ST2 398507703 DUMMY COLLAR
ing the oil seal.
(A)
(B)
(C)
ST2 ST1
DI-00080
DI-00697
1) Adjusting preload for front and rear bearings (A) Pinion height adjusting washer
(B) Preload adjusting spacer
NOTE:
Adjust the bearing preload between front and rear (C) Preload adjusting washer
bearings with spacer and washer. Pinion height ad-
justing washer is not affected by this adjustment. (5) Turn the ST1 by hand to smooth the bear-
The adjustment must not be carried out with oil seal ing, and tighten the self-locking nut while mea-
inserted. suring the initial load or initial torque with a
spring scale or torque wrench. Select the pre-
(1) Install the rear bearing race into the differen-
load adjusting washer and spacer so that the
tial carrier using ST1 and ST2.
specified preload is obtained when nut is tight-
ST1 398477701 HANDLE
ened to the specified torque.
ST2 398477703 DRIFT 2
NOTE:
• Use a new self-locking nut.
• Measure the preload in direction of tangent to the
flange.
• Be careful not to give excessive preload.
• When tightening the self-locking nut, lock ST1
with ST2 as shown in the figure.
ST2 ST1 398507702 DUMMY SHAFT
ST1 ST2 398507704 BLOCK
DI-00079
DI-32

DIFFERENTIALS
Tightening torque: Preload adjusting washer

181.5 N·m (18.5 kgf-m, 133.9 ft-lb)
383705200 2.59 (0.1020)
383715200 2.57 (0.1012)
383725200 2.55 (0.1004)
383735200 2.53 (0.0996)
ST1 383745200 2.51 (0.0988)
383755200 2.49 (0.0980)
ST2
383765200 2.47 (0.0972)
383775200 2.45 (0.0965)
DI-00081 383785200 2.43 (0.0957)
383795200 2.41 (0.0949)
Initial load:
383805200 2.39 (0.0941)
18.1 — 38.8 N (1.8 — 4.0 kgf, 4.1 — 8.7 lbf)
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)
DI-00715 383695203 56.6 (2.228)
Initial torque: 383695204 56.8 (2.236)
0.69 — 1.47 N·m (0.07 — 0.15 kgf-m, 0.51 — 383695205 57.0 (2.244)
1.08 ft-lb) 383695206 57.2 (2.252)
2) Adjusting drive pinion height:

Adjust the drive pinion height with pinion height ad-
justing washer installed between the rear bearing
cone and the back of pinion gear.
(1) Attach the ST2.
NOTE:
At this time, install a provisionally selected or previ-
ously used pinion height adjusting washer. Mea-
DI-00481
sure and record the thickness.
ST2 398507701 DIFFERENTIAL CARRIER
GAUGE
ST3 ST1 RH ST2
N
LH
(A)
DI-00083
(A) Pinion height adjusting washer
DI-33

DIFFERENTIALS
(2) Measure the clearance “N” between the end (Example of calculation)
of ST2 and the end surface of ST1 by using a To = 3.39 mm (0.1335 in)
thickness gauge. N = 0.24 mm (0.0094 in)
NOTE: H=+1
Make sure there is no clearance between the differ- T = 3.39 mm (0.1335 in) + 0.24 mm (0.0094 in)
ential carrier and ST2. – 0.01 mm (0.0004 in) – 0.20 mm (0.0079 in) =
ST1 398507702 DUMMY SHAFT 3.42 mm (0.1346 in)
ST2 398507701 DIFFERENTIAL CARRIER Result: Thickness = 3.42 mm (0.1346 in)
GAUGE Therefore use washer 383605200.
ST2 Part No. Thickness mm (in)
383495200 3.09 (0.1217)
383505200 3.12 (0.1228)
383515200 3.15 (0.1240)
ST1 383525200 3.18 (0.1252)
383535200 3.21 (0.1264)
383545200 3.24 (0.1276)
383555200 3.27 (0.1287)
DI-00084
383565200 3.30 (0.1299)
(3) Obtain the thickness of pinion height adjust- 383575200 3.33 (0.1311)
ing washer to be inserted from the following for- 383585200 3.36 (0.1323)
mula, and replace the temporarily installed
383595200 3.39 (0.1335)
washer with this one.
T = To + N – (H × 0.01) – 0.20 mm (0.0079 in) 383605200 3.42 (0.1346)
383615200 3.45 (0.1358)
T Thickness of pinion height adjusting washer mm (in)
383625200 3.48 (0.1370)
To Thickness of washer temporarily inserted mm (in)
383635200 3.51 (0.1382)
N Clearance of thickness gauge mm (in)
383645200 3.54 (0.1394)
H Figure marked on drive pinion head
383655200 3.57 (0.1406)
Memo:
383665200 3.60 (0.1417)
383675200 3.63 (0.1429)
383685200 3.66 (0.1441)
3) Install the selected pinion height adjusting wash-

er on drive pinion, and press the rear bearing cone
into position with ST.
ST
DI-00085
DI-34

DIFFERENTIALS
4) Insert the drive pinion into the differential carrier, 7) Using the ST, install the oil seal.
and install the preselected preload adjusting spac- NOTE:
er and washer.
• Press-fit until the oil seal end comes 1 mm (0.04
(A) in) inward from end of carrier.
(B) • Apply differential gear oil to the oil seal lips.
(C) ST 498447120 INSTALLER
ST
(D)
DI-00704
(A) Drive pinion

(C) Preload adjusting washer
DI-00089
(D) Differential carrier
8) Press-fit the companion flange with ST1 and
5) Press-fit the front bearing cone with ST1, ST2 ST2.
and ST3. NOTE:
NOTE: Be careful not to damage the bearing.
Use new front bearing cone. ST1 899874100 INSTALLER
ST1 398507703 DUMMY COLLAR ST2 399780104 WEIGHT
ST3 899580100 INSTALLER ST1
ST3
ST1
ST2
DI-00090
ST2
9) Apply seal material on the drive pinion shaft
DI-00087 thread and new self-locking nut seat.
6) Insert the spacer, then press-fit the pilot bearing Seal material:
with ST1 and ST2. THREE BOND 1324 (Part No. 004403042) or
NOTE: equivalent
Use a new pilot bearing.
ST2
ST1
DI-00088
DI-35

DIFFERENTIALS
10) Attach the new self-locking nut and use the ST 12) Assembling differential case
to fix the companion flange in place, then tighten Install the side gears and pinion mate gears, with
the self-locking nut. their side gear thrust washers and pinion mate
shaft, into the differential case.
Tightening torque:
181.5 N·m (18.5 kgf-m, 133.9 ft-lb) NOTE:
ST 498427200 FLANGE WRENCH • Apply gear oil on both sides of the washer and on
the side gear shaft before installing.
• Insert the pinion mate shaft into the differential
case by aligning the lock pin holes.
ST
DI-00091
11) Check the initial torque or initial load.

Initial load:
18.1 — 38.8 N (1.8 — 4.0 kgf, 4.1 — 8.7 lbf)
DI-00715 DI-00686
Initial torque: (1) Measure the side gear backlash.

0.69 — 1.47 N·m (0.07 — 0.15 kgf-m, 0.51 — Side gear backlash:
1.08 ft-lb) 0.10 — 0.20 mm (0.004 — 0.008 in)
DI-00481 DI-00240
(2) Adjust the backlash as specified by select-

ing side gear thrust washer.
Side gear thrust washer
383445201 0.75 — 0.80 (0.0295 — 0.0315)
383445202 0.80 — 0.85 (0.0315 — 0.0335)
383445203 0.85 — 0.90 (0.0335 — 0.0354)
DI-36

DIFFERENTIALS
(3) Check the condition of rotation after apply- 15) Using the ST, press-fit the side bearing outer
ing oil to the gear tooth surfaces and washer race to the side retainer.
surfaces. CAUTION:
(4) Drive the pinion shaft lock pin into the differ- Make sure that the bearing outer races and
ential case. cones are properly assembled.
NOTE: ST 398417700 DRIFT
Use a new pinion shaft lock pin.
ST1 899904100 STRAIGHT PIN REMOVER
13) Install the driven gear to the differential case.
NOTE:
• Before installing bolts, apply seal material to bolt ST
threads.
Seal material:
equivalent
DI-00324
• Make sure there is no clearance between the dif-
ferential case and driven gear. 16) Side retainer shim adjustment
• Tighten opposing bolts in order. (1) The hypoid driven gear backlash and side
bearing preload can be adjusted by the side re-
Tightening torque: tainer shim thickness.
103 N·m (10.5 kgf-m, 76.0 ft-lb) (2) Install the differential case assembly into dif-
ferential carrier in the reverse order of disas-
sembly.
NOTE:
DI-00068
14) Using the ST, press-fit the side bearing cone to

the differential case.
ST 398487700 DRIFT
DI-00065
(3) Install the side retainer shim.

ST
NOTE:
• Be careful not to mix up the side retainer shim
RH and LH.
• Replace broken or corroded side retainer shims
with a new part of the same thickness.
DI-00095 Side retainer shim
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
DI-37

DIFFERENTIALS
(4) Align the arrow mark on the differential car- Backlash:

rier with the arrow mark on the side retainer 0.10 — 0.20 mm (0.004 — 0.008 in)
when installing the side retainer.
NOTE:
Be careful that the side bearing outer race is not
damaged by the bearing roller.
DI-00099
(A) (7) Measure the total preload of the drive pin-

ion. If the total preload is not within specifica-
tion, adjust the thickness of side retainer shims,
(B) DI-00543 increasing/reducing both shims by an even
amount at a time.
(A) Arrow mark (on the side retainer)
(B) Arrow mark (on the differential carrier)
Total preload:
20.7 — 54.4 N (2.1 — 5.5 kgf, 4.7 — 12.2 lbf)
(5) Tighten the side retainer bolts. 17) Recheck the hypoid driven gear to drive pinion
backlash.
Tightening torque:
10.5 N·m (1.1 kgf-m, 7.7 ft-lb) Backlash:
0.10 — 0.20 mm (0.004 — 0.008 in)
DI-00487
DI-00099
(6) Measure the hypoid driven gear to drive pin-
ion backlash. Set the magnet base on differen- 18) Check pinion and hypoid driven gears rotate
tial carrier. Align the contact point of dial gauge smoothly and make sure of the hypoid driven gear
with tooth face of hypoid driven gear, and move runout on its back surface. If the hypoid driven gear
hypoid driven gear while holding drive pinion runout on its back surface exceeds the specifica-
still. Read the value indicated on dial gauge. If tion, check for any foreign objects between the hy-
the backlash is outside the standard range, ad- poid driven gear and differential case, and for any
just the side retainer shim by the following deformation of the case or gear.
method. Hypoid driven gear back surface runout:
•When backlash is less than 0.1 mm (0.004 0.05 mm (0.002 in)
in):
Reduce the thickness of shim on the back side
of the hypoid driven gear and increase the
thickness of shims on the teeth side of the hy-
poid driven gear.
•When backlash exceeds 0.2 mm (0.008 in):
Increase the thickness of shim on the back side
of the hypoid driven gear and reduce the thick-
ness of shims on the teeth side of the hypoid
driven gear.
DI-00101
DI-38

DIFFERENTIALS
19) Check and adjustment of the tooth contact of Corrective action: Increase thickness of pinion
hypoid driven gear and drive pinion height adjusting washer according to the proce-
(1) Apply lead-free red dye evenly on the both dure for bringing drive pinion close to hypoid
sides of three to four teeth of the hypoid driven driven gear side.
gear. Check the contact pattern after rotating
the hypoid driven gear several revolutions back
and forth until a definite contact pattern appears
on the hypoid driven gear.
(2) When the contact pattern is not correct, re-
adjust.
NOTE:
Be sure to wipe off the lead-free red dye completely
after the adjustment is completed.
• Correct tooth contact AT-00212
Check item: Tooth contact pattern is slightly • Flank contact
shifted toward toe side under no-load rota-
tion. (When driving, it moves towards the
Contact pattern
heel side.)
(A)
(B)
AT-00209
MT-01401
Corrective action: Reduce the thickness of pin-
(A) Toe side ion height adjusting washer according to the
(B) Heel side procedure for bringing drive pinion away from
hypoid driven gear.
• Face contact
Contact pattern
AT-00213
AT-00208
DI-39

DIFFERENTIALS
• Toe contact (inside contact) Corrective action: Increase thickness of pinion

Check item: Teeth contact area is too small. height adjusting washer according to the proce-
Contact pattern dure for bringing drive pinion close to hypoid
driven gear side.
AT-00210
AT-00212
ion height adjusting washer according to the 20) If proper tooth contact is not obtained, readjust
procedure for bringing drive pinion away from the drive pinion height by changing the RH and LH
hypoid driven gear. side retainer shims and the hypoid gear backlash.
(1) Drive pinion height
ST2 398507701 DIFFERENTIAL CARRIER
GAUGE
ST2
AT-00213 ST1

Contact pattern
DI-00084
T = To + N – (H × 0.01) – 0.20 mm (0.008 in)

T Thickness of pinion height adjusting washer mm (in)
To Thickness of washer temporarily inserted mm (in)
N Clearance of thickness gauge mm (in)
H Figure marked on drive pinion head
(2) Hypoid gear backlash

Backlash:
AT-00211
0.10 — 0.20 mm (0.004 — 0.008 in)
DI-00099
DI-40

DIFFERENTIALS
21) Remove the RH and LH side retainers. 26) Install the gasket and rear cover, and tighten
22) Install the O-ring to left and right side retainers. the bolts to specified torque.
NOTE: NOTE:
Use new O-rings. Use a new gasket.
23) Install the oil seal to the side retainers on both Tightening torque:
sides. <Ref. to DI-56, REPLACEMENT, Rear Dif-
29.5 N·m (3.0 kgf-m, 21.8 ft-lb)
ferential Side Oil Seal.>
24) Align the arrow mark on the differential carrier
with the arrow mark on the side retainer when in-
stalling the side retainer.
DI-00490
(A)
27) Install the air breather cap.
NOTE:
(B) DI-00543 When installing the air breather cap, do not tap sec-
tion (A). Be sure to tap section (B) to install.
(A)
25) Apply liquid gasket to the bolts indicated by ar-
rows, and tighten the bolts.
(B)
Liquid gasket:
THREE BOND 1110B (Part No. K0879Y0020)
or equivalent
Tightening torque:
10.5 N·m (1.1 kgf-m, 7.7 ft-lb)
DI-00461
DI-00674
DI-41

DIFFERENTIALS
28) Install the drain plug. 1) Adjusting preload for front and rear bearings
NOTE: NOTE:
Apply liquid gasket to the drain plug. Adjust the bearing preload between front and rear
bearings with spacer and washer. Pinion height ad-
Liquid gasket:
justing washer is not affected by this adjustment.
The adjustment must not be carried out with oil seal
equivalent
inserted.
Tightening torque: 2) Using the ST, press-fit the rear bearing race to
49 N·m (5.0 kgf-m, 36.1 ft-lb) the differential carrier.
29) Install the filler plug. ST 398417700 DRIFT
NOTE:
After installing the rear differential assembly to the
vehicle, fill the gear oil, then apply liquid gasket,
and tighten to the specified torque. <Ref. to DI-20,
ST
REPLACEMENT, Differential Gear Oil.>
2. T-TYPE (H3)
NOTE:
• Assemble in the reverse order of disassembly.
• Check and adjust each part during assembly. DI-00318
• Keep the shims and washers in order, so that 3) Using the ST, press-fit the front bearing race to
they are not improperly installed. the differential carrier.
• Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed. NOTE:
• Apply gear oil when installing the bearings and Use a new front bearing race.
thrust washers. ST 398477702 DRIFT
• 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.
• Be careful not to mix up the oil seal RH and LH.
• Apply differential gear oil to the lips when install-
ing the oil seal.
DI-00319
DI-00697
DI-42

DIFFERENTIALS
4) Selecting the pinion height adjusting washer (Example of calculation)

(1) Measure the thickness of the inserted pinion T1 = 3.30 mm (0.1299 in), T2 = +2, T3 = –1
height adjusting washer. T = 3.30 mm (0.1299 in) + {(2 × 0.01) – (–1 ×
0.01)} = 3.33 mm (0.1311 in)
Result: Thickness = 3.33 mm (0.1311 in)
The washer with part number 38336AA310 is
used.
0 Part No. Thickness mm (in)
5
38336AA230 3.09 (0.1217)

15 10 5 0
10
38336AA240 3.12 (0.1228)

38336AA250 3.15 (0.1240)
DI-00320
38336AA260 3.18 (0.1252)
(2) Read the markings on both the current drive 38336AA270 3.21 (0.1264)
pinion gear and the new pinion gear. 38336AA280 3.24 (0.1276)
NOTE: 38336AA290 3.27 (0.1287)
No marking means 0 (zero). 38336AA300 3.30 (0.1299)
38336AA310 3.33 (0.1311)
38336AA320 3.36 (0.1323)
38336AA330 3.39 (0.1335)
+2 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)
DI-00321
38336AA400 3.60 (0.1417)
(3) Calculate the thickness of pinion height ad-
38336AA410 3.63 (0.1429)
justing washer to be inserted from the following
38336AA420 3.66 (0.1441)
formula, and replace the installed washer with a
new washer of the calculated thickness.
5) Install the selected pinion height adjusting wash-
T = T1 + (T2 × 0.01 – T3 × 0.01)
er on drive pinion, and push the rear bearing cone
T
Thickness of selected pinion height adjusting into position with ST.
washer mm (in) ST 18674AA000 INSTALLER
Thickness of inserted pinion height adjusting
T1
washer mm (in)
Number of the installed drive pinion gear marking
T2
mm (in)
T3 Number of new drive pinion gear marking mm (in)
ST
DI-00085
DI-43

DIFFERENTIALS
6) Insert the drive pinion into the differential carrier, 9) Press-fit the companion flange with ST1, ST2,
and install the originally attached preload adjusting and ST3.
spacer and washer. NOTE:
Be careful not to damage the bearing.
(A) ST1 899874100 INSTALLER
(B) ST2 399780104 WEIGHT
(C) ST3 498937110 HOLDER DRIVE PINION
ST1
ST3
(D)
DI-00704
(A) Drive pinion ST2

ST2
(C) Preload adjusting washer
DI-00323
(D) Differential carrier
10) Attach the self-locking nut and use the ST to fix
7) Install the front bearing cone. the companion flange in place, then tighten the
self-locking nut.
NOTE:
Use new front bearing cone. Tightening torque:
8) Insert the spacer and press-fit the pilot bearing 181.5 N·m (18.5 kgf-m, 133.9 ft-lb)
using ST. ST 18633AA000 WRENCH COMPL
NOTE:
Use a new pilot bearing.
ST4 498937110 HOLDER DRIVE PINION
ST2
ST
DI-00091
ST4
ST3
11) Rotate the drive pinion shaft 10 times or more
ST1 to fit it in the respective taper roller bearing, and
ST4 then measure the initial load or initial torque.
Initial load:
ST1 24.1 — 38.6 N (2.5 — 3.9 kgf, 5.4 — 8.7 lbf)
DI-00322
DI-00715
DI-44

DIFFERENTIALS
Initial torque: 13) Remove the self-locking nut while securing the
0.98 — 1.57 N·m (0.10 — 0.16 kgf-m, 0.72 — companion flange with ST.
1.16 ft-lb) ST 18633AA000 WRENCH COMPL
ST
DI-00481 DI-00091
12) When the bearing preload is out of the speci- 14) Extract the companion flange with a puller.
fied range, select the preload adjusting washer and
spacer from the following table in order to make it
(A)
within the specified range.
Preload adjusting washer
383705200 2.59 (0.1020)
383715200 2.57 (0.1012)
383725200 2.55 (0.1004)
383735200 2.53 (0.0996) (B)
DI-00142
383745200 2.51 (0.0988)
383755200 2.49 (0.0980) (A) Companion flange
383765200 2.47 (0.0972) (B) Puller
383775200 2.45 (0.0965)
383785200 2.43 (0.0957) 15) Using the ST, install the oil seal.
383795200 2.41 (0.0949) NOTE:
383805200 2.39 (0.0941) • Use a new oil seal.
383815200 2.37 (0.0933) • Press-fit until the oil seal end comes 1 mm (0.04
383825200 2.35 (0.0925) in) inward from end of carrier.
383835200 2.33 (0.0917) • Apply differential gear oil to the oil seal lips.
383845200 2.31 (0.0909) ST 498447120 INSTALLER

ST
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) DI-00089
DI-45

DIFFERENTIALS
16) Press-fit the companion flange with ST1, ST2, Initial torque:
and ST3. 0.98 — 1.57 N·m (0.10 — 0.16 kgf-m, 0.72 —
ST1 899874100 INSTALLER 1.16 ft-lb)
ST3 498937110 HOLDER DRIVE PINION
NOTE:
Be careful not to damage the bearing.
ST1
ST3
DI-00481
ST2 20) Install the driven gear to the differential case.

ST2
NOTE:
• Before installing bolts, apply seal material to bolt
DI-00323 threads.
17) Apply seal material on the drive pinion shaft Seal material:
thread and new self-locking nut seat.
Seal material: equivalent
THREE BOND 1324 (Part No. 004403042) or • Make sure there is no clearance between the dif-
equivalent ferential case and driven gear.
18) Attach the new self-locking nut and use the ST • Tighten opposing bolts in order.
to fix the companion flange in place, then tighten Tightening torque:
the self-locking nut.
103 N·m (10.5 kgf-m, 76.0 ft-lb)
Tightening torque:
181.5 N·m (18.5 kgf-m, 133.9 ft-lb)
ST 18633AA000 WRENCH COMPL
DI-00068
21) Using the ST, press-fit the side bearing to the

ST differential case.
DI-00071 ST 398487700 DRIFT
19) Check the initial torque or initial load.
Initial load:
24.1 — 38.6 N (2.5 — 3.9 kgf, 5.4 — 8.7 lbf)
ST
DI-00095
DI-00715
DI-46

DIFFERENTIALS
22) Using the ST, press-fit the side bearing outer (4) During installation, align the arrow mark on
race to the side retainer. the differential carrier with the arrow mark on
CAUTION: the side retainer when installing the side retain-
er.
Make sure that the bearing outer races and
cones are properly assembled. NOTE:
ST 398417700 DRIFT Be careful that side bearing outer race is not dam-
aged by the bearing roller.
ST
(A)
DI-00324
(B) DI-00543
23) Side retainer shim adjustment
(1) The hypoid driven gear backlash and side (A) Arrow mark (on the side retainer)
bearing preload can be adjusted by the side re- (B) Arrow mark (on the differential carrier)
tainer shim thickness.
(2) Install the differential case assembly into dif- (5) Tighten the side retainer bolts.
ferential carrier in the reverse order of disas-
sembly. Tightening torque:
10.5 N·m (1.1 kgf-m, 7.7 ft-lb)
NOTE:
DI-00487
DI-00065
(3) Install the side retainer shim.

NOTE:
• Be careful not to mix up the side retainer shim
RH and LH.
• Replace broken or corroded side retainer shims
with a new part of the same thickness.
Side retainer shim
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
DI-47

DIFFERENTIALS
(6) Measure the hypoid driven gear to drive pin- 24) Recheck the hypoid driven gear to drive pinion
ion backlash. Set the magnet base on differen- backlash.
tial carrier. Align the contact point of dial gauge
Backlash:
with tooth face of hypoid driven gear, and move
0.10 — 0.20 mm (0.004 — 0.008 in)
hypoid driven gear while holding drive pinion
still. Read the value indicated on dial gauge. If
the backlash is outside the standard range, ad-
just the side retainer shim by the following
method.
• When backlash is less than 0.1 mm (0.004
in):
Reduce the thickness of shim on the back side
of the hypoid driven gear and increase the
thickness of shims on the teeth side of the hy-
poid driven gear. DI-00099
• When backlash exceeds 0.2 mm (0.008
25) Check drive pinion and hypoid driven gears ro-
in):
tate smoothly and make sure of the hypoid driven
Increase the thickness of shim on the back side gear runout on its back surface. If the runout on the
of the hypoid driven gear and reduce the thick- back side of the hypoid driven gear exceeds the
ness of shims on the teeth side of the hypoid specification, check for any foreign material be-
driven gear. tween the hypoid driven gear and differential case,
Backlash: and for any deformation of the case or gear.
0.10 — 0.20 mm (0.004 — 0.008 in) Hypoid driven gear back surface runout:
0.05 mm (0.002 in)
DI-00099
(7) Measure the total preload of the drive pin- DI-00101

ion. If the total preload is not within specifica-
tion, adjust the thickness of side retainer shims,
increasing/reducing both shims by an even
amount on both sides.
Total preload:
26.5 — 53 N (2.7 — 5.4 kgf, 6.0 — 11.9 lbf)
DI-48

DIFFERENTIALS
26) Checking and adjusting the tooth contact of hy- Corrective action: Increase thickness of pinion
poid driven gear height adjusting washer according to the proce-
(1) Apply lead-free red dye evenly on the both dure for bringing drive pinion close to hypoid
sides of three to four teeth of the hypoid driven driven gear side.
gear. Check the contact pattern after rotating
the hypoid driven gear several revolutions back
and forth until a definite contact pattern appears
on the hypoid driven gear.
(2) When the contact pattern is not correct, re-
adjust.
NOTE:
Be sure to wipe off the lead-free red dye completely
after the adjustment is completed.
• Correct tooth contact AT-00212
Check item: Tooth contact pattern is slightly • Flank contact
shifted toward toe side under no-load rota-
tion. (When driving, it moves towards the
Contact pattern
heel side.)
(A)
(B)
AT-00209
MT-01401
(A) Toe side ion height adjusting washer according to the
(B) Heel side procedure for bringing drive pinion away from
hypoid driven gear.
• Face contact
Contact pattern
AT-00213
AT-00208
DI-49

DIFFERENTIALS
• Toe contact (inside contact) Corrective action: Increase thickness of pinion

Check item: Teeth contact area is too small. height adjusting washer according to the proce-
Contact pattern dure for bringing drive pinion close to hypoid
driven gear side.
AT-00210
AT-00212
ion height adjusting washer according to the 27) If proper tooth contact is not obtained, readjust
procedure for bringing drive pinion away from the drive pinion height by changing the RH and LH
hypoid driven gear. side retainer shims and the hypoid gear backlash.
28) Remove the RH and LH side retainers.
29) Install the O-ring to left and right side retainers.
NOTE:
Use new O-rings.
30) Install the oil seal to the side retainers on both
sides. <Ref. to DI-56, REPLACEMENT, Rear Dif-
ferential Side Oil Seal.>
31) Align the arrow mark on the differential carrier
with the arrow mark on the side retainer during in-
AT-00213 stallation.
Contact pattern
(A)
(B) DI-00543

AT-00211
DI-50

DIFFERENTIALS
32) Apply liquid gasket to the bolts indicated by ar- 35) Install the drain plug.
rows, and tighten the side retainer bolt. NOTE:
Liquid gasket: Use a new gasket.
THREE BOND 1110B (Part No. K0879Y0020) Tightening torque:
or equivalent
60 N·m (6.1 kg-m, 44.3 ft-lb)
Tightening torque: 36) Install the oil temperature switch.
10.5 N·m (1.1 kgf-m, 7.7 ft-lb) NOTE:
a unit.
• After installing the rear differential assembly to
the vehicle, fill the gear oil, then use a new gasket,
and tighten to the specified torque. <Ref. to DI-20,
REPLACEMENT, Differential Gear Oil.>
E: INSPECTION
Wash all the disassembled parts clean, and exam-
DI-00461
ine them for wear, damage and other defects. Re-
pair or replace the defective parts as necessary.
33) Install the gasket and rear cover, and tighten 1) Hypoid driven gear and drive pinion
the bolts to specified torque. • If there is evidently an abnormal tooth contact,
NOTE: find out the cause and adjust until the teeth contact
Use a new gasket. correctly. Replace the gear if there is an excessive
worn or an incapable adjustment.
Tightening torque:
• If crack, cutout or seizure is found, replace the
44 N·m (4.5 kgf-m, 32.5 ft-lb) parts as a set. Slight damage of some teeth can be
34) Install the air breather cap. corrected by oil stone or the like.
NOTE: 2) Side gear and pinion mate gear
When installing the air breather cap, do not tap sec- • Replace if cracks, scoring or other defects are
tion (A). Be sure to tap section (B) to install. evident on the tooth surface.
• Replace if thrust washer contact surface is worn
or seized. Slight damages of the surface can be
(A) corrected by oil stones or equivalent.
3) Bearing
(B) 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 sliding surfaces are abnormally worn,
burned, or cracked.
8) Companion flange
Replace if the oil seal lip contact surface shows
cracking.
DI-00679
DI-51

DIFFERENTIALS
9) Rear differential oil temperature switch (T-type 2. HYPOID DRIVEN GEAR BACKLASH
(H3)) Using a dial gauge, check the backlash of hypoid
Check the rear differential oil temperature switch driven gear.
for continuity.
Hypoid driven gear backlash:
Resistance Criteria
0.10 — 0.20 mm (0.004 — 0.008 in)
Less than 1 Ω Normal If the hypoid driven gear backlash is not within the
1 MΩ or more Replacement specification, adjust the side bearing preload or re-
pair if necessary.
DI-00534
DI-00099
1. SIDE GEAR BACKLASH (T-TYPE (B2)) 3. HYPOID DRIVEN GEAR RUNOUT ON ITS
Using a dial gauge, check the backlash of side BACK SURFACE
gear.
Using a dial gauge, check the hypoid driven gear
Side gear backlash: back surface runout.
0.10 — 0.20 mm (0.004 — 0.008 in) Hypoid driven gear back surface runout:
If the side gear backlash is not within the specifica- 0.05 mm (0.002 in)
tion, select the side gear thrust washer and adjust
If the hypoid driven gear runout exceeds specifica-
the side gear backlash to the specification.
tion, replace the hypoid driven gear.
DI-00315
DI-00101
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-32, ASSEM-
BLY, Rear Differential (T-type).>
DI-52

DIFFERENTIALS
5. TOTAL PRELOAD 3) Set the gauge inside of the companion flange,

Using a spring scale, check the total preload. and measure the runout.
Total preload: Limit of runout:

T-type (B2): 0.08 mm (0.003 in)
20.7 — 54.4 N (2.1 — 5.5 kgf, 4.7 — 12.2 lbf)
T-type (H3):
26.5 — 53 N (2.7 — 5.4 kgf, 6.0 — 11.9 lbf)
If the total preload is not within the specification,
adjust the side retainer shim.
DI-00361
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.
DI-00117 5) If the runout exceeds the limit after changing the
phase, replace the companion flange and recheck
6. COMPANION FLANGE the runout.
1) If rust or dirt is attached to the companion flange, 6) If the runout exceeds the limit after replacing the
remove them. companion flange, the drive pinion may be assem-
2) Set a dial gauge at a companion flange surface bled incorrectly or bearing is faulty.
(mating surface of propeller shaft and companion
flange), and then measure the companion flange F: ADJUSTMENT
runout. 1. SIDE GEAR BACKLASH (T-TYPE (B2))
Limit of runout: Adjust the side gear backlash. <Ref. to DI-32, AS-
0.08 mm (0.003 in) SEMBLY, Rear Differential (T-type).>
2. HYPOID DRIVEN GEAR BACKLASH
Adjust hypoid driven gear backlash. <Ref. to DI-32,
ASSEMBLY, Rear Differential (T-type).>
3. TOOTH CONTACT BETWEEN HYPOID
DRIVEN GEAR AND DRIVE PINION
Adjust the tooth contact between hypoid driven
gear and drive pinion gear. <Ref. to DI-32, ASSEM-
BLY, Rear Differential (T-type).>
DI-00360
4. TOTAL PRELOAD
Adjust the side retainer shim. <Ref. to DI-32, AS-
SEMBLY, Rear Differential (T-type).>
DI-53
Rear Differential Front Oil Seal

DIFFERENTIALS
5. Rear Differential Front Oil Seal • T-type (H3)
A: INSPECTION
Check 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 (A)
(B)
2) Shift the select lever or gear shift lever to neutral.
3) Release the parking brake. DI-00593
5) Disconnect the oil temperature switch connec- (A) Oil temperature switch
tor. (T-type (H3)) (B) Drain plug
7) Install the drain plug.

NOTE:
drain plug.
(A)
Liquid gasket:
equivalent
DI-00749
Tightening torque:
(A) Oil temperature switch connector T-type (B2);
49 N·m (5.0 kgf-m, 36.1 ft-lb)
6) Remove the drain plug and filler plug or the oil T-type (H3);
temperature switch, and drain the gear oil. 60 N·m (6.1 kgf-m, 44.3 ft-lb)
NOTE: 8) Remove the rear exhaust pipe and muffler.
Remove the oil temperature switch and adapter as • 6MT model
a unit. <Ref. to EX(STI)-13, REMOVAL, Rear Exhaust
• T-type (B2) Pipe.> <Ref. to EX(STI)-15, REMOVAL, Muffler.>
• 5MT model
<Ref. to EX(w/o STI)-2, General Description.>
(A)
(B)
DI-00522
(A) Filler plug

(B) Drain plug AT-04522

11) Check the initial torque and write it down.
DI-54
Rear Differential Front Oil Seal

DIFFERENTIALS
12) Remove the self-locking nut while holding the 15) Using the ST, install the oil seal.
companion flange with ST. NOTE:
ST 18633AA000 WRENCH COMPL (T-TYPE • Use a new oil seal.
(H3))
• Apply differential gear oil to the oil seal lips.
ST 498427200 FLANGE WRENCH (T-TYPE ST 498447120 INSTALLER
(B2))
ST ST
DI-00292
DI-00194
16) Use a plastic hammer to install companion
13) Remove the companion flange using ST.
flange.
17) Tighten the self-locking nut to the specified
ST
torque so that the rotating resistance of the com-
panion flange is the same value as that before re-
placing the oil seal.
NOTE:
• Use a new self-locking nut.
• Before installing the self-locking nut, apply seal
material to self-locking nut threads.
Seal material:
DI-00196 THREE BOND 1324 (Part No. 004403042) or
equivalent
14) Remove the oil seal using ST or screwdriver.
ST 398527700 PULLER ASSY Tightening torque:
167 — 196 N·m (17.0 — 20.0 kgf-m, 123.2 —
144.6 ft-lb)
ST 18633AA000 WRENCH COMPL (T-TYPE
(H3))
ST 498427200 FLANGE WRENCH (T-TYPE
(B2))
ST ST
DI-00197
DI-00199
18) Hereafter, reassemble in the reverse order of

disassembly.
19) After installing, fill the differential carrier with
gear oil up to the bottom of the filler plug hole or the
oil temperature switch hole. <Ref. to DI-20, RE-
DI-55
Rear Differential Side Oil Seal

DIFFERENTIALS
6. Rear Differential Side Oil Seal

A: INSPECTION
Check that there is no oil leakage from the side oil
seal. If there is any leakage, replace the oil seal.
B: REPLACEMENT
1) Remove the rear differential. <Ref. to DI-23, RE-
MOVAL, Rear Differential (T-type).>
2) Remove the rear differential side oil seal using a
ST or screwdriver wrapped with vinyl tape to pre-
vent the side retainer from scratching.
ST
DI-00208
3) Using the ST, install the side oil seal.

NOTE:
• Apply differential gear oil to the oil seal lips.
ST 398437700 DRIFT
ST
DI-00209
4) Install the rear differential. <Ref. to DI-25, IN-

STALLATION, Rear Differential (T-type).>
DI-56
Rear Differential Front Member

DIFFERENTIALS
7. Rear Differential Front Member

A: REMOVAL
3) Support the rear differential using transmission
jack, and then remove the rear differential front
member.
(A) DI-00540
(A) Rear differential front member
B: INSTALLATION
Install the rear differential front member with a new
self-locking nut.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 110 N·m (11.2 kgf-m, 81.1 ft-lb)
T2
T1
DI-00541
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 front
member for cracking, hardening and damage.
If cracking, hardening or damage is excessive, re-
place rear differential front member.
DI-57
Rear Differential Mount Bushing

DIFFERENTIALS
8. Rear Differential Mount Bush- 4) Set ST1, ST2, ST3, ST4 and ST5 as shown in
the figure.
ing ST1 41399FG091 SPECIAL TOOL SHAFT
A: INSPECTION ST2 41399FG070 SPECIAL TOOL NUT
ST3 41399FG050 SPECIAL TOOL SLEEVE
Check the rear differential mounting bushing for ST4 41399FG080 SPECIAL TOOL BEARING
cracks, hardening, or damage. If cracking, harden-
ST5 41399FG010 SPECIAL TOOL A
ing, or damage is excessive, replace the rear differ-
ential mounting bushing.
ST2 ST3 ST4 ST5 ST1
B: REPLACEMENT
CAUTION:
If there was so much rust in the rear differential
mount bushing, remove the rust before starting
work.
1) Remove the rear differential. <Ref. to DI-23, RE-
(A)
MOVAL, Rear Differential (T-type).>
2) Fit the ST to the periphery of the sub frame cyl- DI-00656
inder, and make sure that the ST does not contact
with welded spots or spatters. (A) 5 mm (0.2 in) or less
ST 41399FG010 SPECIAL TOOL A
5) Fit and hold the ST1 and ST2 to the rear differ-
(A) ential mount bushing from the rear side of vehicle.
ST1 41399FG031 SPECIAL TOOL C
ST
ST2 41399FG061 SPECIAL TOOL RING
ST1
(A)
DI-00655
ST2
(A) Welded spot
3) If the ST contacts with welded spots or spatters, DI-00657

remove the excessive welds or spatters with sand-
er or the equivalent so that the ST contacts the cyl- (A) Front side of vehicle
inder peripheral part.
CAUTION:
Performing the operation with the ST contact-
ing with welded spots or spatters may break the
ST. Be sure to remove excessive welds or spat-
ters before the operation.
DI-58

DIFFERENTIALS
6) Insert the ST set in the step 4) through the rear 7) Hold the ST1 to prevent it from rotating, and
differential mount bushing hole from the front side screw in the ST3 by hand till there is no loose fit on
of vehicle, and screw in the ST1 by hand till the the ST2.
front end of ST1 comes out slightly from the rear CAUTION:
end of ST2.
When setting the ST to the vehicle, always
ST1 41399FG091 SPECIAL TOOL SHAFT make sure that the ST2 fits the periphery of the
ST2 41399FG061 SPECIAL TOOL RING sub frame cylinder and is not tilted.
ST1 41399FG091 SPECIAL TOOL SHAFT
ST2
ST2 41399FG010 SPECIAL TOOL A
ST3 41399FG070 SPECIAL TOOL NUT
ST1
ST2
ST1
ST3
ST1 ST2
DI-00659
8) Hold the ST1 with a tool to prevent it from rotat-

ing, and screw in the ST2 to remove the rear differ-
ential mount bushing.
CAUTION:
• Rotation of ST1 will damage the screw at the
rear end of rear differential mount bushing.
DI-00708 Never rotate the ST1.
• If the ST starts to tilt while removing the rear
differential mount bushing, stop the work and
set the ST again.
ST2
ST1
DI-00660
DI-59

DIFFERENTIALS
9) Set ST1, ST2, ST3, ST4, ST5 and rear differen- 10) Attach ST1 to the ST2, and fit and hold the STs
tial mount bushing as shown in the figure. as a unit to the sub frame from the rear side of ve-
NOTE: hicle.
• Set the ST2 nut near to the end of ST1 screw. ST1 41399FG061 SPECIAL TOOL RING
• Hold the rear differential mount bushing with the ST2 41399FG041 SPECIAL TOOL D
marked side facing toward the rear of the vehicle,
and set the rear differential mount bushing to the
ST so that the arrow mark faces upward.
ST1
• Mark the bottom end of rear differential mount
bushing to identify the installing direction.
ST2 41399FG070 SPECIAL TOOL NUT ST2
ST3 41399FG050 SPECIAL TOOL SLEEVE
ST4 41399FG080 SPECIAL TOOL BEARING
ST5 41399FG020 SPECIAL TOOL B
ST1 ST3 ST5

ST2
ST1
ST2 ST4
(A)
(D)
DI-00662
11) Insert the ST set in the step 9) through the sub

frame from the front side of vehicle, and screw in
(B)
UP
the ST1 by hand till the front end of ST1 comes out
slightly from the rear end of ST2.
CAUTION:
(C) Set the rear differential mount bushing with its
mark facing the bottom end direction.
Z
DI-00661
(A) 8 mm (0.31 in) or more

(B) Arrow mark
(C) Mark
(D) Marked position
DI-60

DIFFERENTIALS
ST1 41399FG091 SPECIAL TOOL SHAFT 13) Screw in the ST2 while holding the ST1 with a
ST2 41399FG061 SPECIAL TOOL RING tool to prevent it from rotating, and press-fit the rear
differential mount bushing to the front end of sub
frame cylinder.
ST1
ST2
(A) ST1
ST1
DI-00665
14) Make sure that the rear differential mount bush-

ing is inserted to the front end of sub frame cylinder.
ST2
(A)
DI-00709
(A) Mark
12) Hold the ST1 to prevent it from rotating, and

screw in the ST2 by hand till there is no loose fit on
the ST and the rear differential mount bushing. DI-00666
CAUTION: (A) Front side of vehicle

Make sure that the ST and rear differential
mount bushing are not tilted. 15) Install the rear differential. <Ref. to DI-25, IN-
ST1 41399FG091 SPECIAL TOOL SHAFT STALLATION, Rear Differential (T-type).>
ST2
ST1
DI-00664
DI-61

DIFFERENTIALS

A: INSPECTION
Symptom or trouble Possible cause Remedy
1. Oil leakage (1) Worn, scratched, or incorrectly seated Repair or replace.
front or side oil seal. Scored, battered or
excessively worn sliding surface of com-
panion flange.
(2) Clogged or damaged air breather cap. Clean, repair or replace.
(3) Loose bolts on the side retainer, or Tighten the bolts to specified torque.
incorrectly fitted O-ring. Replace the O-ring.
(4) Loose rear cover attachment bolts or Replace the gasket, and tighten the bolts
damaged gasket. to specified torque.
(5) Loose filler plug or drain plug. • Apply liquid gasket, and tighten to the
specified torque. (T-type (B2))
• Replace the gasket, and tighten to the
specified torque. (T-type (H3))
(6) Wear, damage or incorrect fitting of Repair or replace.
drive shaft, side retainer or oil seal.
2. Seizure (1) Insufficient backlash for hypoid gear. Readjust or replace.
NOTE: (2) Excessive preload for side, rear or Readjust or replace.
Seized or damaged parts should be re- front bearing.
placed, and also other parts should be (3) Insufficient or improper oil used. Add recommended differential oil to the
thoroughly checked for any defect and specified level.
should be repaired or replaced as re-
quired.
3. Damage (1) Improper backlash for hypoid gear. Readjust or replace.
NOTE: (2) Insufficient or excessive preload for Readjust or replace.
Damaged parts should be replaced, and side, rear or front bearing.
also other parts should be thoroughly (3) Excessive backlash for side gear. • Replace gear or thrust washer. (T-type
checked for any defect and should be re- (B2))
paired or replaced as required. • Replace the differential case assembly.
(T-type (H3))
(4) Loose bolts and nuts such as hypoid Retighten.
driven gear bolt.
(5) Damage due to overloading. Replace.
4. Noises when starting or shifting (1) Improper tooth contact of hypoid Readjust. (Drive pinion shim adjustment,
gears driven gear and drive pinion backlash adjustment)
NOTE: (2) Excessive backlash for hypoid driven Replace the gear or the pinion height
Noises may be caused by differential as- gear adjusting washer.
sembly, universal joint, wheel bearing, (3) Excessive backlash for side gear. • Replace gear or thrust washer. (T-type
etc. Find out what is actually making noise (B2))
before disassembling. • Replace the differential case assembly.
(T-type (H3))
(4) Insufficient preload for front or rear Readjust.
bearing.
(5) Loose drive pinion nut. Tighten to the specified torque.
(6) Loose bolts and nuts such as side Tighten to the specified torque.
retainer attachment bolt.
DI-62

DIFFERENTIALS
Symptom or trouble Possible cause Remedy

5. Noises when cornering (1) Damaged differential gear. • Replace the differential gear. (T-type
(B2))
• Replace the differential case assembly.
(T-type (H3))
(2) Excessive wear or damage of thrust Replace the thrust washer. (T-type (B2))
washer.
(3) Broken pinion mate shaft. Replace the pinion mate shaft. (T-type
(B2))
(4) Stuck or damaged side bearing Replace.
6. Gear noise (1) Improper tooth contact of hypoid Readjust or replace the hypoid gear set.
NOTE: driven gear and drive pinion
Since noises from engine, muffler, trans- (2) Improper backlash of the hypoid Readjust.
mission, propeller shaft, wheel bearings, driven gear
tires, and body are sometimes mistaken (3) Scored or chipped teeth of hypoid Replace hypoid gear set.
for noises from differential assembly, be gear.
careful in checking them. Inspection
methods to locate noises include coast- (4) Scuffed hypoid gear Replace hypoid gear set.
ing, accelerating, cruising, and lifting-up (5) Improper preload for front or rear Readjust.
all four wheels. Perform these inspections bearings.
according to the condition of trouble. (6) Stuck, scored or chipped teeth of front Replace.
When listening to noises, shift the gear or rear bearing
into four-wheel drive and fourth speed po- (7) Stuck, scored or chipped teeth of side Replace.
sition, trying to pick up only differential bearing
noise.
(8) Vibrating differential gear. Replace the differential gear.
DI-63
TRANSFER CASE
TC
Page
2. Extension Case ..........................................................................................3
3. Transfer Case and Extension Case Assembly ...........................................4
4. Oil Seal .......................................................................................................5
5. Transfer Drive Gear ...................................................................................6
6. Transfer Driven Gear .................................................................................7
7. Center Differential ......................................................................................8
General Description
TRANSFER CASE
A: NOTE
For general description, refer to “6MT” or “5MT”
section.
6MT model:
<Ref. to 6MT-2, General Description.>
5MT model:
<Ref. to 5MT-2, General Description.>
TC-2
Extension Case
TRANSFER CASE
2. Extension Case
A: NOTE
For removal, installation and inspection, refer to
“6MT” section. <Ref. to 6MT-43, Extension Case.>
TC-3

TRANSFER CASE
3. Transfer Case and Extension

Case Assembly
A: NOTE
“5MT” section. <Ref. to 5MT-34, Transfer Case and
Extension Case Assembly.>
TC-4
Oil Seal
TRANSFER CASE
4. Oil Seal
A: NOTE
For inspection and replacement, refer to “6MT” or
“5MT” section.
6MT model:
5MT model:
TC-5
Transfer Drive Gear

TRANSFER CASE
5. Transfer Drive Gear

A: NOTE
“6MT” or “5MT” section.
6MT model:
<Ref. to 6MT-53, Transfer Drive Gear.>
5MT model:
<Ref. to 5MT-40, Transfer Drive Gear.>
TC-6

TRANSFER CASE
6. Transfer Driven Gear

A: NOTE
6MT model:
<Ref. to 6MT-55, Transfer Driven Gear.>
5MT model:
<Ref. to 5MT-42, Transfer Driven Gear.>
TC-7
Center Differential
TRANSFER CASE
7. Center Differential
A: NOTE
6MT model:
<Ref. to 6MT-57, Center Differential.>
5MT model:
<Ref. to 5MT-44, Center Differential.>
TC-8
DRIVE SHAFT SYSTEM
DS
Page
2. Propeller Shaft .........................................................................................11
3. Front Axle .................................................................................................14
4. Front Hub Unit Bearing ............................................................................18
5. Rear Axle .................................................................................................20
6. Rear Hub Unit Bearing .............................................................................24
7. Front Drive Shaft ......................................................................................27
8. Rear Drive Shaft .......................................................................................35
General Description
DRIVE SHAFT SYSTEM
A: SPECIFICATION
1. PROPELLER SHAFT
Propeller shaft type EDJ 3UJ+CPS
Front propeller shaft Joint-to-Joint length: L1 mm (in) 735.5 (28.96) 633 (24.92)
Rear propeller shaft Joint-to-Joint length: L2 mm (in) 698 (27.48) 728.5 (28.68)
D1 63.5 (2.499) 70.0 (2.756)
Outer diameter of tube: mm (in)
D2 57.5 (2.264) 57.0 (2.244)
(A) L1 L2
D1 D2
(B)
L1 L2
D1 D2
DS-00520
(A) 3UJ type (B) EDJ type
DS-2
General Description
DRIVE SHAFT SYSTEM
2. FRONT DRIVE SHAFT ASSEMBLY

Model Type of drive shaft Axle diameterφ mm (in) Axle length mm (in)
Except for STI model EBJ + PTJ 22 (0.87) 361.4 (14.23)
STI model AC + AAR 28 (1.10) 343.1 (13.51)
(A)
(B)
DS-00440
(A) Axle diameter (B) Axle length
3. REAR DRIVE SHAFT ASSEMBLY

Model Type of drive shaft Axle diameterφ mm (in) Axle length mm (in)
Except for STI model EBJ + DOJ 22 (0.87) 383.1 (15.08)
STI model EBJ + EDJ 25 (0.98) 339.5 (13.37)
(A)
(B)
DS-00409
(A) Axle diameter (B) Axle length
DS-3
General Description
DRIVE SHAFT SYSTEM
B: COMPONENT
1. PROPELLER SHAFT
(2)
(1)
T2
(3)
T1
T2
(4)
T1
DS-00511
(1) Propeller shaft (3UJ type) (3) Rear differential (T-type) Tightening torque: N·m (kgf-m, ft-lb)
(2) Propeller shaft (DOJ-type) (4) Rear differential (VA2-type) T1: 31 (3.16, 22.9)
T2: 52 (5.30, 38.4)
DS-4
General Description
DRIVE SHAFT SYSTEM
2. FRONT AXLE
(1)
(2)
(3)
(4)
(5)
(6)
(8)
(9)
(10)
(7)
T2
(14)
(11)
T1
(12)
(13)
DS-00441
(1) Circlip (7) Boot band (13) Front hub unit bearing
(2) Baffle plate (8) Boot (AAR) (14) Axle nut
(3) Outer race (AAR) (9) AC shaft ASSY
(4) Snap ring (10) Boot (AC) Tightening torque: N·m (kgf-m, ft-lb)
(5) Trunnion (11) Housing T1: 220 (22.43, 162.3)
(6) Grommet (12) Hub bolt T2: 65 (6.63, 47.9)
DS-5
General Description
DRIVE SHAFT SYSTEM
3. REAR AXLE
(1)
(2)
(3)
(5)
(6)
(7)
(8)
(8)
(10)
(4)
(9)
(8)
(11)
T1
(12)
(13)
(15)
(16)
(14)
T2
DS-00463
(1) Baffle plate (8) Boot band (15) Rear axle housing
(2) Outer race (DOJ) (9) Boot (DOJ) (16) Bushing
(3) Snap ring (10) Boot (BJ)
(4) Inner race (11) EBJ shaft ASSY Tightening torque: N·m (kgf-m, ft-lb)
(5) Ball (12) Rear hub unit bearing T1: 65 (6.63, 47.9)
(6) Cage (13) Hub bolt T2: 190 (19.37, 140.1)
(7) Snap ring (14) Axle nut
DS-6
General Description
DRIVE SHAFT SYSTEM
• STI model
(1)
(2)
(3)
(5)
(6)
(7)
(8)
(8)
(10)
(4)
(9)
(8)
(11)
T1
(12)
(13)
(15)
(16)
(14)
T2
DS-00463
(1) Baffle plate (8) Boot band (15) Rear axle housing
(2) Outer race (EDJ) (9) Boot (EDJ) (16) Bushing
(3) Snap ring (10) Boot (EBJ)
(4) Inner race (11) EBJ shaft ASSY Tightening torque: N·m (kgf-m, ft-lb)
(5) Ball (12) Rear hub unit bearing T1: 65 (6.63, 47.9)
(6) Cage (13) Hub bolt T2: 190 (19.37, 140.1)
(7) Snap ring (14) Axle nut
DS-7
General Description
DRIVE SHAFT SYSTEM
C: CAUTION
any work.
turers.
• Apply grease onto sliding or revolving surfaces before installation.
• Before installing snap rings, apply sufficient amount of grease to avoid damage and deformation.
• Before securing a part on a vise, place cushioning 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 Used for tightening the boot band.
(A)
TOOL (A) Jig for the band
(B) Ratchet wrench
(B)
ST-925091000
926470000 AXLE SHAFT • Used for removing the axle shaft.
PULLER • Used together with AXLE SHAFT PULLER
PLATE (28099PA110).
ST-926470000
SIDE OIL SEAL seal.
INSTALLER
ST18675AA000
28099PA080 HUB STAND Used for assembling hub bolt in hub.
ST28099PA080
DS-9
General Description
DRIVE SHAFT SYSTEM

28099PA110 AXLE SHAFT Exchange with the plate of the AXLE SHAFT
PULLER PLATE PULLER (926470000) to use.
ST28099PA110
28099PA090 OIL SEAL PROTEC- • Used for installing the rear drive shaft to the
TOR rear differential.
• For protecting the oil seal.
ST28099PA090
28399SA010 OIL SEAL PROTEC- • Used for installing front drive shaft into front
TOR differential.
• For protecting the oil seal.
ST28399SA010
28399AG000 HUB STAND Used for extracting hub bolt.
ST28399AG000
2. GENERAL TOOL
TOOL NAME 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.
Crowbar Used for extracting drive shaft.
DS-10
Propeller Shaft
DRIVE SHAFT SYSTEM
2. Propeller Shaft 8) Make alignment marks on the flange yoke and

rear differential before removal.
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 center EDJ with a cloth or rubber (A)
material before removing propeller shaft, as shown
in the figure. The rubber boot may be damaged due
to interference with adjacent metal parts while
bending the EDJ during removal. DS-00028
(A) Alignment mark
9) Remove the three bolts holding the propeller

shaft to the rear differential.
10) Remove the remaining bolt.
11) Remove the two bolts which hold center bear-
ing to vehicle body.
DS-00239

2) Shift the select lever or gear shift lever to neutral.
5) Remove the center exhaust pipe.
7) Remove the heat shield cover. DS-00141
12) Remove the propeller shaft from transmission.

CAUTION:
• Be careful not to damage oil seals and con-
tact surface of the sleeve yoke.
• Cover the center exhaust pipe with a cloth to
(A)
keep off any oil spilled from transmission when
removing propeller shaft.
NOTE:
DS-00230 Use a container to catch oil flowing from propeller
shaft.
(A) Heat shield cover
DS-00030
DS-11
Propeller Shaft
DRIVE SHAFT SYSTEM
13) Install extension cap (A) to the transmission. C: INSPECTION

NOTE: NOTE:
If extension cap (A) is not available, place vinyl bag Do not disassemble propeller shaft. Check the fol-
over opening and fasten with string to prevent gear lowing and replace if necessary.
oil from leaking. • Dents or cracks on the tube surface
• Splines for deformation or abnormal wear
(A)
• 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
DS-00031
B: INSTALLATION 2) Remove the heat shield cover.
1) Insert the sleeve yoke into the transmission and 3) Check for any looseness of the yoke flange
attach center bearing to body. 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.
DS-00141
Tightening torque:
52 N·m (5.30 kgf-m, 38.4 ft-lb)
2) Align the alignment marks (A), and connect the
flange yoke and rear differential.
DS-00035
(A)
DS-00028
Tightening torque:
31 N·m (3.16 kgf-m, 22.9 ft-lb)
4) Install the center exhaust pipe.
5) Install the rear exhaust pipe and muffler.
DS-12
Propeller Shaft
DRIVE SHAFT SYSTEM
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:
Limit: 0.6 mm (0.024 in)
(A)
(B)
DS-00036
(A) Propeller shaft

(B) Dial gauge
4. CENTER BEARING FREE PLAY

1) Remove the front and center exhaust pipes.
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-00037
DS-13
Front Axle
DRIVE SHAFT SYSTEM
3. Front Axle 7) Remove the cotter pin and castle nut securing
the tie-rod end to the housing knuckle arm.
A: REMOVAL (A)
wheels.
2) Lift the crimped section of axle nut. (B)
(C)
DS-00042
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
DS-00038
3) Remove the axle nut using a socket wrench 8) Using a puller, remove the tie-rod ball joint from
while depressing the brake pedal. knuckle arm.
CAUTION:
Do not loosen the axle nut while the front axle is
loaded. Doing so may damage the hub bearing.
4) Remove the stabilizer link.
DS-00043
9) Remove the ABS wheel speed sensor assembly

and harness.
DS-00262
5) Remove the disc brake caliper from the housing,

and suspend it from strut using a wire.
6) Remove the disc rotor from the hub.
NOTE:
If 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.
DS-00249
10) Remove the bolts which secure the sensor har-

ness to the strut.
DS-00041
DS-00144
DS-14
Front Axle
DRIVE SHAFT SYSTEM
11) Remove the front arm ball joint from the hous- B: INSTALLATION
ing.
1) Align the alignment mark on the camber adjust-
ing bolt head, and tighten the housing and strut us-
ing a new flange nut.
Tightening torque:
155 N·m (15.81 kgf-m, 114.3 ft-lb)
2) Install the front drive shaft. <Ref. to DS-27, IN-
STALLATION, Front Drive Shaft.>
3) Install the front arm ball joint to the housing.
Tightening torque:
DS-00045 50 N·m (5.10 kgf-m, 36.9 ft-lb)
12) Remove the front drive shaft from the transmis- 4) Install the ABS sensor harness to the strut.
sion. 5) Install the ABS wheel speed sensor on the hous-
13) Remove the front drive shaft assembly from the ing.
hub. If it is hard to remove, use the ST. Tightening torque:
ST1 926470000 AXLE SHAFT PULLER 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
ST2 28099PA110 AXLE SHAFT PULLER 6) Install the disc rotor to hub.
PLATE 7) Install the disc brake caliper on the housing.
Tightening torque:
17-inch type
155 N·m (15.81 kgf-m, 114.3 ft-lb)
16-inch type
80 N·m (8.16 kgf-m, 59 ft-lb)
ST1 8) Install the stabilizer link.
Tightening torque:
ST2
38 N·m (3.87 kgf-m, 28 ft-lb)
DS-00145 9) Connect the tie-rod end ball joint to the knuckle
arm with a castle nut.
14) After scribing an alignment mark on camber ad-
justing bolt head, remove the bolts which connect CAUTION:
the housing and strut, and disconnect the housing When connecting the tie-rod, do not hit the cap
from strut. at bottom of tie-rod end with a hammer.
Tightening torque:
27 N·m (2.75 kgf-m, 19.9 ft-lb)
10) Tighten the castle nut to specified torque and
tighten further within 60° until the pin hole is aligned
with the slot in the nut. Bend the cotter pin to lock.
(A)
(B)
DS-00046
(C)
DS-00042
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
DS-15
Front Axle
DRIVE SHAFT SYSTEM
11) While depressing the brake pedal, tighten a C: DISASSEMBLY

new axle nut to the specified torque and lock it se-
1) Remove the four bolts from the housing (A), and
curely.
remove the front hub unit bearing and disc cover.
CAUTION:
Do not apply weight to the front axle before
tightening the axle nut. Doing so may damage
the hub bearing. (A)
Tightening torque:
220 N·m (22.43 kgf-m, 162.3 ft-lb)
12) After tightening the axle nut, lock it securely.
DS-00231
CAUTION:
• Do not get closer the tool which charged
magnetism to magnetic encoder.
• Be careful not to damage the magnetic en-
coder.
DS-00048 (2)
13) Install the wheel. (1)
Tightening torque:
100 N·m (10.20 kgf-m, 73.8 ft-lb)
essary.
DS-00250
(1) Magnetic encoder

(2) Front hub unit bearing
2) Disassemble the front hub unit bearing. <Ref. to

DS-19, DISASSEMBLY, Front Hub Unit Bearing.>
DS-16
Front Axle
DRIVE SHAFT SYSTEM
D: ASSEMBLY E: INSPECTION
1) Assemble the front hub unit bearing. <Ref. to 1) Moving the front tire up and down by hand,
DS-19, ASSEMBLY, Front Hub Unit Bearing.> check there is no play in bearing, and check the
2) Place the disc cover between housing (A) and wheel rotates smoothly.
front hub unit, and tighten the four bolts.
(A)
DS-00061
DS-00231 2) Inspect the lean of axis direction using a dial
Tightening torque: gauge. Replace the bearing if the load range ex-
65 N·m (6.63 kgf-m, 47.9 ft-lb) ceeds the limitation.
CAUTION: Service limit:
• Do not get closer the tool which charged Maximum: 0.05 mm (0.0020 in)
coder.
(2)
(1)
DS-00062
DS-00250

(2) Front hub unit bearing
DS-17
Front Hub Unit Bearing

DRIVE SHAFT SYSTEM
4. Front Hub Unit Bearing CAUTION:

A: REMOVAL magnetism to magnetic encoder.
1) Lift up the vehicle, and then remove the front • Be careful not to damage the magnetic en-
wheels. coder.
2) Lift the crimped section of axle nut. (2)
(1)
DS-00250
DS-00038
3) Remove the axle nut using a socket wrench (2) Front hub unit bearing
while depressing the brake pedal.
CAUTION: 7) Remove the front hub unit bearing. If it is hard to
Do not loosen the axle nut while the front axle is remove, use the ST.
loaded. Doing so may damage the hub bearing. ST1 926470000 AXLE SHAFT PULLER
4) Remove the disc brake caliper from the housing, ST2 28099PA110 AXLE SHAFT PULLER
and suspend it from strut using a wire. PLATE
5) 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.
ST1
ST2
DS-00145
B: INSTALLATION
1) Place the disc cover between housing (A) and
front hub unit, and tighten the four bolts.
DS-00041
6) Remove the four bolts from the housing.

(A)
(A)
DS-00231
Tightening torque:
65 N·m (6.63 kgf-m, 47.9 ft-lb)
DS-00231
2) Install the front drive shaft. <Ref. to DS-27, IN-
(A) Housing STALLATION, Front Drive Shaft.>
3) Tighten the axle nut temporarily.
DS-18
Front Hub Unit Bearing

DRIVE SHAFT SYSTEM
4) Install the disc rotor to hub. D: ASSEMBLY

5) Install the disc brake caliper on the housing.
1) Attach the hub to the ST securely.
Tightening torque: ST 28099PA080 HUB STAND
17-inch type
(1)
155 N·m (15.81 kgf-m, 114.3 ft-lb)
16-inch type
80 N·m (8.16 kgf-m, 59 ft-lb)
6) While depressing the brake pedal, tighten a new
axle nut to the specified torque and lock it securely.
CAUTION: ST
the hub bearing. DS-00253
Tightening torque: (1) Front hub unit bearing

220 N·m (22.43 kgf-m, 162.3 ft-lb)
7) After tightening the axle nut, lock it securely. 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-17, INSPECTION, Front Axle.>
CAUTION:
DS-00048 If there is any fault in the bearing, replace hub
8) Install the wheel. unit bearing.
Tightening torque:
100 N·m (10.20 kgf-m, 73.8 ft-lb)
C: DISASSEMBLY
Using the ST and a hydraulic press, push out the
hub bolts.
CAUTION:
• Be careful not to hammer the hub bolts. This
may deform the hub.
• Do not reuse the hub bolt.
ST 28399AG000 HUB STAND
NOTE:
Since the hub unit bearing (1) can not be disassem-
bled, only hub bolts can be removed.
(1)
ST
DS-00252
DS-19
Rear Axle
DRIVE SHAFT SYSTEM
5. Rear Axle 8) Remove the four bolts from the rear housing.
A: REMOVAL
wheels.
3) Lift the crimped section of axle nut.
DS-00414
9) Remove the rear hub unit bearing.

CAUTION:
coder.
DS-00038
4) Remove the axle nut using a socket wrench
(2)
CAUTION: (1)
Do not loosen the axle nut while the rear axle is

5) Remove the brake hose bracket and the rear
ABS wheel speed sensor.
DS-00251

(2) Rear hub unit bearing
DS-00412
6) Remove the disc brake caliper from the rear

housing, and suspend it from vehicle using a string.
DS-00360
FU-03358
7) Remove the rear disc rotor.
DS-20
Rear Axle
DRIVE SHAFT SYSTEM
NOTE: 12) Separate the upper arm, trailing link and rear
If it is hard to remove, use the ST. lateral link from the rear housing.
ST1 926470000 AXLE SHAFT PULLER
ST2 28099PA110 AXLE SHAFT PULLER
PLATE
ST1
ST2
DS-00415
13) Remove the rear axle.

DS-00122 B: INSTALLATION
10) Remove the snap pin and nut from the front lat- 1) Temporarily tighten the rear housing to the up-
eral link. per arm.
2) Aligning with the mounting hole of the rear brake
(1)
back plate, temporarily tighten the rear hub unit
bearing to the rear housing.
CAUTION:
(2) • Be careful not to damage the magnetic en-
coder.
(2)
RS-00189
(1)
(1) Snap pin
(2) Nut
11) Separate the rear housing and the ball joint us-
ing the puller.
DS-00251

RS-00190
DS-00360
3) Attach the rear drive shaft to the rear hub unit

bearing.
DS-21
Rear Axle
DRIVE SHAFT SYSTEM
4) Tighten the new axle nut temporarily. 11) After tightening the axle nut, lock it securely.
CAUTION:
Use new axle nuts.
5) Attach the links to the rear housing and tighten
them to the specified torque.
Tightening torque:
Upper arm
80 N·m (8.16 kgf-m, 59 ft-lb)
Front lateral link
60 N·m (6.12 kgf-m, 44.3 ft-lb)
DS-00048
Rear lateral link
80 N·m (8.16 kgf-m, 59 ft-lb) 12) Install the rear wheels.
Trailing link Tightening torque:
90 N·m (9.18 kgf-m, 66.4 ft-lb) 100 N·m (10.20 kgf-m, 73.8 ft-lb)
6) Tighten the four bolts of the rear housing. 13) Connect the battery ground terminal.
Tightening torque: 14) Inspect the wheel alignment and adjust if nec-
65 N·m (6.63 kgf-m, 47.9 ft-lb) essary.
C: DISASSEMBLY
1. REAR HUB UNIT BEARING
1) Remove the four bolts from the rear housing,
and remove the rear hub unit bearing and back
plate.
DS-00414
7) Install the rear disc rotor.

8) Install the rear disc brake caliper on the rear
housing.
Tightening torque:
17-inch type DS-00414
65 N·m (6.63 kgf-m, 47.9 ft-lb)
15-inch type CAUTION:
66 N·m (6.73 kgf-m, 48.7 ft-lb) • Be careful not to damage the magnetic en-
9) Install the brake hose bracket and rear ABS coder.
wheel speed sensor. • Do not get closer the tool which charged
Tightening torque:
Brake hose bracket (2)
33 N·m (3.36 kgf-m, 24.3 ft-lb) (1)

Rear ABS wheel speed sensor
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
10) While pressing the brake pedal, tighten the new
axle nuts to the specified torque.
CAUTION:
Do not apply weight to the rear axle before
tightening the axle nut. Doing so may damage DS-00251
the hub bearing.
Tightening torque:
190 N·m (19.37 kgf-m, 140.1 ft-lb) (2) Rear hub unit bearing
DS-22
Rear Axle
DRIVE SHAFT SYSTEM
2) Disassemble the rear hub unit bearing. <Ref. to

DS-25, DISASSEMBLY, Rear Hub Unit Bearing.>
2. BUSHING
For the removal procedure of bushing, refer to
“Rear Trailing Link” in “REAR SUSPENSION”.
<Ref. to RS-11, REAR HOUSING BUSHING, DIS-
ASSEMBLY, Rear Trailing Link.>
D: ASSEMBLY
1. REAR HUB UNIT BEARING
Assemble each part in the reverse order of disas-
sembly.
Tightening torque:
Rear hub unit bearing
65 N·m (6.63 kgf-m, 47.9 ft-lb)
2. BUSHING
For the installation procedure of bushing, refer to
“Rear Trailing Link” in “REAR SUSPENSION”.
<Ref. to RS-12, REAR HOUSING BUSHING, AS-
SEMBLY, Rear Trailing Link.>
E: INSPECTION
1) Moving the rear tire up and down by hand, check
that there is no backlash in bearing, and check that
the wheel rotates smoothly.
DS-00061
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)
DS-00062
DS-23
Rear Hub Unit Bearing

DRIVE SHAFT SYSTEM
6. Rear Hub Unit Bearing 7) Remove the rear hub unit bearing.
CAUTION:
A: REMOVAL • Be careful not to damage the magnetic en-
1) Lift up the vehicle, and then remove the rear coder.
wheels. • Do not get closer the tool which charged
2) Lift the crimped section of axle nut. magnetism to magnetic encoder.
(2)
(1)
DS-00038 DS-00251
CAUTION:
4) Remove the disc brake caliper from the rear
housing, and suspend it from vehicle using a string.
DS-00360
NOTE:
If it is hard to remove, use the ST.
FU-03358
5) Remove the rear disc rotor. PLATE
6) Remove the four bolts from the rear housing.
ST1
ST2
DS-00122
DS-00414
DS-24

DRIVE SHAFT SYSTEM
B: INSTALLATION 6) While pressing the brake pedal, tighten the new

1) Aligning with the mounting hole of the rear brake
back plate, temporarily tighten the rear hub unit Tightening torque:
bearing to the rear housing. 190 N·m (19.4 kgf-m, 140.1 ft-lb)
CAUTION: CAUTION:
• Be careful not to damage the magnetic en- Do not apply weight to the rear axle before
coder. tightening the axle nut. Doing so may damage
• Do not get closer the tool which charged the hub bearing.
magnetism to magnetic encoder. 7) After tightening the axle nut, lock it securely.
(2)
(1)
DS-00251 DS-00048
(1) Magnetic encoder 8) Install the rear wheels.

(2) Rear hub unit bearing Tightening torque:
100 N·m (10.20 kgf-m, 73.8 ft-lb)
2) Tighten the four bolts of the rear housing.
C: DISASSEMBLY
Using the ST and a hydraulic press, push out the
hub bolts.
CAUTION:
• Be careful not to hammer the hub bolts. This
may deform the hub.
• Do not reuse the hub bolt.
ST 28399AG000 HUB STAND
NOTE:
DS-00414
Since the hub unit bearing can not be disassem-
Tightening torque: bled, only hub bolts can be removed.
65 N·m (6.63 kgf-m, 47.9 ft-lb)
3) Tighten the new axle nut temporarily.
4) Install the rear disc rotor.
5) Install the disc brake caliper on the rear housing.
(1)
Tightening torque:
17-inch type ST
65 N·m (6.63 kgf-m, 47.9 ft-lb)
15-inch type
66 N·m (6.73 kgf-m, 48.7 ft-lb)
DS-00254
DS-25

DRIVE SHAFT SYSTEM
D: ASSEMBLY
1) Attach the hub to the ST securely.
ST 28099PA080 HUB STAND
(1)
ST
DS-00255
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
1) Moving the rear tire up and down by hand, check
there is no backlash in bearing, and check the
wheel rotates smoothly.
DS-00183
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-00062
DS-26
Front Drive Shaft

DRIVE SHAFT SYSTEM
7. Front Drive Shaft 9) Using a bar, remove the front drive shaft from
transmission.
A: REMOVAL CAUTION:
1) Disconnect the ground cable from battery. Be careful not to allow the bar to damage holder
2) Lift up the vehicle, and then remove the front area.
wheels.
3) Lift the crimped section of axle nut. B: INSTALLATION
1) Replace the differential side retainer oil seal with
a new part.
NOTE:
After pulling out the drive shaft, be sure to replace
with a new oil seal.
6MT model: <Ref. to 6MT-28, REPLACEMENT,
Differential Side Retainer Oil Seal.>
5MT model: <Ref. to 5MT-31, REPLACEMENT,
DS-00038 Differential Side Retainer Oil Seal.>
2) Insert the AC into hub splines.
4) Remove the axle nut using a socket wrench 3) Draw the drive shaft into specified position.
CAUTION:
CAUTION:
Do not hammer drive shaft when installing it.
Do not loosen the axle nut while the front axle is
5) Using the ST, install the front drive shaft to trans-
5) Drain the transmission gear oil.
mission.
6) Remove the stabilizer link from front arm.
7) Disconnect the front arm ball joint from the hous-
ing.
ST
AT-00110
FS-00106 6) Connect the front arm ball joint to the housing.

8) Remove the front drive shaft assembly. If it is Tightening torque:
hard to remove, use ST1 and ST2. 50 N·m (5.10 kgf-m, 36.9 ft-lb)
ST1 926470000 AXLE SHAFT PULLER 7) Install the stabilizer link.
ST2 28099PA110 AXLE SHAFT PULLER CAUTION:
PLATE Be sure to use a new self-locking nut.
Tightening torque:
38 N·m (3.87 kgf-m, 28 ft-lb)
8) While pressing the brake pedal, tighten the new
ST1 CAUTION:
ST2
the hub bearing.
DS-00145 Tightening torque:
220 N·m (22.43 kgf-m, 162.3 ft-lb)
DS-27
Front Drive Shaft

DRIVE SHAFT SYSTEM
9) After tightening axle nut, lock it securely. 4) Remove the PTJ outer race from shaft assem-
10) Fill transmission gear oil. bly.
11) Install the front wheels. 5) Wipe off grease.
Tightening torque: CAUTION:
100 N·m (10.20 kgf-m, 73.8 ft-lb) The grease is a special type of grease. Do not
12) Connect the battery ground terminal. mix with other grease.
13) Inspect the wheel alignment and adjust if nec- 6) Place alignment marks on the roller kit and trun-
essary. nion.
C: DISASSEMBLY
1. EXCEPT FOR STI MODEL
1) Place alignment marks on the shaft and outer
race.
DS-00106
2) Remove the PTJ boot band and boot.

CAUTION:
Be careful not to damage the boot.
DS-00109
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-00107
3) Remove the snap ring from PTJ outer race.
DS-00110
DS-00108
DS-28
Front Drive Shaft

DRIVE SHAFT SYSTEM
9) Remove the snap ring and trunnion. 3) Place the drive shaft between wooden blocks
CAUTION: and fix it on a vise.
Be sure to wrap shaft splines with vinyl tape to CAUTION:
protect the boot from scratches. Do not set the only drive shaft on a vise.
DS-00111 DS-00417
10) Remove the PTJ boot. 4) Tap the staking are of the outer race alternately
11) Remove the O-ring from the groove of the with a plastic or wooden bar, and remove one roller
shaft. at a time.
NOTE: CAUTION:
The EBJ is a non-disassembly part, so the axle dis- • Tap the staking area (A) of the outer race.
assembly stops here. • Do not use a metal bar as the outer race may
deform.
2. STI MODEL • Be careful not to damage the roller parts.
1) Place alignment marks on the shaft and outer
race.
(A)
DS-00419
DS-00106
2) Remove the AAR boot band and boot.

CAUTION:
Be careful not to damage the boot.
DS-00418
5) Remove the outer race from shaft assembly.

CAUTION:
Make sure to have your associate held the outer
race when removing the third roller to prevent
DS-00107
the outer race from falling.
DS-29
Front Drive Shaft

DRIVE SHAFT SYSTEM
6) Wipe off grease. 10) Remove the snap ring and trunnion.
CAUTION: CAUTION:
The grease is a special type of grease. Do not Be sure to wrap shaft splines with vinyl tape to
mix with other grease. protect the boot from scratches.
7) Place alignment marks on the roller kit and trun-
nion.
DS-00111
11) Remove the AAR boot.

NOTE:
The AC is a non-disassembly part, so the drive
shaft disassembly stops here.
D: ASSEMBLY
1) Roll up a thick piece of paper to a size where the
shaft can pass through, and affix with tape to form
a cylinder.
2) Attach a new O-ring on this cylinder.
DS-00109 CAUTION:
8) Remove the roller kit from trunnion. • Always use a new O-ring.
• Be careful that the O-ring does not become
CAUTION:
scratched and that there are no foreign objects
Be careful with the roller kit position.
attached to it.
9) Place alignment marks on the trunnion and
• Make sure to install the O-ring so that it does
shaft.
not twist as much as possible.
• Do not stretch the O-ring to 30 mm (1.18 in)
inner diameter or more.
(1)
(2)
DS-00110
DS-00451
(1) O-ring
(2) Cylinder made with thick paper, etc.
DS-30
Front Drive Shaft

DRIVE SHAFT SYSTEM
3) Pass the cylinder material onto the shaft, and 6) Pass the PTJ small diameter boot band through
slide in the direction of the shaft axis. the shaft.
7) Wrap vinyl tape around the splines of the shaft.
CAUTION:
To prevent damage to the boots, make sure to
(1)
always wrap with vinyl tape for protection.
8) Install a new PTJ boot.
(2) CAUTION:
Make sure to fit securely on the boot groove of
(3) the shaft.
DS-00452
(1)
(1) Cylinder material
(2) O-ring
(3) Shaft
(2)
4) Clean the shaft boot groove, and wipe off the
grease.
5) Slide the cylinder material near the shaft boot
groove, and move the O-ring from the cylinder ma- (3) DS-00454
terial onto the shaft boot groove.
(1) PTJ boot
CAUTION:
(2) O-ring
• Attach the O-ring to the shaft boot groove
(3) Boot groove
center.
• Be careful that the O-ring does not become 9) Match the alignment marks, and attach the trun-
scratched and that there are no foreign objects nion onto the shaft.
attached to it.
• Make sure to install the O-ring so that it does
not twist as much as possible.
• With the O-ring attached, do not wash with
kerosene, gasoline, etc.
(1) (2) (3) (1)
DS-00110
10) Attach the snap ring to the shaft.

CAUTION:
(4) Confirm that the snap ring is completely fitted
DS-00453 in the shaft groove.
11) Fill 100 to 110 g (3.53 to 3.88 oz) of specified
(1) Shaft
grease into the interior of the PTJ outer race.
(2) Cylinder material
(3) O-ring Grease:
(4) Boot groove NKG302
12) Apply a thin coat of specified grease to the roll-
er kit and trunnion.
DS-31
Front Drive Shaft

DRIVE SHAFT SYSTEM
13) Match the alignment marks of the roller kit and 19) Tighten the boot bands using ST, torque
trunnion, and attach the roller kit. wrench and socket flex handle.
CAUTION: ST 28099AC000 BOOT BAND PLIER
Be careful with the roller kit position. CAUTION:
The large boot band is to be tightened so that
the omega shaped part is at the position indi-
cated in the figure below.
(1)
(2)
(3)
DS-00456
(1) Omega shaped part

(2) Boot band
(3) Outer race
Y
ONL
(C) (D)
DS-00109
14) Match the alignment marks of the shaft and

(B) ST
outer race, and attach the outer race.
(A) (E)
DS-00120
(A) Large boot band

(B) Boot
(C) Torque wrench
(D) Socket flex handle
DS-00106 (E) Outer race
15) Install the snap ring in the groove of the PTJ
outer race. Tightening torque:
Large boot band
CAUTION: 178 N·m (18.2 kgf-m, 131.3 ft-lb)
Pull the shaft lightly and make sure that the Small boot band
snap ring is completely fitted in the groove. 145 N·m (14.8 kgf-m, 106.9 ft-lb)
16) Apply an even coat of the specified grease 30 20) Extend and retract the PTJ repeatedly so that
to 40 g (1.06 to 1.41 oz) to the entire inner surface grease is spread evenly.
of boot.
17) Attach the PTJ boot taking care not to twist it.
CAUTION:
• Clean the large end of PTJ boot and the boot
groove well, and remove the grease and other
substances.
• When installing the PTJ boot, position the
outer race of the PTJ at center of the stroke.
18) Set the new boot band at the specified position.
DS-32
Front Drive Shaft

DRIVE SHAFT SYSTEM
2. STI MODEL 9) Install the AAR boot and grommet taking care
not to twist it.
NOTE:
Use specified grease. CAUTION:
• Replace the boot and grommet as a set.
AAR side:
• Do not let grease get on groove of the outer
ONE LUBER C race side.
1) Pass the AAR boot through the shaft.
2) Align alignment marks and install the trunnion on
(3) (2) (1)
the shaft. Install the snap ring into the shaft groove
securely.
DS-00444
(1) Outer race

(2) Grommet
DS-00110
(3) Boot
grease into the interior of AAR outer race. 10) Insert a flat tip screwdriver, etc. between outer
4) Apply a thin coat of specified grease to the roller race and grommet to make pressure inside of boot
and trunnion. as high as barometric pressure.
5) Place the drive shaft between wooden blocks 11) Install the new large boot band and small boot
and fix it on a vise. band at the required positions.
12) Tighten the boot bands using ST, torque
CAUTION:
wrench and socket flex handle.
Do not set the only drive shaft on a vise.
ST 28099AC000 BOOT BAND PLIER
6) Align the alignment marks on the shaft and outer
Y
race.
ONL
7) Tap the insertion upper part of the outer race al- (C) (D)
ternately using a plastic or wood bar shown in the
figure, and then insert the roller one by one.
(B) ST
CAUTION:
• Do not use a metal bar as the outer race may
deform.
• Do not tap on the end of outer race (shaft (A) (E)
part).
DS-00120
• Be careful not to deform the baffle plate.
(A) Large boot band
(B) Boot
(C) Torque wrench
(D) Socket flex handle
(E) AAR
Clearance at the crimped section of the boot

band:
Large boot band
DS-00420 1 mm (0.04 in) or less
8) Apply an even coat of the specified grease 30 to Small boot band
40 g (1.06 to 1.41 oz) to the entire inner surface of 1 mm (0.04 in) or less
boot. 13) Extend and retract the AAR repeatedly to pro-
vide an equal coating of grease.
DS-33
Front Drive Shaft

DRIVE SHAFT SYSTEM
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.
• AAR and AC
Check for seizure, corrosion, damage, wear and
excessive 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-34
Rear Drive Shaft

DRIVE SHAFT SYSTEM
8. Rear Drive Shaft 8) Remove the rear drive shaft from the rear differ-
ential by using the ST.
A: REMOVAL ST 28099PA100 DRIVE SHAFT REMOVER
1) Disconnect the ground cable from battery. NOTE:
2) Lift up the vehicle, and then remove the rear Fit the ST to the bolts as shown in the figure to pre-
wheels. vent damage of the side bearing retainer.
3) Lift the crimped section of axle nut.
ST
DS-00038 (A)

CAUTION:
5) Drain differential gear oil.
6) Remove the rear trailing link. <Ref. to RS-10,
REMOVAL, Rear Trailing Link.>
7) Remove the rear lateral link. <Ref. to RS-16, RE-
MOVAL, Rear Lateral Link.> DI-00491
(A) Bolt
9) Remove the rear drive shaft from the rear axle. If

it is hard to remove, use ST1 and ST2.
PLATE
ST1
ST2
DS-00122
DS-35
Rear Drive Shaft

DRIVE SHAFT SYSTEM
B: INSTALLATION 6) Attach the links to the rear housing and tighten

them to the specified torque.
1) Replace the rear differential side oil seal. <Ref.
to DI-56, REPLACEMENT, Rear Differential Side Tightening torque:
Oil Seal.> Stabilizer link
NOTE: 38 N·m (3.87 kgf-m, 28 ft-lb)
After pulling out the drive shaft, be sure to replace Shock absorber
with a new oil seal. 80 N·m (8.16 kgf-m, 59 ft-lb)
2) Insert the EBJ into rear hub splines. Rear lateral link
80 N·m (8.16 kgf-m, 59 ft-lb)
CAUTION: Trailing link
• Be careful not to damage the magnetic en- 90 N·m (9.18 kgf-m, 66.4 ft-lb)
coder. 7) While pressing the brake pedal, tighten the new
• Do not get closer the tool which charged axle nuts to the specified torque.
CAUTION:
(2)
Do not apply weight to the rear axle before
(1) tightening the axle nut. Doing so may damage
the hub bearing.
Tightening torque:
190 N·m (19.37 kgf-m, 140.1 ft-lb)
8) Lock the axle nut securely.
DS-00251

3) Draw the rear drive shaft into specified position.

CAUTION:
Do not hammer drive shaft when installing it. DS-00048
9) Fill differential gear oil.
5) Using the ST, install the rear drive shaft to the
10) Install the rear wheels.
rear differential.
ST 28099PA090 OIL SEAL PROTECTOR Tightening torque:
100 N·m (10.20 kgf-m, 73.8 ft-lb)
essary.
ST
DI-00223
DS-36
Rear Drive Shaft

DRIVE SHAFT SYSTEM
C: DISASSEMBLY 6) Wipe off the grease and take out the ball bear-
ings.
CAUTION:
1) Using a flat tip screwdriver or plier, loosen the The grease is a special grease (grease for con-
boot band on the large end of DOJ boot. stant velocity joints). Do not mix with other
CAUTION: greases.
Be careful not to damage the boot. NOTE:
Disassemble exercising care not to lose balls.
(A)
(B)
DS-00124
2) Remove the boot band on the small end of DOJ DS-00126

boot in the same manner.
3) Remove the large end of DOJ boot from DOJ (A) Outer race
outer race. (B) Grease
4) Remove the round snap ring at the neck of DOJ
outer race with a flat tip screwdriver. 7) 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.
8) Using pliers, remove the snap ring fixing the in-
ner race to the shaft.
9) Take out the DOJ inner race.
10) Take off the DOJ cage from shaft and remove
the DOJ boot.
CAUTION:
Wrap shaft splines with vinyl tape to protect the
boot from scratches.
DS-00125
11) Remove the EBJ boot using the same proce-
5) Take out the DOJ outer race from the shaft as- dures as for the DOJ boot.
sembly.
NOTE:
The EBJ is a non-disassembly part, so the drive
DS-37
Rear Drive Shaft

DRIVE SHAFT SYSTEM
2. STI MODEL 6) Wipe off the grease and take out the ball bear-
1) Using a flat tip screwdriver or plier, loosen the ings.
boot band on the large end of EDJ boot. CAUTION:
CAUTION: The grease is a special grease (grease for con-
Be careful not to damage the boot. stant velocity joints). Do not mix with other
greases.
NOTE:
Disassemble exercising care not to lose balls.
(A)
(B)
DS-00124
2) Remove the boot band on the small end of EDJ

boot in the same manner.
3) Remove the large end of EDJ boot from EDJ DS-00126
outer race.
(A) Outer race
4) Remove the round snap ring at the neck of EDJ
(B) Grease
outer race with a flat tip screwdriver.
7) 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.
8) Using pliers, remove the snap ring fixing the in-
ner race to the shaft.
9) Take out the EDJ inner race.
10) Take off the EDJ cage from shaft and remove
the EDJ boot.
CAUTION:
DS-00125
5) Remove the EDJ outer race from shaft assem- boot from scratches.
bly. 11) Remove the EBJ boot using the same proce-
dures as for the EDJ boot.
NOTE:
The EBJ is a non-disassembly part, so the drive
DS-38
Rear Drive Shaft

DRIVE SHAFT SYSTEM
D: ASSEMBLY 5) Install the cage to inner race fixed upon shaft.
1. STI MODEL NOTE:

Fit the cage with the protruding section aligned with
CAUTION: the track on the inner race, and turn by a half pitch.
boot from scratches. (B)
(A)
NOTE:
Use specified grease.
EBJ side:
NKG814
EDJ side:
NKG814
1) Install the EBJ boot to the specified position, and DS-00129
fill it with 50 to 60 g (1.76 to 2.12 oz) of specified
grease. (A) Inner race
2) Place the EDJ boot at the center of shaft. (B) Cage
3) Insert the EDJ cage onto shaft.
NOTE:
grease into the inner side of the EDJ outer race.
Insert the cage with the cutout portion facing the
7) Apply a thin coat of specified grease to the cage
shaft end, since the cage has an orientation.
pocket and ball.
(A) 8) Insert the 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)
(B) (B)
DS-00395
(A) Cage
(B) Cutout portion
4) Install the EDJ inner race on shaft and fix the

snap ring in place with pliers. DS-00126
NOTE: (A) Outer race

Confirm that the snap ring is completely fitted in the (B) Grease
shaft groove.
DS-00128
DS-39
Rear Drive Shaft

DRIVE SHAFT SYSTEM
10) Install the snap ring in the groove on the EDJ 16) Tap the clip with the punch provided at the end
outer race. of the ST.
NOTE: ST 925091000 BAND TIGHTENING TOOL
• Assure that the balls, cage and inner race are NOTE:
completely fitted in the outer race of EDJ. Tap to an extent that the boot underneath is not
• Use care not to place the matched position of damaged.
snap ring in the ball groove of outer race.
• Pull the shaft lightly and assure that the circlip is
completely fitted in the groove.
DS-00133
17) Cut off the band with an allowance of about 10

mm (0.39 in) left from the clip and bend this allow-
DS-00125 ance over the clip.
11) Apply an even coat of the specified grease [20 NOTE:
to 30 g (0.71 to 1.06 oz)] to the entire inner surface Be careful so that the end of the band is in close
of boot. Also apply grease to the shaft. contact with clip.
12) Install the EDJ boot taking care not to twist it. 18) Install the EBJ boot using the same procedures
NOTE: as for the EDJ boot.
• The inside of the large end of EDJ boot and the 19) Extend and retract the EDJ repeatedly to pro-
boot groove shall be cleaned so as to be free from vide an equal coating of grease.
grease and other substances.
• When installing the EDJ boot, position the outer 2. EXCEPT FOR STI MODEL
race of EDJ at center of the stroke. CAUTION:
13) Put a new band through the clip and wind twice Wrap shaft splines with vinyl tape to protect the
in the band groove of the boot. boot from scratches.
14) Pinch the end of band with pliers. Hold the clip NOTE:
and tighten securely. Use specified grease.
NOTE:
EBJ side:
When tightening boot, use care so that the air with-
NKG814
in the boot is appropriate.
15) Tighten the band using the ST. DOJ side:
ST 925091000 BAND TIGHTENING TOOL NKG814
NOTE: 1) Install the EBJ boot to the specified position, and
fill it with 50 to 60 g (1.76 to 2.12 oz) of specified
Tighten the band until it cannot be moved by hand.
grease.
2) Place the DOJ boot at the center of shaft.
DS-00132
DS-40
Rear Drive Shaft

DRIVE SHAFT SYSTEM
3) Insert the DOJ cage onto shaft. 6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified
NOTE: grease into the inner side of the DOJ outer race.
Insert the cage with the cutout portion facing the 7) Apply a thin coat of specified grease to the cage
shaft end, since the cage has an orientation. pocket and ball.
8) Insert the ball bearings into the cage pocket.
(A) 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)
(B)
(B)
DS-00395
(A) Cage
(B) Cutout portion
4) Install the DOJ inner race on shaft and fix the DS-00126
snap ring in place with pliers.
(A) Outer race
NOTE: (B) Grease
Confirm that the snap ring is completely fitted in the
shaft groove. 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.
DS-00128
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.
(B)
(A)
DS-00125
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:
DS-00129 • The inside of the large end of DOJ boot and the
boot groove shall be cleaned so as to be free from
(A) Inner race grease and other substances.
(B) Cage • When installing the DOJ boot, position the outer
race of DOJ at center of the stroke.
DS-41
Rear Drive Shaft

DRIVE SHAFT SYSTEM
13) Put a new band through the clip and wind twice E: INSPECTION
in the band groove of the boot.
Check the removed parts for damage, wear, corro-
14) Pinch the end of band with pliers. Hold the clip
sion etc. Repair or replace if defective.
and tighten securely.
• EDJ (high-efficiency compact double offset joint)
NOTE: Check for seizure, corrosion, damage, wear and
When tightening boot, use care so that the air with- excessive play.
in the boot is appropriate. • DOJ (Double Offset Joint)
15) Tighten the band using the ST. Check for seizure, corrosion, damage, wear and
ST 925091000 BAND TIGHTENING TOOL excessive play.
NOTE: • EBJ (high-efficiency compact ball fixed joint)
Tighten the band until it cannot be moved by hand. Check for seizure, corrosion, damage, wear and
excessive 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
16) Tap the clip with the punch provided at the end
of the ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tap to an extent that the boot underneath is not
damaged.
DS-00133
17) 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.
NOTE:
Be careful so that the end of the band is in close
contact with clip.
18) Install the EBJ boot using the same procedures
as for the DOJ boot.
19) Extend and retract the DOJ repeatedly to pro-
vide an equal coating of grease.
DS-42

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-13, CEN-
TER BEARING FREE PLAY, INSPECTION, Pro-
peller Shaft.>
Runout of propeller shaft Check for deflection of the propeller shaft. <Ref.
to DS-13, 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-6,
WHEEL BALANCING, INSPECTION, Tire and
Wheel.>
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-8,
Front strut Check the front strut. <Ref. to FS-26, INSPEC-
TION, Front Strut.>
Rear shock absorber Check the rear shock absorber. <Ref. to RS-14,
INSPECTION, Rear Shock Absorber.>
Front drive shaft Check the front drive shaft. <Ref. to DS-34,
INSPECTION, Front Drive Shaft.>
Rear drive shaft Check the rear drive shaft. <Ref. to DS-42,
INSPECTION, Rear Drive Shaft.>
Front hub unit bearing Check the front hub unit bearing. <Ref. to DS-19,
INSPECTION, Front Hub Unit Bearing.>
Rear hub unit bearing Check the rear hub unit bearing. <Ref. to DS-26,
INSPECTION, Rear Hub Unit Bearing.>
Noise from the underbody Wheel is out of balance. Check the wheel balance. <Ref. to WT-6,
WHEEL BALANCING, INSPECTION, Tire and
Wheel.>
Front wheel alignment Check the front wheel alignment. <Ref. to FS-8,
Rear wheel alignment Check the rear wheel alignment. <Ref. to RS-8,
Front strut Check the front strut. <Ref. to FS-26, INSPEC-
TION, Front Strut.>
Rear shock absorber Check the rear shock absorber. <Ref. to RS-14,
INSPECTION, Rear Shock Absorber.>
DS-43
VDC
Page
2. Vehicle Dynamics Control System .............................................................7
3. VDC Control Module and Hydraulic Control Unit (VDCCM&H/U) ..............8
4. ABS Sequence Control ............................................................................14
5. VDC Sequence Control ............................................................................17
6. Yaw Rate and G Sensor ..........................................................................20
7. Steering Angle Sensor .............................................................................22
8. Front ABS Wheel Speed Sensor ..............................................................24
9. Rear ABS Wheel Speed Sensor ..............................................................26
10. Front Magnetic Encoder ...........................................................................27
11. Rear Magnetic Encoder ...........................................................................28
12. VDC OFF Switch ......................................................................................29
General Description
A: SPECIFICATION
Item Specification or identification
ABS wheel speed sensor gap Front 0.77 — 1.43 mm (0.030 — 0.056 in)
(for reference) Rear 0.43 — 1.78 mm (0.017 — 0.070 in)
RH K1 (White)
ABS wheel speed sensor Front
Identifications of harness LH K2 (Yellow)
(marks, color) RH P5 (White)
Rear
LH P6 (Yellow)
STI model SN
VDCCM&H/U Identification
Except for STI model SM
VDC-2
General Description
B: COMPONENT
1. ABS WHEEL SPEED SENSOR
(3)
T1
T1
(5)
(4)
T1
(2)
(1)
T2
VDC00520
(1) Front ABS wheel speed sensor (4) Hub unit bearing Tightening torque: N·m (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 (3.36, 24.3)
VDC-3
General Description
2. YAW RATE & G SENSOR
(1)
(2)
VDC00447
(1) Yaw rate & G sensor (2) Bracket Tightening torque: N·m (kgf-m, ft-lb)
T: 7.5 (0.76, 5.5)
3. STEERING ANGLE SENSOR
(1)
VDC00196
(1) Steering angle sensor
VDC-4
General Description
4. VDC CONTROL MODULE & HYDRAULIC CONTROL UNIT (VDCCM&H/U)

(4) (5)
(3)
(2) (7)
(6)
(1)
(9)
(8)
T2
(10)
T1
T2
T2
(11)
VDC00480
(1) VDC control module and hydraulic (6) Primary inlet (11) Bracket
control unit (VDCCM&H/U)
(2) Front RH outlet (7) Secondary inlet
(3) Rear LH outlet (8) Damper Tightening torque: N·m (kgf-m, ft-lb)
(4) Rear RH outlet (9) Spacer T1: 7.5 (0.76, 5.5)
(5) Front LH outlet (10) Damper T2: 33 (3.36, 24.3)
VDC-5
General Description
C: CAUTION
• Wear appropriate work clothing, including a helmet, protective goggles and protective shoes when per-
forming any work.
• Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.
D: PREPARATION TOOL
1. SPECIAL TOOL
MONITOR III KIT
ST1B022XU0
2. GENERAL TOOL
TOOL NAME REMARKS
Circuit tester Used for measuring resistance and voltage.
Pressure gauge Used for measuring oil pressure.
TORX® bit E5 Used for replacing VDC control module.
VDC-6
Vehicle Dynamics Control System

2. Vehicle Dynamics Control System

A: WIRING DIAGRAM
Refer to “Vehicle Dynamics Control System” in the wiring diagram. <Ref. to WI-67, WIRING DIAGRAM, Ve-
hicle Dynamics Control System.>
B: ELECTRICAL SPECIFICATION
Refer to the Control Module I/O Signal of the “Vehicle Dynamics Control System (VDC) (DIAGNOSTICS)”.
<Ref. to VDC(diag)-14, ELECTRICAL SPECIFICATION, Control Module I/O Signal.>
C: INSPECTION
Refer to the “Vehicle Dynamics Control System (VDC) (DIAGNOSTICS)”. <Ref. to VDC(diag)-110, INSPEC-
TION, General Diagnostic Table.>
D: NOTE
For operation procedures of each component of the vehicle dynamics control system, refer to the respective
section.
• VDC control module & hydraulic control unit (VDCCM&H/U): <Ref. to VDC-8, VDC Control Module and Hy-
draulic Control Unit (VDCCM&H/U).>
• Yaw rate & G sensor: <Ref. to VDC-20, Yaw Rate and G Sensor.>
• Steering angle sensor: <Ref. to VDC-22, Steering Angle Sensor.>
• Front ABS wheel speed sensor: <Ref. to VDC-24, Front ABS Wheel Speed Sensor.>
• Rear ABS wheel speed sensor: <Ref. to VDC-26, Rear ABS Wheel Speed Sensor.>
• Front magnetic encoder: <Ref. to VDC-27, Front Magnetic Encoder.>
• Rear magnetic encoder: <Ref. to VDC-28, Rear Magnetic Encoder.>
• VDC OFF switch: <Ref. to VDC-29, VDC OFF Switch.>
VDC-7
VDC Control Module and Hydraulic Control Unit (VDCCM&H/U)

3. VDC Control Module and Hy- 6) Remove the nuts and remove the VDCCM&H/U.
draulic Control Unit (VDC- CAUTION:
• Do not drop or bump the VDCCM&H/U.
CM&H/U) • Do not turn the VDCCM&H/U upside down or
A: REMOVAL place it sideways for storage.
• Be careful not to let foreign matter enter the
1) Disconnect the ground cable from battery. VDCCM&H/U.
2) Use compressed air to remove moisture and • Be careful that no water enters the connec-
dust around the VDCCM&H/U. tors.
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.
VDC00450
7) Remove the VDCCM&H/U bracket.

B: INSTALLATION
1) Install the VDCCM&H/U bracket.
Tightening torque:
33 N·m (3.36 kgf-m, 24.3 ft-lb)
2) Install the VDCCM&H/U with a new nut by align-
VDC00449 ing the damper groove of the VDCCM&H/U to the
4) Disconnect the brake pipes from the VDC- bracket side claw.
CM&H/U. Tightening torque:
5) Wrap the brake pipe with a vinyl bag so as not to 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
spill the brake fluid on the vehicle body.
CAUTION:
If brake fluid is spilled on the painted surface of
the vehicle body, wash it off immediately with
water and wipe clean.
VDC00450
VDC-8

3) Connect the brake pipes to their correct VDC- C: INSPECTION

CM&H/U positions.
1) Check the condition of connection and settle-
Tightening torque: ment of connector.
T1: 15 N·m (1.53 kgf-m, 11.1 ft-lb) 2) Check the mark used for VDCCM&H/U identifi-
T2: 19 N·m (1.94 kgf-m, 14 ft-lb) cation.
Refer to “SPECIFICATION” for identification mark.
T1 <Ref. to VDC-2, SPECIFICATION, General De-
scription.>
(1)
T2
VDC00451
4) Connect the VDCCM&H/U connector.

NOTE: VDC00452
• Be sure to remove all foreign matter from inside
the connector before connecting. (1) Identification mark
• Make sure the VDCCM&H/U connector is se-
curely locked. 1. CHECKING THE HYDRAULIC UNIT ABS
5) Bleed air from the brake system. <Ref. to BR-39, OPERATION BY PRESSURE GAUGE
PROCEDURE, Air Bleeding.> 1) Lift up the vehicle, and then remove the wheel.
6) Check the parameter to confirm that the applied 2) Remove the air bleeder screws from FL and FR
models and grades of the relevant vehicle are in- caliper bodies.
cluded. <Ref. to VDC(diag)-21, PARAMETER 3) Connect two pressure gauges to FL and FR cal-
CHECK, OPERATION, Subaru Select Monitor.> iper bodies.
7) If the applied model and grade of the target ve-
hicle are not included on the {Confirm on parame- CAUTION:
ter} display screen, perform parameter selection • Use a pressure gauge used exclusively for
and registration. <Ref. to VDC(diag)-21, PARAME- brake fluid measurement.
TER SELECTION, OPERATION, Subaru Select • Do not use the pressure gauge used for the
Monitor.> measurement of transmission oil. Doing so will
cause the piston seal to expand and deform.
NOTE:
• When the VDCCM&H/U is replaced with a new NOTE:
part, be sure to perform the selection · registration Wrap sealing tape around the pressure gauge.
operation.
• For the selection and registration of parameter,
the Subaru Select Monitor is required.
• When the registration has not been performed,
the DTC code “Parameter selection error” is detect-
ed together with the ABS/EBD/VDC warning light il-
lumination.
ABS00134
VDC-9

4) Bleed air from the pressure gauges and the FL 2. CHECKING THE HYDRAULIC UNIT ABS
and FR caliper bodies. OPERATION WITH THE BRAKE TESTER
5) Perform ABS sequence control. <Ref. to VDC- 1) Set wheels other than the one to measure on
14, ABS Sequence Control.> free rollers.
6) When the hydraulic unit begins to work, first the 2) Prepare for ABS sequence control. <Ref. to
FL side performs decompression, hold and com- VDC-14, ABS Sequence Control.>
pression, and then the FR side performs decom- 3) Set the front wheels or rear wheels on the brake
pression, hold and compression. tester and set the gear to “neutral”.
7) Read values indicated on the pressure gauge
and check if the fluctuation of the values between
decompression and compression meets the stan-
dard values. Depress the brake pedal and check
that the kick-back is normal, and tightness is nor-
mal.
3,500 kPa 3,500 kPa
Initial value
(36 kgf/cm2, 511 psi) (36 kgf/cm2, 511 psi) (1)
500 kPa 500 kPa
When ABS00136
(5 kgf/cm2, 73 psi) (5 kgf/cm2, 73 psi)
depressurized
or less or less
3,500 kPa 3,500 kPa
When
pressurized
or more or more
8) Disconnect the pressure gauges from FL and FR

caliper bodies.
9) Install the air bleeder screws of FL and FR cali-
per bodies. (1)
10) Remove the air bleeder screws from RL and
RR caliper bodies. ABS00137
11) Connect two pressure gauges to RL and RR (1) Brake tester

caliper bodies.
12) Bleed air from the brake system. <Ref. to BR- 4) Operate the brake tester.
39, PROCEDURE, Air Bleeding.> 5) Perform ABS sequence control. <Ref. to VDC-
13) Bleed air from RL and RR caliper bodies, and 14, ABS Sequence Control.>
pressure gauge. 6) When the hydraulic unit begins to work, check
14) Perform ABS sequence control. <Ref. to VDC- the following work sequence.
14, ABS Sequence Control.> (1) The FL wheel performs decompression,
15) When the hydraulic unit begins to work, first the hold and compression in sequence, and subse-
RR side performs decompression, hold and com- quently the FR wheel repeats the cycle.
pression, and then the RL side performs decom- (2) The RR wheel performs decompression,
pression, hold and compression. hold and compression in sequence, and subse-
16) Read values indicated on the pressure gauge quently the RL wheel repeats the cycle.
and check if the fluctuation of the values between 7) Read values indicated on the brake tester and
decompression and compression meets specifica- check if the fluctuation of the values between de-
tion. Depress the brake pedal and check that the compression and compression meets specifica-
kick-back is normal, and tightness is normal. tion.
17) Disconnect the pressure gauge from the RL
and RR caliper bodies. Front wheel Rear wheel
18) Install the air bleeder screws of RL and RR cal- 1,000 N 1,000 N
Initial value
iper bodies. (102 kgf, 225 lbf) (102 kgf, 225 lbf)
19) Bleed air from the brake system. <Ref. to BR- 500 N 500 N
39, PROCEDURE, Air Bleeding.> When depressurized (51 kgf, 112 lbf) (51 kgf, 112 lbf)
or less or less
1,000 N 1,000 N
When pressurized (102 kgf, 225 lbf) (102 kgf, 225 lbf)
or more or more
VDC-10

8) After the inspection, depress the brake pedal 10) Remove the air bleeder screws from RL and
and check that it is not abnormally hard, and tight- RR caliper bodies.
ness is normal. 11) Connect two pressure gauges to RL and RR
caliper bodies.
3. CHECKING THE HYDRAULIC UNIT VDC 12) Bleed air from RL and RR caliper bodies, and
OPERATION USING A PRESSURE GAUGE pressure gauge.
1) Lift up the vehicle, and then remove the wheel. 13) Perform VDC sequence control. <Ref. to VDC-
2) Remove the air bleeder screws from FL and FR 17, VDC Sequence Control.>
caliper bodies. 14) When the hydraulic unit begins to work, first the
3) Connect two pressure gauges to FL and FR cal- RR side performs compression, hold, and decom-
iper bodies. pression, and then the RL side performs compres-
CAUTION: sion, hold, and decompression.
• Use a pressure gauge used exclusively for 15) Read the values indicated on the pressure
brake fluid measurement. gauges and check if it is within specification. De-
• Do not use a pressure gauge used for the press the brake pedal and check that it is not abnor-
measuring transmission oil pressure, as the mally hard, and tightness is normal.
piston seal may expand and deform. 16) Disconnect the pressure gauge from the RL
and RR caliper bodies.
NOTE: 17) Install the air bleeder screws of RL and RR cal-
Wrap sealing tape around the pressure gauge. iper bodies.
18) Bleed air from the brake system. <Ref. to BR-
39, PROCEDURE, Air Bleeding.>
4. CHECK HYDRAULIC UNIT VDC OPERA-
TION WITH BRAKE TESTER
1) Set wheels other than the one to measure on
free rollers.
2) Prepare to operate the VDC sequence control.
<Ref. to VDC-17, VDC Sequence Control.>
ABS00134
3) Set the front wheels or rear wheels on the brake
tester and set the gear to neutral.
4) Bleed air from the pressure gauge.
5) Perform VDC sequence control. <Ref. to VDC-
17, VDC Sequence Control.>
6) When the hydraulic unit begins to work, first the
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 (1)
decompression and compression meets specifica-
tion. Depress the brake pedal and check that it is ABS00136
not abnormally hard, and tightness is normal.
3,000 kPa 3,000 kPa
When pres-
surized
or more or more
500 kPa 500 kPa
When depres-
surized
or less or less
(1)
8) Disconnect the pressure gauges from FL and FR
ABS00137
caliper bodies.
9) Install the air bleeder screws of FL and FR cali- (1) Brake tester
per bodies.
VDC-11

4) Operate the brake tester. 3) Set the pump motor section of the removed VD-
5) Perform VDC sequence control. <Ref. to VDC- CCM&H/U face down on a vise.
17, VDC Sequence Control.> NOTE:
6) When the hydraulic unit begins to work, check Before securing a part on a vise, place cushioning
the following work sequence. material such as wood blocks, aluminum plate, or
(1) The FL wheel performs compression, hold cloth between the part and the vise.
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. (1)
7) Read values indicated on the brake tester and (2)
check if the fluctuation of the values between de-
compression and compression meets specifica-
tion.
ABS00430
2,000 N 2,000 N
When pressurized (204 kgf, 450 lbf) (204 kgf, 450 lbf) (1) Aluminum plate, etc.
or more or more
(2) Vise
500 N 500 N
When depressur-
ized
(51 kgf, 112 lbf) (51 kgf, 112 lbf) 4) Using TORX® bit E5, remove the four screws of
or less or less
VDCCM.
8) After the inspection, depress the brake pedal NOTE:
and check that it is not abnormally hard, and tight- Do not re-use the screws.
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.
ABS00431
• Because the seal of the VDCCM cannot be re-
placed, do not pull or peel it by lifting it up. 5) Slowly pull out the VDCCM upward from the H/U.
• Because the screw of the H/U will become NOTE:
slightly worn in every replacement procedure, 5 To prevent damaging of coil section, remove the
times is the maximum number of times for re- VDCCM straight up from H/U without twisting.
placement. If a problem is found such as not 6) Make sure there is no dirt or damage on the seal-
being able to torque the screw to specifications ing surface of the H/U.
even before 5 replacement operations are per-
formed, replace the H/U body. CAUTION:
• When installing the VDCCM, always use new • Do not clean the VDCCM&H/U by applying
screws. compressed air.
• When the sealing surface of the VDCCM or H/U • Even if damage is found on the H/U seal, do
is dirty or damaged and it cannot be cleaned or not attempt repair by filing or with a metal
repaired, replace with a new part. scraper. To remove the seal residue, always
1) Remove the VDCCM&H/U. <Ref. to VDC-8, RE- use a plastic scraper. Do not use chemical such
MOVAL, VDC Control Module and Hydraulic Con- as paint thinner, etc., to clean.
trol Unit (VDCCM&H/U).> 7) Position the coil of the new VDCCM to align with
2) To prevent entry of foreign objects and brake flu- the H/U valve.
id leakage, plug the oil pressure port of the VDC- 8) To prevent deformation of the VDCCM housing
CM&H/U using a screw plug, etc. cover, hold the corner of VDCCM and install it to
the H/U without tilting.
VDC-12

9) Using a TORX® bit E5, attach/tighten new E: ADJUSTMENT

screws in the order of (1) through (4).
When the following replacement, removal and in-
CAUTION: stallation are performed, be sure to perform the
Always use new screws. centering of the steering angle sensor and zero
point setting of yaw rate & G sensor.
Tightening torque:
• VDCCM&H/U
1.5 N·m (0.15 kgf-m, 1.1 ft-lb)
(1) (3) • Yaw rate & G sensor
• Steering wheel parts (Including airbag)
• Suspension parts
• Wheel alignment adjustment
1) Park the vehicle straight on a level surface. (With
engine operating in the “Neutral” range)
2) Check that steering wheel is positioned at the
center. (When the center position is not correct, ad-
(4) (2) just the wheel alignment.)
ABS00432 3) Set the Subaru Select Monitor to the vehicle,
10) Check that there is no foreign matter in mating and select the {Set mode Str.A.Sen.N&Lat.GS-
surface between the VDCCM&H/U. en.0p} in the «Function Check Sequence» screen.
11) Using a TORX® bit E5, tighten the screws in the (Follow the steps on the display.)
order of (1) through (4) again. 4) On «Brake Control System» display, select {Cur-
rent Data Display & Save}, and check that the
Tightening torque: steering angle sensor shows “0 deg”.
3 N·m (0.31 kgf-m, 2.2 ft-lb) 5) When the “0 deg” is not displayed, repeat the
12) Check that there is no gap in the mating sur- above steps and check that the “0 deg” is dis-
face between VDCCM&H/U. played.
13) Install the VDCCM&H/U to the vehicle. 6) Drive the vehicle for 10 minutes, and check that
14) Bleed air from the brake system. <Ref. to BR- the ABS and VDC warning light is not illuminated.
39, PROCEDURE, Air Bleeding.> 7) Check that there is no unnecessary VDC opera-
15) Perform the selection · registration operation of tion or steering control loss. If there is a malfunc-
parameter. <Ref. to VDC(diag)-21, PARAMETER tion, repeat the steps above.
SELECTION, OPERATION, Subaru Select Moni-
tor.>
NOTE:
• After replacing the VDCCM, be sure to perform
the selection · registration operation of parameter.
• For the selection and registration of parameter,
the Subaru Select Monitor is required.
• When the registration has not been performed,
the DTC code “Parameter selection error” is detect-
ed together with the ABS/EBD/VDC warning light il-
lumination.
16) Check the parameter to confirm that the ap-
plied models and grades of the relevant vehicle are
included. <Ref. to VDC(diag)-21, PARAMETER
CHECK, OPERATION, Subaru Select Monitor.>
17) If the applied models and grades of the relevant
vehicle are not included, perform the selection ·
registration operation of parameter with the {Con-
firm on parameter} screen again. <Ref. to VDC(di-
ag)-21, PARAMETER SELECTION, OPERATION,
18) Execute Clear Memory after parameter selec-
tion and registration operations because the DTC
for “Parameter selection error” is memorized.
VDC-13
ABS Sequence Control

4. ABS Sequence Control

A: OPERATION
1) While the ABS sequence control is being performed, the operation of the hydraulic unit can be checked us-
ing the brake tester or pressure gauge after the hydraulic unit solenoid valve operation.
2) ABS sequence control can be started by the Subaru Select Monitor.
1. ABS SEQUENCE CONTROL WITH SUBARU SELECT MONITOR
NOTE:
In the event of any trouble, the ABS sequence control will not operate.
1) Connect the Subaru Select Monitor to data link connector under the driver’s side instrument panel lower
cover.
3) Run the “PC application for Subaru Select Monitor”.
4) Set the Subaru Select Monitor to “Brake Control System” mode.
5) When the “Function Check Sequence” is selected, the “ABS sequence control” will start.
6) Execute the following operations when the message “Press Brake Pedal Firmly” is displayed.
(1) When using a brake tester, press the brake pedal pad with a force of 1,000 N (102 kgf, 225 lbf).
(2) When using a pressure gauge, press the brake pedal so that the pressure gauge indicates 3,500 kPa
(36 kgf/cm2, 511 psi).
7) Press the “OK” after “Press “OK”” is displayed.
8) The brake system being operated is displayed on the Subaru Select Monitor.
VDC-14

2. CONDITIONS FOR ABS SEQUENCE CONTROL
V max < 4 km/h (2.5 MPH)

(1) V max < 10 km/h (6 MPH)
OFF ON
(2) (15) (19) (18) (19) (20)
(16) (17) (16) (17) (16) (17) (16)

(3)
OFF ON
(4)
OFF ON (21)
(5)
(18)
OFF ON
(6)
OFF ON
(7)
(21)
OFF (18)
(8) ON
(9) OFF ON
(10) OFF ON
OFF ON
(11)
OFF ON
(12)
(13) OFF ON
OFF ON
(14)
(22) (23)
(24)
(25)
(26)
(27)
(28)
ABS00943
VDC-15

(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
NOTE:
The control operation starts at point A.
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION OF ABS SEQUENCE CONTROL
When the following conditions develop, the ABS sequence control stops and ABS operation is returned to the
normal control mode.
• When the speed of at least one wheel reaches 10 km/h (6 MPH).
• When the brake pedal is released during ABS sequence control and the stop light switch is becomes OFF.
• After completion of ABS sequence control.
• When a malfunction is detected.
VDC-16
VDC Sequence Control

5. 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 WITH SUBARU SELECT MONITOR
NOTE:
In the event of any trouble, sequence control will not operate.
1) Connect the Subaru Select Monitor to data link connector under the driver’s side instrument panel lower
cover.
3) Run the “PC application for Subaru Select Monitor”.
4) Set the Subaru Select Monitor to “Brake Control System” mode.
5) When the “VDC Inspection Mode” is selected from the “Function Check Sequence” menu, the “VDC se-
quence control” will start.
6) Press the “OK” after “Press “OK”” is displayed.
7) Operation points will be displayed on Subaru Select Monitor.
VDC-17

2. CONDITIONS FOR VDC SEQUENCE CONTROL

V max < 4 km/h (2.5 MPH)
(1) V max < 10 km/h (6 MPH)
OFF ON (21)
(2) (20) (24) (25) (24) (26)
(22) (23) (22) (23) (22) (23) (22)

(3)
(4) (23) VDC

(22) (22)
(37)
OFF
(5)
OFF ON
(6)
(7)
(8)
(29) (25) (30) (31)
OFF
(9)
(29) (25) (30) (31)
OFF
(10)
OFF
(11)
OFF
(12)
OFF
(13)
OFF
(14)
OFF
(15)
OFF
(16)
OFF
(17)
OFF
(18)
(19) ON
(27) (28)
(32)
(33)
(34)
(35)
(36)
VDC00607
VDC-18

(1) All wheel speed (14) FR compression valve (26) 1.6 seconds
(2) Ignition key (15) RR decompression valve (27) Point A
(3) ABS warning light (16) RR compression valve (28) Reset
(4) VDC warning light (17) RL decompression valve (29) 0.8 seconds
(5) Stop light switch (18) RL compression valve (30) 1.2 seconds
(6) Valve relay (19) Pump motor (31) 0.4 seconds
(7) VDC switching valve 1 FL (20) 1.5 seconds (32) Master cylinder pressure
(8) VDC switching valve 1 FR (21) Approx. 3 seconds (33) FR wheel cylinder pressure
(9) VDC switching valve 2 FL (22) Light OFF (34) FL wheel cylinder pressure
(10) VDC switching valve 2 FR (23) Light ON (35) RL wheel cylinder pressure
(11) FL decompression valve (24) 3.4 seconds (36) RR wheel cylinder pressure
(12) FL compression valve (25) 1 second (37) Hill start assist warning light
(13) FR decompression valve
NOTE:
The control operation starts at point A.
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION OF VDC SEQUENCE CONTROL
When the following conditions develop, the VDC sequence control stops and VDC operation is returned to
the normal control mode.
• When the speed of at least one wheel reaches 10 km/h (6 MPH).
• When the brake pedal is pressed during sequence control and the stop light switch is set to ON.
• After completion of VDC sequence control.
• When a malfunction is detected.
VDC-19
Yaw Rate and G Sensor

6. Yaw Rate and G Sensor

A: REMOVAL
2) Remove the console box. <Ref. to EI-51, Con-
sole Box.>
3) Disconnect the connector from yaw rate & G
sensor.
4) Remove the nut and remove the yaw rate & G
sensor.
CAUTION:
Do not drop or hit the yaw rate & G sensor.
VDC00453
B: INSTALLATION
Tightening torque:
7.5 N·m (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 & 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-13,
ADJUSTMENT, VDC Control Module and Hy-
draulic Control Unit (VDCCM&H/U).>
VDC-20
Yaw Rate and G Sensor

C: INSPECTION
1. YAW RATE & G SENSOR SIGNAL
Step Check Yes No
1 CHECK YAW RATE & G SENSOR. Are the indicated values when Go to step 2. Repair the harness
1) Turn the ignition switch to OFF. the vehicle is placed horizon- connector between
2) Connect the Subaru Select Monitor connec- tally, Lateral G sensor: –1.5 — yaw rate & G sen-
tor to the data link connector. 1.5 m/s2, Yaw rate sensor: –4 sor and
3) Turn the ignition switch to ON. — 4 deg/s? VDCCM&H/U. Or
4) Set the Subaru Select Monitor connector to replace yaw rate &
the {Brake Control System} mode. G sensor.
5) Select {Current Data Display & Save}.
6) Read the output of yaw rate & G sensor.
2 CHECK G SENSOR. Is the value 6.8 — 12.8 m/s2 Go to step 3. Repair the harness
1) Remove the console box. when the yaw rate & G sensor connector between
2) Remove the yaw rate & G sensor from vehi- is inclined 90° to the forward? yaw rate & G sen-
cle without disconnecting the connector. sor and
3) Read the display of Subaru Select Monitor. VDCCM&H/U. Or
NOTE: replace yaw rate &
When the yaw rate & G sensor is moved with its G sensor.
power supply on, DTC of yaw rate & G sensor
may be recorded.
3 CHECK G SENSOR. Is the value –6.8 — –12.8 m/s2 Go to step 4. Repair the harness
Read the display of Subaru Select Monitor. when the yaw rate & G sensor connector between
NOTE: is inclined 90° to the rearward? yaw rate & G sen-
When the yaw rate & G sensor is moved with its sor and
power supply on, DTC of yaw rate & G sensor VDCCM&H/U. Or
may be recorded. replace yaw rate &
G sensor.
4 CHECK G SENSOR. Is the value 6.8 — 12.8 m/s2 Go to step 5. Repair the harness
Read the display of Subaru Select Monitor. when the yaw rate & G sensor connector between
NOTE: is inclined 90° to the right? yaw rate & G sen-
G sensor.
5 CHECK G SENSOR. Is the value –6.8 — –12.8 m/s2 Yaw rate & G sen- Repair the harness
Read the display of Subaru Select Monitor. when the yaw rate & G sensor sors are normal. connector between
NOTE: is inclined 90° to the left? yaw rate & G sen-
G sensor.
VDC-21
Steering Angle Sensor

7. Steering Angle Sensor 8) Remove the screws and remove the steering
column cover upper.
A: REPLACEMENT
CAUTION:
• Do not perform the removal except unless re-
placing.
• If the sensor needs replacement, replace
along with the combination switch assembly
once every three times for the protection of the
threaded portion.
1) Set the steering wheel in a straight-ahead posi-
tion. LI-01144
2) Disconnect the ground cable from battery. 9) Disconnect the connector of roll connector and
3) Remove the driver’s airbag module. <Ref. to AB- steering angle sensor.
16, REMOVAL, Driver’s Airbag Module.> 10) Remove the screws which secure the roll con-
WARNING: nector to steering column.
Always refer to “Airbag System” when perform-
ing the airbag module repair service. <Ref. to
AB-5, CAUTION, General Description.>
4) Remove the steering wheel. <Ref. to PS-13, RE-
MOVAL, Steering Wheel.>
5) Remove the screws and remove the steering
column cover lower.
AB-02604
11) Remove the vinyl tape binding the harness,

and remove the steering angle sensor from roll
connector.
WW-00547
6) Remove the harness cover lock.

7) Remove the screws and detach the knee protec-
tor.
VDC00885
LI-01143
VDC-22
Steering Angle Sensor

12) Turn the protrusion portion of new steering an- 16) Install the roll connector to combination switch
gle sensor to match the alignment mark of inspec- and bind the harness with vinyl tape as originally
tion hole. bound.
CAUTION:
Be careful not to allow foreign matter to enter
into inspection hole.
(1)
(2)
(3)
AB-02604
17) Install the steering wheel. <Ref. to PS-13, IN-

STALLATION, Steering Wheel.>
VDC00209
Tightening torque:
(1) Protrusion portion 39 N·m (3.98 kgf-m, 28.8 ft-lb)
(2) Inspection hole
18) Install the airbag module to the steering wheel.
<Ref. to AB-16, INSTALLATION, Driver’s Airbag
(3) Alignment mark
Module.>
13) Align the center of roll connector. <Ref. to AB- WARNING:
27, INSTALLATION, Roll Connector.> Always refer to “Airbag System” before per-
14) Apply the grease provided with the new part on forming the service operation. <Ref. to AB-5,
the 4 locations of the protrusion on the steering an- CAUTION, General Description.>
gle sensor. 19) Connect the ground cable to battery.
CAUTION:
After completion of installation, adjust the fol-
lowing two positions.
• Positioning to the center of steering angle
sensor
• Positioning the yaw rate & G sensors to zero
The above procedure is required for the VDC-
(1) CM to identify vehicle position afterward. For
the setting procedures of the 2 steps above, re-
ABS00435 fer to “Adjustment” in “VDC Control Module &
Hydraulic Control Unit (VDCCM&H/U)”. <Ref. to
(1) Grease application location VDC-13, ADJUSTMENT, VDC Control Module
and Hydraulic Control Unit (VDCCM&H/U).>
15) Align the position of the protrusion and install
roll connector to steering angle sensor.
Tightening torque:
0.5 N·m (0.05 kgf-m, 0.36 ft-lb)
VDC00885
VDC-23
Front ABS Wheel Speed Sensor

8. Front ABS Wheel Speed Sen- B: INSTALLATION

sor CAUTION:
Be careful not to damage the sensor.
A: REMOVAL Install each part in the reverse order of removal.
Tightening torque:
2) Disconnect the ABS wheel speed sensor con-
Sensor:
nector located next to the front strut mounting
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
house in the engine compartment.
Bracket:
3) Remove the bolts and then remove the sensor
harness bracket. 33 N·m (3.36 kgf-m, 24.3 ft-lb)
(1)
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
(2)
steering wheel effort.
C: INSPECTION
ABS00386
1. CHECK WITH SUBARU SELECT MONI-
TOR
(1) To the front ABS wheel speed sensor connector 1) Connect the Subaru Select Monitor to the data
(2) Sensor harness bracket link connector.
2) Select {Current Data Display & Save}. Check if
4) Remove the bolts which secure the sensor har- the speed indicated on the display changes in the
ness to the front strut. same manner as the speedometer reading during
5) Remove the bolts, and remove the front ABS acceleration/deceleration when the steering wheel
wheel speed sensor from the front housing. is in the straight-ahead position.
CAUTION: 3) If the speed indicated on the display does not
• Be careful not to damage the sensor. change, check the ABS wheel speed sensor. <Ref.
• Do not apply excessive force to the sensor to VDC-24, ABS WHEEL SPEED SENSOR, IN-
harness. SPECTION, Front ABS Wheel Speed Sensor.>
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) Check the ABS wheel speed sensor cable for
discontinuity. If defective, replace the ABS wheel
speed sensor.
ABS00387
VDC-24
Front ABS Wheel Speed Sensor

3) 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
1.4 V
0.7 V
(1)
12 V
1 2
2
(2)
1
100
ABS00388
(1) Oscilloscope
(2) ABS wheel speed sensor
4) Replace the ABS wheel speed sensor if the in-

spection result is not within the standard value.
VDC-25
Rear ABS Wheel Speed Sensor

9. Rear ABS Wheel Speed Sen- 5) Remove the bolts, and remove the rear ABS
wheel speed sensor from the rear axle.
sor
CAUTION:
A: REMOVAL • Be careful not to damage the sensor.
1) Disconnect the ground cable from battery. • Do not apply excessive force to the sensor
2) Disconnect the connector from the rear ABS harness.
wheel speed sensor.
FU-03357
RS-00266
B: INSTALLATION
3) Remove the sensor harness clamp of the rear
CAUTION:
sub frame.
Be careful not to damage the sensor.
Tightening torque:
Sensor:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
Bracket:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
NOTE:
Check the identification (mark) on the harness to
ABS-01015 make sure there is no warpage. (RH: P5 (White),
4) Remove the bolts and then remove the sensor LH: P6 (Yellow))
harness bracket from the upper arm. C: INSPECTION
Refer to “INSPECTION” in “Front ABS Wheel
Speed Sensor”. <Ref. to VDC-24, INSPECTION,
Front ABS Wheel Speed Sensor.>
RS-00257
VDC-26
Front Magnetic Encoder

10.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-18, 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 dam-
age. If necessary, replace with a new hub unit bear-
ing.
NOTE:
Because the magnetic encoder is integrated with
hub unit bearing assembly, replace the hub unit
bearing with a new part if there is any defect found
on the magnetic encoder.
VDC-27
Rear Magnetic Encoder

11.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-24, 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-25, INSTAL-
LATION, 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
hub unit bearing assembly, replace the hub unit
bearing with a new part if there is any defect found
on the magnetic encoder.
VDC-28
VDC OFF Switch

12.VDC OFF Switch

A: REMOVAL
NOTE:
VDC mode change switch is equipped with STI MT
model only, and it is also used as VDC OFF switch.
1) Remove the instrument panel lower cover. <Ref.
to EI-49, REMOVAL, Instrument Panel Lower Cov-
er.>
2) Remove the screws, and then remove the VDC
OFF switch.
4 3 2 1
VDC00541
B: INSTALLATION
C: INSPECTION
1) Check the resistance between the VDC OFF
switch terminals.
Switch position Terminal No. Standard
OFF 2—3 1 MΩ or more
ON 2—3 Less than 1 Ω
2) Replace the VDC OFF switch if the inspection

result is not within the standard value.
VDC-29

(DIAGNOSTICS)
VDC(diag)
Page
2. Check List for Interview ..............................................................................4
3. General Description .................................................................................10
4. Electrical Component Location ................................................................12
5. Control Module I/O Signal ........................................................................14
6. Subaru Select Monitor ..............................................................................18
8. Inspection Mode .......................................................................................26
10. Warning Light Illumination Pattern ...........................................................28
13. General Diagnostic Table .......................................................................110

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 open 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
1 CHECK PRE-INSPECTION. Is the component that might Go to step 2. Repair or replace
1) Ask the customer when and how the trouble influence the VDC problem nor- each component.
occurred using the interview check list. <Ref. to mal?
VDC(diag)-4, Check List for Interview.>
2) Before performing diagnostics, check the
component which might affect VDC problems.
<Ref. to VDC(diag)-10, INSPECTION, General
Description.>
2 CHECK INDICATION OF DTC. Is DTC displayed on Subaru Record the DTC. Go to step 3.
1) Turn the ignition switch to OFF. Select Monitor? Go to step 4.
2) Connect the Subaru Select Monitor to data
link connector.
3) Turn the ignition switch to ON and run the
4) Read the DTC using the Subaru Select
Monitor. <Ref. to VDC(diag)-25, OPERATION,
Read Diagnostic Trouble Code (DTC).>
NOTE:
If the communication function of the Subaru Se-
lect Monitor cannot be executed properly,
check the communication circuit. <Ref. to
VDC(diag)-22, COMMUNICATION FOR INI-
TIALIZING IMPOSSIBLE, INSPECTION, Sub-
3 PERFORM GENERAL DIAGNOSTICS. Do the VDC warning light and Finish the diagno- Check the combi-
1) Perform the inspection by referring to “Gen- ABS warning light go off after sis. nation meter cir-
eral Diagnostic Table”. <Ref. to VDC(diag)-110, starting the engine? cuit. <Ref. to
INSPECTION, General Diagnostic Table.> VDC(diag)-34,
2) Perform the Clear Memory Mode. <Ref. to ABS WARNING
VDC(diag)-27, OPERATION, Clear Memory LIGHT DOES NOT
Mode.> GO OFF, Warning
3) Perform the Inspection Mode. <Ref. to Light Illumination
VDC(diag)-26, PROCEDURE, Inspection Pattern.> <Ref. to
Mode.> VDC(diag)-38,
4) Read the DTC. <Ref. to VDC(diag)-25, VDC WARNING
OPERATION, Read Diagnostic Trouble Code LIGHT AND VDC
(DTC).> INDICATOR
5) Check the DTC is not displayed. LIGHT DO NOT
GO OFF, Warning
Light Illumination
Pattern.>
4 CHECK FREEZE FRAME DATA. Are freeze frame data Record the freeze Go to step 5.
Using the Subaru Select Monitor, check the recorded? frame data. Go to
freeze frame data of the VDC control module. step 5.
VDC(diag)-2

Step Check Yes No

5 PERFORM DIAGNOSIS. Is DTC displayed? Repeat step 5 until Finish the diagno-
1) Refer to “List of Diagnostic Trouble Code DTC is not shown. sis.
(DTC)”.
NOTE:
For the DTC list, refer to “List of Diagnostic
Trouble Code (DTC)”. <Ref. to VDC(diag)-48,
LIST, List of Diagnostic Trouble Code (DTC).>
2) Correct the cause of trouble.
3) Perform the Clear Memory Mode. <Ref. to
VDC(diag)-27, OPERATION, Clear Memory
Mode.>
4) Perform the Inspection Mode. <Ref. to
VDC(diag)-26, PROCEDURE, Inspection
Mode.>
5) Read the DTC. <Ref. to VDC(diag)-25,
OPERATION, Read Diagnostic Trouble Code
(DTC).>
VDC(diag)-3

2. Check List for Interview

A: CHECK
Check the following item about the vehicle’s state.
1. STATE OF ABS WARNING LIGHT
ABS warning light Always
illuminates. Sometimes
Only once
Does not illuminate
• When/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 switch to ON
Immediately after turning the ignition switch to START
When 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
• Part name:
• Operating condition:
VDC(diag)-4

2. STATE OF VDC WARNING LIGHT & VDC INDICATOR LIGHT

VDC warning light & Always
VDC indicator light Sometimes
illuminates. Only once
Does not illuminate
ACC
ON (before starting engine)
START
ON (after starting engine, engine is running)
ON (after starting engine, engine is at a standstill)
While accelerating — km/h
— MPH
— MPH
Steering time: Sec.
Steering time: Sec.
• Part name:
VDC(diag)-5

3. STATE OF VDC OFF & VDC TRACTION MODE INDICATOR LIGHT

NOTE:
This check list for interview is applied to 6MT model.
The VDC OFF & Always
VDC traction mode Sometimes
indicator light illumi- Only once
nates. Does not illuminate
ACC
START
— MPH
— MPH
Steering time: Sec.
Steering time: Sec.
• Part name:
VDC(diag)-6

4. STATE OF VDC OFF INDICATOR LIGHT

NOTE:
This check list for interview is applied to 5MT model.
VDC OFF indicator Always
light comes on. Sometimes
Only once
Does not illuminate
ACC
START
— MPH
— MPH
Steering time: Sec.
Steering time: Sec.
• Part name:
VDC(diag)-7

5. 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)-8

Condition a) Brakes Deceleration: G

continuous / intermittent
b) Accelerator Acceleration: G
continuous / intermittent
c) Vehicle speed km/h MPH
Advancing
When 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: mm (in)
Front LH tire: mm (in)
Rear RH tire: mm (in)
Rear LH tire: mm (in)
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) Using T-type tires: Yes / No
k) Condition of suspension alignment:
l) Load condition:
m) Repaired parts are used: Yes / No
• Content:
n) Others:
VDC(diag)-9
General Description
3. General Description 5. BRAKE DRAG

Check for brake drag.
A: CAUTION
6. BRAKE PAD AND ROTOR
1. SUPPLEMENTAL RESTRAINT SYSTEM
Check the brake pad and rotor.
“AIRBAG” • Front <Ref. to BR-16, INSPECTION, Front Brake
Airbag system wiring harness is routed near the Pad.> <Ref. to BR-17, INSPECTION, Front Disc
ABS wheel speed sensor and VDCCM&H/U. Rotor.>
CAUTION: • Rear <Ref. to BR-25, INSPECTION, Rear Brake
• Do not use electrical test equipment on wir- Pad.> <Ref. to BR-27, INSPECTION, Rear Disc
ing harness and connector circuits of the air- Rotor.>
bag system. 7. TIRES
• Be careful not to damage the airbag system
wiring harness when servicing the ABS wheel Check the tire specifications, tire wear and air pres-
speed sensor and VDCCM&H/U. sure. <Ref. to WT-2, SPECIFICATION, General
Description.>
B: INSPECTION
Before performing diagnosis, check the following
items which might affect VDC problems.
1. BATTERY
Measure the battery voltage and check electrolyte.
Standard voltage:
12 V or more
Specific gravity:
1.260 or more
2. GROUND
Check the tightening torque of ground (GB-5) bolt
of VDC.
Tightening torque:
13 N·m (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 VDC-10,
CHECKING THE HYDRAULIC UNIT ABS OPERA-
TION WITH THE BRAKE TESTER, INSPECTION,
VDC Control Module and Hydraulic Control Unit
(VDCCM&H/U).>
• When not using the brake tester <Ref. to VDC-9,
CHECKING THE HYDRAULIC UNIT ABS OPERA-
TION BY PRESSURE GAUGE, INSPECTION,
VDC Control Module and Hydraulic Control Unit
(VDCCM&H/U).>
VDC(diag)-10
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
MONITOR III KIT
ST1B022XU0
2. GENERAL TOOL
TOOL NAME REMARKS
VDC(diag)-11


A: LOCATION
(8) (9)
(7)
(15) (4) (5) (6)
(3)
(2)
(1)
(12) (11) (10)

(13)
(14)
(11) (10)
VDC00971
(1) VDC control module and hydraulic (6) VDC OFF & VDC traction mode (11) ABS wheel speed sensor
control unit (VDCCM&H/U) indicator light (6MT model)
VDC OFF indicator light (5MT
model)
(2) Connector (7) VDC warning light & VDC indica- (12) Yaw rate & G sensor
tor light
(3) Engine control module (ECM) (8) Steering angle sensor (13) Data link connector
(4) Brake warning light (EBD warning (9) VDC OFF switch (14) Stop light and brake switch
light)
(5) ABS warning light (10) Magnetic encoder (15) Hill start assist warning light
VDC(diag)-12

(4)
(1)
(6) (5) (16)

(7)
VDC00455 VDC00972
(8) (11)
(10)
VDC00544 (10)
VDC00234
(13)
(12)
VDC00456 VDC00545
VDC(diag)-13

5. Control Module I/O Signal

B310
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00457
NOTE:
• Terminal numbers in VDCCM&H/U connector are shown in the figure.
• When the connector is removed from the VDCCM&H/U, the brake warning light (EBD warning light), ABS
warning light, VDC OFF & VDC traction mode indicator light (6MT model), VDC OFF indicator light (5MT
model), VDC warning light & VDC indicator light, and the hill start assist warning light illuminate.
VDC(diag)-14

Terminal No. Input/Output signal

Content
(+) — (–) Measured value and measuring conditions
Power supply 28 — 25 10 — 15 V when the ignition switch is ON.
Power supply 26 — 25 4.5 — 16.5 V
Front LH wheel
Signal 1 5.9 — 16.8 mA: Rectangle waveform
Power supply 5 — 25 4.5 — 16.5 V
Front RH wheel
ABS wheel speed Signal 6 5.9 — 16.8 mA: Rectangle waveform
sensor Power supply 2 — 25 4.5 — 16.5 V
Rear LH wheel
Power supply 3 — 25 4.5 — 16.5 V
Rear RH wheel
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.
1.5 V or less when the stop light is OFF; otherwise,
Stop light switch 30 — 25
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 ←→ 5 V pulse
1 Ω or less when the switch is ON; 1 MΩ or more
VDC OFF switch 31 — 25
when the switch is OFF.
Ground 25 —
VDC(diag)-15

B: WIRING DIAGRAM
(3)
(5)
(20)
(1) (2)
(21)
(22)
(23)
(36)
(24)
(41)
(25) (6)
(26)
(4)
(29)
(30) (28)
(42) (31)
M (7)
(8)
(27) (9)
(32)
(10)
(43) (33) (11)
(12)
(34)
(13)
(35) (14)
(15)
(37)
(16)
(38) (17)
(39) (18)
(40) (19)
VDC00681
VDC(diag)-16

(1) Battery (16) Primary cut solenoid valve (31) Body integrated unit
(2) Ignition switch (17) Primary suction solenoid valve (32) Engine control module (ECM)
(3) VDC control module and hydraulic (18) Secondary cut solenoid valve (33) Driver’s control center differential
control unit (VDCCM&H/U) control module (6MT model only)
(4) VDC control module (19) Secondary suction solenoid valve (34) Steering angle sensor
(5) Valve relay (20) Data link connector (35) Yaw rate & G sensor
(6) Motor relay (21) VDC OFF switch (36) Pressure sensor
(7) Motor (22) Combination meter (37) Front ABS wheel speed sensor LH
(8) Front inlet solenoid valve LH (23) VDC OFF & VDC traction mode (38) Front ABS wheel speed sensor
indicator light (6MT model) RH
model)
(9) Front outlet solenoid valve LH (24) VDC warning light & VDC indica- (39) Rear ABS wheel speed sensor LH
tor light
(10) Front inlet solenoid valve RH (25) ABS warning light (40) Rear ABS wheel speed sensor
RH
(11) Front outlet solenoid valve RH (26) Brake warning light (EBD warning (41) Hill start assist warning light
light)
(12) Rear inlet solenoid valve LH (27) Parking brake switch (42) Back-up light switch
(13) Rear outlet solenoid valve LH (28) Brake fluid level switch (43) Clutch switch
(14) Rear inlet solenoid valve RH (29) Stop light and brake switch
(15) Rear outlet solenoid valve RH (30) Stop light
VDC(diag)-17

6. Subaru Select Monitor 8) If VDC and Subaru Select Monitor cannot com-
municate, check the communication circuit. <Ref.
A: OPERATION to VDC(diag)-22, COMMUNICATION FOR INI-
TIALIZING IMPOSSIBLE, INSPECTION, Subaru
1. HOW TO USE SUBARU SELECT MONI- Select Monitor.>
TOR 9) Record the DTC and data.
1) Prepare the Subaru Select Monitor kit. <Ref. to
VDC(diag)-11, SPECIAL TOOL, PREPARATION
TOOL, General Description.>
EN-05692
2) Prepare PC with Subaru Select Monitor in-

stalled.
3) Connect the USB cable to SDI (Subaru Diagno-
sis Interface) and USB port on the personal com-
puter (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
4) Connect the diagnosis cable to SDI.
5) Connect SDI to data link connector located in the
lower portion of the instrument panel (on the driv-
er’s side).
EN-06148
CAUTION:
Do not connect the scan tools other than the
6) Start the PC.
7) Turn the ignition switch to ON (engine OFF) and
run the “PC application for Subaru Select Monitor”.
NOTE:
For detailed operation procedures, refer to “PC ap-
plication help for Subaru Select Monitor”.
VDC(diag)-18

2. READ CURRENT DATA

1) On «Main Menu» display, select {Each System Check}.
2) On «System Selection Menu» display, select {Brake Control System}.
3) When {VDC} is displayed, select the [OK] button.
4) On «Brake Control Diagnosis» display, select {Current Data Display & Save}.
5) On «Data Display Menu» display, select the data display method.
6) Using the scroll key, scroll the display screen up or down until necessary data is shown.
Unit of
Display Contents to be displayed
measure
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
Steer Angle Sensor Op Steering angle detected by steering angle sensor is displayed. deg
Yaw Rate Sensor Output Vehicle angular speed detected by yaw rate sensor is displayed. deg/s
Pressure Sensor Output Brake fluid pressure detected by pressure sensor is displayed. bar
Lateral G sensor Output Vehicle lateral acceleration detected by lateral G sensor is displayed. m/s2
IG power supply voltage Voltage supplied to VDCCM&H/U is displayed. V
E/G Control Stop 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
ON/OFF condition of VDC OFF & VDC traction mode indicator light (6MT model)
OFF Lamp ON or OFF
or VDC OFF indicator light (5MT model) is displayed.
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
M. Relay monitor Voltage Voltage applied to the motor relay is displayed. V
OFF SW Signal Operation condition of VDC OFF switch is displayed. ON or OFF
Brake SW Brake ON/OFF is displayed. ON or OFF
Fr Rr G sensor Output Vehicle longitudinal acceleration detected by longitudinal G sensor is displayed. m/s2
Clutch Signal Clutch ON/OFF is displayed. ON or OFF
Reverse Signal Reverse gear ON/OFF is displayed. ON or OFF
NOTE:
For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.
VDC(diag)-19

3. FUNCTION CHECK
Display Contents of display Index No.
ABS Sequence Control Mode Operate the valve and pump motor continuously
<Ref. to VDC-14, ABS Sequence Control.>
to perform the ABS sequence control.
VDC Check Mode Operate the valve and pump motor continuously
<Ref. to VDC-17, VDC Sequence Control.>
to perform the VDC sequence control.
Set up mode for Neutral of Set the steering angle sensor neutral position
Steering Angle Sensor & Lat- and the lateral G sensor “0” point. <Ref. to VDC-22, Steering Angle Sensor.>
eral G Sensor 0 point
4. FREEZE FRAME DATA

NOTE:
• Data stored at the time of trouble occurrence is shown on display.
• 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 “?” appears on the Subaru Select Monitor display. This shows it may be
an unreliable reading.
Display Contents to be displayed Display Contents to be displayed
Steering Angle Steering angle detected by steering Gear Position Gear position on malfunction occurrence
Sensor Op angle sensor is displayed. is displayed.
Yaw Rate SensorVehicle angular speed detected by yaw IG power supply Voltage supplied to VDC control module
Output rate sensor is displayed. voltage is displayed.
Lateral G sensor
Vehicle lateral acceleration detected by Steering angle Whether the absolute angle of the steer-
Output lateral G sensor is displayed. flag ing angle sensor was determined is dis-
played.
Pressure Sen- Brake fluid pressure detected by pres-
sor Output sure sensor is displayed. E/G Control Stop Engine control command signal is dis-
Vehicle Speed Vehicle speed calculated by VDC control Flag played.
module is displayed. VDC Control VDC control condition is displayed.
Flag
FR Wheel Speed Wheel speed detected by front ABS
wheel speed sensor RH is displayed in EBD Control EBD control condition is displayed.
km/h or MPH. Flag
FL Wheel Speed Wheel speed detected by front ABS TCS Control TCS control condition is displayed.
wheel speed sensor LH is displayed in Flag
km/h or MPH. ABS Control ABS control condition is displayed.
RR Wheel Wheel speed detected by rear ABS Flag
Speed wheel speed sensor RH is displayed in OFF Switch ON/OFF condition of the VDC operated
km/h or MPH. Detection by the driver is displayed.
RL Wheel Speed Wheel speed detected by rear ABS Brake Switch Brake ON/OFF is displayed.
wheel speed sensor LH is displayed in Longitudinal G Vehicle longitudinal acceleration
km/h or MPH. sensor output detected by longitudinal G sensor is dis-
Accel. Opening Acceleration opening is displayed. played.
Angle Clutch Switch Clutch ON/OFF is displayed.
Engine Speed Engine speed on malfunction occur- Reverse Signal Reverse gear ON/OFF is displayed.
rence is displayed.
VDC(diag)-20

5. PARAMETER SELECTION 6. PARAMETER CHECK

CAUTION: NOTE:
• Subaru Select Monitor is required for param- The parameter data registered in the VDCCM is
eter selection. shown on the display.
• This function can be used for the replace- 1) Connect the Subaru Select Monitor.
ment part of VDCCM&H/U and VDCCM. 2) On «Main Menu» display, select {Each System
NOTE: Check}.
• When the VDCCM is replaced with a replace- 3) On «System Selection Menu» display, select
ment part, be sure to perform the parameter selec- {Brake Control System}.
tion/registration to the VDCCM using this function. 4) Click the [OK] button after {VDC} is displayed.
• For confirmation of applied models, refer to the 5) On «Brake Control Diagnosis» display, select
“Model number plate” attached to the vehicles. {Confirm on parameter}.
<Ref. to ID-2, IDENTIFICATION, Identification.> 6) On the {Confirm on parameter} display screen,
• When the applied model is entered wrong, re-en- check that the applied model and grade of the tar-
try is possible. get vehicle are included, and click the [OK] button.
• When the registration has not been performed, 7) If the applied model and grade of the target ve-
the DTC code “Parameter selection error” is detect- hicle are not included on the {Confirm on parame-
ed together with the ABS/EBD/VDC warning light il- ter} display screen, perform parameter selection
lumination. and registration. <Ref. to VDC(diag)-21, PARAME-
1) Connect the Subaru Select Monitor. TER SELECTION, OPERATION, Subaru Select
2) On «Main Menu» display, select {Each System Monitor.>
Check}.
{Brake Control System}.
5) On «Brake Control Diagnosis» display, select
{Select Parameter}.
6) Check the applied model and option code indi-
cated 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 option code input screen appears after
entering the applied model, enter the option code
consisting of 4-digit alphanumeric characters, and
press the [Enter] key When the option code is 3 dig-
its, add “0” in front and enter the code as 4 digits.
9) 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.
10) Execute Clear Memory after parameter selec-
tion and registration operations because the DTC
for “Parameter selection error” is memorized.
VDC(diag)-21

B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
TROUBLE SYMPTOM:
Communication is impossible between VDC and Subaru Select Monitor.
WIRING DIAGRAM:
Vehicle Dynamics Control System <Ref. to WI-67, Vehicle Dynamics Control System.>
BATTERY
MAIN SBF
E
No.13
SBF-6
M/B
DATA LINK
CONNECTOR
IGNITION
SWITCH 16
7
B40
No.33
B440
F/B
2
2
B441
E
25
28
B310 VDCCM & H/U
B40 B310 B440
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 B441
1 2 3 4 5 6 7 8 22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
9 10 11 12 13 14 15 16 1 2 3 4 5
VDC00547
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 VDC mode
using Subaru
Select Monitor.
2 CHECK BATTERY. Is the voltage 11 V or more? Go to step 3. Charge or replace
1) Turn the ignition switch to OFF. the battery.
2) Measure the battery voltage.
VDC(diag)-22

Step Check Yes No

3 CHECK BATTERY TERMINAL. Is there poor contact at battery Repair or tighten Go to step 4.
terminal? the battery termi-
nal.
4 CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Go to step 8. Go to step 5.
MUNICATION. on Subaru Select Monitor?
2) Using the Subaru Select Monitor, check
whether communication to other systems can
be executed normally.
5 CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Replace the Go to step 6.
MUNICATION. on Subaru Select Monitor? VDCCM only.
1) Turn the ignition switch to OFF. <Ref. to VDC-12,
2) Disconnect the VDCCM&H/U connector. REPLACEMENT,
3) Turn the ignition switch to ON. VDC Control Mod-
4) Check whether communication to other sys- ule and Hydraulic
tems can be executed normally. Control Unit
(VDCCM&H/U).>
6 CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or Go to step 7. Repair the harness
2) Disconnect the connectors from ECM, air- data link connec-
bag CM, TPMS & keyless entry CM, DCCD CM tor.
(6MT model only) and body integrated unit.
CAUTION:
When disconnecting the connector from air-
bag CM, always follow the precautions on
AB section. <Ref. to AB-5, CAUTION, Gener-
al Description.>
7 CHECK HARNESS CONNECTOR BETWEEN Is the voltage less than 1 V? Go to step 8. Repair the harness
VDCCM&H/U AND DATA LINK CONNEC- and connector
TOR. between each con-
1) Turn the ignition switch to ON. trol module and
2) Measure the voltage between data link con- data link connec-
nector and chassis ground. tor.
8 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 9. Repair harness
VDCCM&H/U AND DATA LINK CONNEC- and connector
TOR. between
Measure the resistance between VDCCM&H/U VDCCM&H/U and
connector and data link connector. data link connec-
(B310) No. 7 — (B40) No. 7:
9 CHECK INSTALLATION OF VDCCM&H/U Is the VDCCM&H/U connector Go to step 10. Insert VDCCM&H/U
CONNECTOR. inserted into VDCCM&H/U until connector into
Turn the ignition switch to OFF. the clamp locks onto it? VDCCM&H/U.
10 CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 — 15 V? Go to step 11. Repair the open
1) Turn the ignition switch to ON. (engine OFF) circuit and poor
2) Measure the ignition power supply voltage contact of the con-
between VDCCM&H/U connector and chassis nector between
ground. VDCCM&H/U and
Connector & terminal battery.
VDC(diag)-23

Step Check Yes No

11 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 10 Go to step 12. Repair the open
VDCCM&H/U AND CHASSIS GROUND. Ω? circuit of
1) Turn the ignition switch to OFF. VDCCM&H/U
2) Disconnect the connector from the ground harness
VDCCM&H/U. and poor contact of
3) Measure the resistance of harness between connector.
VDCCM&H/U connector and chassis ground.
12 CHECK POOR CONTACT OF CONNECTOR. Is there poor contact of control Repair the connec- Replace the
module power supply, ground tor. VDCCM only.
circuit and data link connector? <Ref. to VDC-12,
REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-24


Code (DTC)
A: OPERATION
Check}.
3) Click the [OK] button after {VDC} is displayed.
{Diagnostic Code(s) Display}.
5) Record the DTC and data.
NOTE:
• For details concerning DTCs, refer to “List of Di-
agnostic Trouble Code (DTC)”. <Ref. to VDC(di-
ag)-48, List of Diagnostic Trouble Code (DTC).>
• 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.
Display Contents to be displayed
(Current) The current DTC is displayed on Subaru
Select Monitor display screen.
(Before 1) The latest DTC from the history of previous
problems is displayed on Subaru Select
Monitor display screen.
(Before 2) The second latest DTC from the history of
previous problems is displayed on the Sub-
aru Select Monitor display screen.
(Before 3) The third latest DTC from the history of
previous problems is displayed on Subaru
Select Monitor display screen.
VDC(diag)-25
Inspection Mode
8. Inspection Mode
A: PROCEDURE
Reproduce the malfunction occurrence condition
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)-26
Clear Memory Mode


A: OPERATION
Check}.
{Clear Memory}.
5) When «Clear Memory ?» is shown on the
screen, click the “YES” button.
6) When «Done» and «Turn Ignition Switch OFF»
are shown on the screen, turn the ignition switch to
OFF.
NOTE:
For detailed operation procedures, refer to “PC ap-
plication help for Subaru Select Monitor”.
VDC(diag)-27
Warning Light Illumination Pattern

10.Warning Light Illumination Pattern

A: INSPECTION
(4)
(3) (3)
(2)
(1)
(7)
(6) (8) (6)

(5),(15)
(7)
(6) (6)
(9)
(7)
(6) (6)
(10)
(11)
(7)
(6)
(12)
(13) (14)
VDC00606
(1) Ignition switch (6) Light OFF (11) Several seconds (depending on
engine coolant temperature)
(2) OFF (7) Light ON (12) Brake warning light (EBD warning
light)
(3) ON (8) 2 seconds (13) Parking brake
(4) Engine start (9) VDC OFF & VDC traction mode (14) Released
indicator light (6MT model)
model)
(5) ABS warning light (10) VDC warning light & VDC indica- (15) Hill start assist warning light
tor light
NOTE:
• The illumination pattern above shows proper condition.
• While hill start assist is OFF, hill start assist warning light (15) always illuminates to indicate that hill start
assist does not operate. (6MT model only)
1) When warning lights or indicator lights do not illuminate in accordance with this illumination pattern, there
must be an electrical malfunction.
2) When warning lights or indicator lights remain constantly OFF, check the combination meter circuit or CAN
communication circuit. <Ref. to VDC(diag)-31, VDC WARNING LIGHT & VDC INDICATOR LIGHT, VDC
OFF & VDC TRACTION MODE INDICATOR LIGHT DO NOT COME ON, Warning Light Illumination Pat-
tern.> <Ref. to VDC(diag)-32, VDC WARNING LIGHT & VDC INDICATOR LIGHT, VDC OFF INDICATOR
LIGHT DO NOT COME ON, Warning Light Illumination Pattern.> <Ref. to VDC(diag)-33, ABS WARNING
LIGHT DOES NOT COME ON, Warning Light Illumination Pattern.> <Ref. to VDC(diag)-33, HILL START
ASSIST WARNING LIGHT DOES NOT COME ON, Warning Light Illumination Pattern.>
VDC(diag)-28

3) When ABS warning light does not go off, check the combination meter circuit or CAN communication cir-
cuit. <Ref. to VDC(diag)-34, ABS WARNING LIGHT DOES NOT GO OFF, Warning Light Illumination Pat-
tern.>
4) When hill start assist warning light does not go off, check the status of hill start assist OFF mode setting,
combination meter circuit, or CAN communication circuit. <Ref. to VDC(diag)-35, HILL START ASSIST
WARNING LIGHT DOES NOT GO OFF, Warning Light Illumination Pattern.>
5) When the VDC OFF & VDC traction mode indicator light (6MT model), VDC OFF indicator light (5MT mod-
el), or VDC warning light & VDC indicator light does not go off, check the combination meter circuit or CAN
communication circuit. <Ref. to VDC(diag)-36, VDC OFF & VDC TRACTION MODE INDICATOR LIGHT DO
NOT GO OFF, Warning Light Illumination Pattern.> <Ref. to VDC(diag)-37, VDC OFF INDICATOR LIGHT
DOES NOT GO OFF, Warning Light Illumination Pattern.> <Ref. to VDC(diag)-38, VDC WARNING LIGHT
AND VDC INDICATOR LIGHT DO 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 warning light goes off while driving at approximately 12 km/h (7
MPH). However, the ABS system does not work while the ABS warning light is illuminated.
• It may take several minutes before the VDC warning light & VDC indicator light goes off, if the vehicle is
parked under low temperature for a specified 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 rollers, when the wheels lock or spin after starting the engine,
ABS warning light, and VDC warning light & VDC indicator light may illuminate because VDCCM&H/U de-
tects the abnormal conditions from ABS wheel speed sensors. In this case, this is not a malfunction. Perform
the Clear Memory Mode. <Ref. to VDC(diag)-27, Clear Memory Mode.>
6) Warning light illumination pattern at VDC mode change (6MT model only)
If the VDC OFF & VDC traction mode indicator light illumination pattern when the VDC OFF switch is oper-
ated does not match the following, check the VDC OFF switch circuit, CAN communication circuit or combi-
nation meter circuit. <Ref. to VDC(diag)-42, VDC TRACTION MODE, VDC MODE DOES NOT CHANGE,
Warning Light Illumination Pattern.>
(3) (3) (3)
(2) (4) (2) (5) (2) (4) (2)

(1)
(9)
(8)
(7) (7)
(6)
(11) (12) (13) (11)

(10)
VDC00595
(1) VDC OFF switch (6) VDC OFF & VDC traction mode (10) VDC mode
indicator light
(2) OFF (7) Light OFF (11) Normal mode
(3) ON (8) Green light (12) Traction mode
(4) 2 seconds or less (9) Yellow illumination (13) OFF mode
(5) 2 seconds or more, 10 seconds or
less
VDC(diag)-29

7) Warning light illumination pattern at hill start assist OFF mode change (6MT model only)
When the VDC OFF switch is kept pressed, the VDC OFF & VDC traction mode indicator light illuminates in
green at first, then turns yellow, and then goes off in approx. 8 seconds. If the switch is released in 5 seconds
after the light goes off then pressed again in 2 seconds, hill start assist warning light illuminates then mode
is changed to hill start assist OFF mode. If hill start assist function ON/OFF does not change, check VDC
OFF switch circuit, CAN communication circuit or combination meter circuit. <Ref. to VDC(diag)-45, HILL
START ASSIST ON/OFF MODE, VDC MODE DOES NOT CHANGE, Warning Light Illumination Pattern.>
(3) (3)
(4) (4)
(2) (2)
(1)
(6)
(4)
(2) (2)
(5)
(8)
(4)
(9)
(2) (2)
(7) (10)
(4) (4)
(12) (12)
(2) (2)
(11)
(4)
(13)
(2)
VDC00689
(1) Ignition key (6) 2 seconds or less (10) 5 seconds or less

(2) OFF (7) VDC OFF & VDC traction mode (11) Hill start assist warning light
indicator light
(3) Start (8) Approx. 8 seconds (until (7) goes (12) Yellow illumination
off)
(4) ON (9) Illumination changes from in green (13) Hill start assist function
to in yellow.
(5) VDC OFF switch
NOTE:
• Hill start assist warning light always illuminates to inform that the hill start assist does not operate during
hill start assist OFF mode.
• For procedure of changing hill start assist function ON/OFF, refer to “Hill start assist”. <Ref. to BR-49, OP-
ERATION, Hill Start Assist.>
VDC(diag)-30

B: VDC WARNING LIGHT & VDC INDICATOR LIGHT, VDC OFF & VDC TRAC-
TION MODE INDICATOR LIGHT DO NOT COME ON
NOTE:
This diagnosis is applied to 6MT model.
• Defective CAN communication
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), the VDC OFF & VDC traction mode indicator light,
and VDC warning light & VDC indicator light do not illuminate.
NOTE:
When the VDC OFF switch is pressed for 10 seconds or more, the VDC traction mode indicator light goes off,
and subsequent switch operations are not accepted. When turning the ignition switch from OFF to ON, the
OFF operation enabled status is restored.
Step Check Yes No
1 CHECK OTHER INDICATOR LIGHT. Does other indicator light illumi- Go to step 2. Perform the self-
Turn the ignition switch to ON. nate soon after “ON”? diagnosis of com-
bination meter.
<Ref. to IDI-5,
SELF-DIAGNO-
SIS, INSPEC-
TION,
Combination Meter
System.>
2 CHECK VDCCM. Is the «VDC Warning Light» Go to step 3. Replace the
When the engine does not start, display the cur- output ON? VDCCM only.
rent data of VDCCM using Subaru Select Mon- <Ref. to VDC-12,
itor. REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
3 CHECK LAN SYSTEM. Is there any fault in LAN sys- Perform the diag- Go to step 4.
Perform the diagnosis for LAN system. <Ref. to tem? nosis according to
LAN(diag)-2, Basic Diagnostic Procedure.> DTC for LAN sys-
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
4 CHECK COMBINATION METER. Is combination meter OK? Replace the Replace the com-
Check the combination meter. <Ref. to IDI-5, VDCCM only. bination meter.
INSPECTION, Combination Meter System.> <Ref. to VDC-12, <Ref. to IDI-18,
REPLACEMENT, Combination
VDC Control Mod- Meter.>
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-31

C: VDC WARNING LIGHT & VDC INDICATOR LIGHT, VDC OFF INDICATOR
LIGHT DO NOT COME ON
NOTE:
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), VDC OFF indicator light and VDC warning light &
VDC indicator light do not illuminate.
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- Go to step 2. Perform the self-
Turn the ignition switch to ON. nate soon after “ON”? diagnosis of com-
bination meter.
<Ref. to IDI-5,
SELF-DIAGNO-
SIS, INSPEC-
TION,
Combination Meter
System.>
2 CHECK VDCCM. Is the «VDC Warning Light» Go to step 3. Replace the
When the engine does not start, display the cur- output ON? VDCCM only.
rent data of VDCCM using Subaru Select Mon- <Ref. to VDC-12,
itor. REPLACEMENT,
VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-32

D: ABS WARNING LIGHT DOES NOT COME ON

TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), ABS warning light and hill start assist warning light
do not come on.
Step Check Yes No
1 CHECK OTHER LIGHTS TURN ON. Do other warning lights illumi- Go to step 2. Perform the self-
Turn the ignition switch to ON. (engine OFF) nate? diagnosis of com-
bination meter.
<Ref. to IDI-5,
SELF-DIAGNO-
SIS, INSPEC-
TION,
Combination Meter
System.>
2 READ DTC. Is DTC displayed? Perform the diag- Go to step 3.
Read the DTC. <Ref. to VDC(diag)-25, Read nosis according to
Diagnostic Trouble Code (DTC).> DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
E: HILL START ASSIST WARNING LIGHT DOES NOT COME ON

For the diagnostic procedures, refer to “ABS WARNING LIGHT DOES NOT COME ON”. <Ref. to VDC(diag)-
33, ABS WARNING LIGHT DOES NOT COME ON, Warning Light Illumination Pattern.>
VDC(diag)-33

F: ABS WARNING LIGHT DOES NOT GO OFF

TROUBLE SYMPTOM:
When starting the engine, the ABS warning light is kept ON.
Step Check Yes No
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-34

G: HILL START ASSIST WARNING LIGHT DOES NOT GO OFF

TROUBLE SYMPTOM:
When starting the engine, the hill start assist warning light is kept ON.
Step Check Yes No
1 CHECK TRANSMISSION TYPE. Is the transmission type 6MT? Go to step 2. Go to step 3.
2 RELEASE HILL ASSIST OFF MODE. Does the hill start assist warn- VDC is normal. Go to step 3.
Perform the procedure for releasing hill assist ing light go off?
OFF mode. <Ref. to BR-49, OPERATION, Hill
Start Assist.>
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-35

H: VDC OFF & VDC TRACTION MODE INDICATOR LIGHT DO NOT GO OFF
NOTE:
• VDC OFF switch is shorted.
TROUBLE SYMPTOM:
When starting the engine, VDC OFF indicator light is kept ON.
NOTE:
stored.
Step Check Yes No
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK VDC OFF SWITCH. Is the VDC OFF switch normal? Go to step 3. Replace the VDC
Remove and check VDC OFF switch. <Ref. to OFF switch. <Ref.
VDC-29, VDC OFF Switch.> to VDC-29, VDC
OFF Switch.>
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-36

I: VDC OFF INDICATOR LIGHT DOES NOT GO OFF

NOTE:
• VDC OFF switch is shorted.
TROUBLE SYMPTOM:
When starting the engine, VDC OFF indicator light is kept ON.
NOTE:
stored.
Step Check Yes No
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
Remove and check VDC OFF switch. <Ref. to OFF switch. <Ref.
VDC-29, VDC OFF Switch.> to VDC-29, VDC
OFF Switch.>
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-37

J: VDC WARNING LIGHT AND VDC INDICATOR LIGHT DO NOT GO OFF

• Defective engine
TROUBLE SYMPTOM:
When starting the engine, the VDC warning light & VDC indicator light remains lit.
Step Check Yes No
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK ENGINE. Does the malfunction indicator Repair the engine. Go to step 3.
light illuminate?
3 CHECK ENGINE COOLANT TEMPERA- When the engine coolant tem- Normal Go to step 4.
TURE. perature is too low, the VDC
Warm up the engine, and check if the VDC warning light & VDC indicator
warning light & VDC indicator light illumination light illuminates. Do the lights
condition changes. go off when the engine is
warmed up?
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-38

K: 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.
VDC(diag)-39

WIRING DIAGRAM:
Parking brake / brake fluid level warning light system <Ref. to WI-153, Parking Brake / Brake Fluid Level
Warning Light System.>
BATTERY
MAIN SBF
SBF-6
E
*1 : TERMINAL No. OPTIONAL

ARRANGEMENT AMONG 1, 2, 3, 4 AND 5
IGNITION
SWITCH
*2 : TERMINAL No. OPTIONAL

ARRANGEMENT AMONG 6, 7, 8, 9 AND 10
No. 5
2
BRAKE FLUID LEVEL

PARKING BRAKE/
WARNING LIGHT
I/F
COMBINATION
MICRO COMPUTER METER
i10
CAN TRANSCEIVER &
RECEIVER
26
27
i77
i3
*1 *1
24
B38
*2 *2 B16
1 BRAKE FLUID
B99 R3 2 LEVEL SWITCH
3 3 5
B438 B437
R4
C15
PARKING
B3
B9
A1
A9
35
10
BRAKE
SWITCH
B310 A: i84 B: B280 C: B281
VDCCM & H/U BODY INTEGRATED UNIT
B16 B437 B438 B310 i10
1 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
2 22 23 24 25 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
i3 B99
1 2 3 4 5
A: i84 B: B280 C: B281
6 7 8 9 10 11 12
1 2 3 4
1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 3 4 5 6 7
5 6 7 8 9 10
11 12 13 14 15 16 i77 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 7 8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
17 18 19 20 21 22 24 25 26 27 28 29 30 31 32 33 34 35 18 19 20 21 22 23 24 25 26 20 21 22 23 24 25 26 27 28
23 24 25 26 27 28 1 2 3 4 5 6 7 8 9 10
VDC01085
VDC(diag)-40

Step Check Yes No

1 CHECK INSTALLATION OF VDCCM&H/U Is the connector firmly Go to step 2. Insert the
CONNECTOR. inserted? VDCCM&H/U con-
1) Turn the ignition switch to OFF. nector until it is
2) Check that the VDCCM&H/U connector is locked by clamp.
inserted until it is locked by clamp.
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
3 CHECK BRAKE FLUID AMOUNT. Does the level of the brake fluid Go to step 4. Replenish brake
Check the amount of brake fluid in the reservoir amount fall between the lines of fluid to the speci-
tank of master cylinder. “MAX” and “MIN”? fied value.
4 CHECK BRAKE FLUID LEVEL SWITCH. Is the resistance 1 MΩ or Go to step 5. Replace the mas-
1) Turn the ignition switch to OFF. more? ter cylinder. <Ref.
2) Disconnect the level switch connector (B16) to BR-32, Master
from master cylinder. Cylinder.>
3) Measure the resistance of master cylinder
terminals.
Terminals
No. 1 — No. 2:
5 CHECK GROUND SHORT OF HARNESS. Is the resistance 1 MΩ or Go to step 6. Repair the harness
1) Disconnect the connector (i10) from combi- more? between combina-
nation meter. tion meter and
2) Measure the resistance between combina- brake fluid level
tion meter connector and chassis ground. switch.
(i10) No. 8 — Chassis ground:
6 CHECK PARKING BRAKE SWITCH. Is the resistance 1 MΩ or Go to step 7. Replace the park-
1) Disconnect the connector (R4) from parking more? ing brake switch.
brake switch.
3) Measure the resistance between parking
brake switch terminal and chassis ground.
1) Disconnect the connector (B281) from body more? between body inte-
integrated unit. grated unit and
2) Measure the resistance between body inte- parking brake
grated unit connector and chassis ground. switch.
8 CHECK POOR CONTACT OF CONNECTOR. Is there poor contact? Repair the connec- Go to step 9.
Check for poor contact of all connectors. tor.
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-41

L: VDC MODE DOES NOT CHANGE

1. VDC TRACTION MODE
NOTE:
DETECTING CONDITION
• Defective VDC OFF switch
TROUBLE SYMPTOM:
Even when the VDC OFF switch is operated, the VDC traction mode indicator light does not illuminate, or the
illumination color does not change. (The VDC mode does not change)
NOTE:
• When the VDC OFF switch is pressed (2 seconds or less), the VDC traction mode indicator light illumi-
nates in green. (Traction mode)
• When the VDC OFF switch is held down (2 seconds or more, 10 seconds or less), the VDC OFF indicator
light illuminates in yellow. (VDC OFF mode)
• When the VDC OFF switch is pressed for 10 seconds or more, the VDC traction mode indicator light goes
off, and subsequent switch operations are not accepted. When turning the ignition switch from OFF to ON,
the OFF operation enabled status is restored.
VDC(diag)-42

WIRING DIAGRAM:
B310
VDCCM & H/U
31
2
VDC OFF
SWITCH
B318
3
B318 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00994
Step Check Yes No

VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK HARNESS. Is the resistance less than 1 Ω? Go to step 3. Repair the harness
1) Turn the ignition switch to OFF. between the
2) Disconnect the connector from the VDCCM&H/U and
VDCCM&H/U and VDC OFF switch. VDC OFF switch
3) Measure the resistance of harness between connectors.
the VDCCM&H/U and VDC OFF switch con-
nectors.
(B310) No. 31 — (B318) No. 2:
VDC(diag)-43

Step Check Yes No

Measure the resistance between VDCCM&H/U more? between the
connector and chassis ground. VDCCM&H/U and
Connector & terminal VDC OFF switch
(B310) No. 31 — Chassis ground: connectors.
4 CHECK HARNESS. Is the resistance less than 10 Go to step 5. Repair the harness
Measure the resistance of harness between Ω? between the VDC
VDC OFF switch connector and chassis OFF switch con-
ground. nector and chassis
Check the VDC OFF switch. <Ref. to VDC-29, OFF switch. <Ref.
INSPECTION, VDC OFF Switch.> to VDC-29, VDC
OFF Switch.>
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-44

2. HILL START ASSIST ON/OFF MODE

DETECTING CONDITION
• Defective VDC OFF switch
TROUBLE SYMPTOM:
Hill start assist warning light does not illuminate or go off when hill start assist function ON/OFF is changed.
(Hill start assist mode does not change.)
NOTE:
• When the VDC OFF switch is kept pressed, the VDC traction mode indicator light illuminates in green at
first, then turns yellow, and then goes off in approx. 8 seconds. If the switch is released in 5 seconds after the
light goes off then pressed again in 2 seconds, hill start assist warning light illuminates then mode is changed
to hill start assist OFF mode.
• Hill start assist warning light always illuminates to inform that the hill start assist does not operate during
hill start assist OFF mode.
• For procedure of changing hill start assist function ON/OFF, refer to “Hill start assist”. <Ref. to BR-49, OP-
ERATION, Hill Start Assist.>
• When the VDC OFF switch is held down for 10 seconds or more and the VDC traction mode indicator light
goes off, if the switch is not pressed again within 5 seconds, subsequent switch operations will not be ac-
cepted. When turning the ignition switch from OFF to ON, the operation enabled status is restored.
VDC(diag)-45

WIRING DIAGRAM:
B310
VDCCM & H/U
31
2
VDC OFF
SWITCH
B318
3
B318 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00994
Step Check Yes No

VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK HARNESS. Is the resistance less than 1 Ω? Go to step 3. Repair the harness
1) Turn the ignition switch to OFF. between the
2) Disconnect the connector from the VDCCM&H/U and
VDCCM&H/U and VDC OFF switch. VDC OFF switch
3) Measure the resistance of harness between connectors.
the VDCCM&H/U and VDC OFF switch con-
nectors.
(B310) No. 31 — (B318) No. 2:
VDC(diag)-46

Step Check Yes No

Measure the resistance between VDCCM&H/U more? between the
Connector & terminal VDC OFF switch
(B310) No. 31 — Chassis ground: connectors.
4 CHECK HARNESS. Is the resistance less than 10 Go to step 5. Repair the harness
Measure the resistance of harness between Ω? between the VDC
VDC OFF switch connector and chassis OFF switch con-
ground. nector and chassis
Check the VDC OFF switch. <Ref. to VDC-29, OFF switch. <Ref.
INSPECTION, VDC OFF Switch.> to VDC-29, VDC
OFF Switch.>
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-47


A: LIST
Detailed
code
07B1H Front Right ABS Open/high input of front <Ref. to VDC(diag)-53, DTC C0021 FRONT RIGHT ABS
C0021 07B2H Sensor Circuit Open ABS wheel speed sen- SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Proce-
07C0H or Short sor RH dure with Diagnostic Trouble Code (DTC).>
0720H
072FH
0736H Front ABS wheel speed <Ref. to VDC(diag)-56, DTC C0022 FRONT RIGHT ABS
Front Right ABS
C0022 0737H sensor RH signal mal- SENSOR SIGNAL, Diagnostic Procedure with Diagnostic
Sensor Signal
0738H function Trouble Code (DTC).>
073AH
073CH
06B1H Front Left ABS Sen- Open/high input of front <Ref. to VDC(diag)-53, DTC C0023 FRONT LEFT ABS
C0023 06B2H sor Circuit Open or ABS wheel speed sen- SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Proce-
06C0H Short sor LH dure with Diagnostic Trouble Code (DTC).>
0620H
062FH
0636H Front ABS wheel speed <Ref. to VDC(diag)-56, DTC C0024 FRONT LEFT ABS
Front Left ABS Sen-
C0024 0637H sensor LH signal mal- SENSOR SIGNAL, Diagnostic Procedure with Diagnostic
sor Signal
063AH
063CH
09B1H Rear Right ABS Open/high input of rear <Ref. to VDC(diag)-53, DTC C0025 REAR RIGHT ABS
C0025 09B2H Sensor Circuit Open ABS wheel speed sen- SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Proce-
09C0H or Short sor RH dure with Diagnostic Trouble Code (DTC).>
0920H
092FH
0936H Rear ABS wheel speed <Ref. to VDC(diag)-56, DTC C0026 REAR RIGHT ABS
Rear Right ABS
C0026 0937H sensor RH signal mal- SENSOR SIGNAL, Diagnostic Procedure with Diagnostic
Sensor Signal
093AH
093CH
08B1H Rear Left ABS Sen- Open/high input of rear <Ref. to VDC(diag)-54, DTC C0027 REAR LEFT ABS SEN-
C0027 08B2H sor Circuit Open or ABS wheel speed sen- SOR CIRCUIT OPEN OR SHORT, Diagnostic Procedure
08C0H Short sor LH with Diagnostic Trouble Code (DTC).>
0820H
082FH
0836H Rear ABS wheel speed <Ref. to VDC(diag)-57, DTC C0028 REAR LEFT ABS SEN-
Rear Left ABS Sen-
C0028 0837H sensor LH signal mal- SOR SIGNAL, Diagnostic Procedure with Diagnostic Trou-
sor Signal
0838H function ble Code (DTC).>
083AH
083CH
0A10H
0A41H
0A4BH ABS wheel speed sen- <Ref. to VDC(diag)-59, DTC C0029 ANY OF WHEEL SEN-
Any of Wheel Sen-
C0029 0A4DH sor signal malfunction SORS SIGNAL, Diagnostic Procedure with Diagnostic Trou-
sors Signal
0A52H in one of four wheels ble Code (DTC).>
0A56H
0A60H
0DB8H
Front inlet solenoid <Ref. to VDC(diag)-60, DTC C0031 FR HOLD VALVE MAL-
0DC0H FR Hold Valve Mal-
C0031 valve RH malfunction in FUNCTION, Diagnostic Procedure with Diagnostic Trouble
0DC1H function
VDCCM&H/U Code (DTC).>
0DD0H
VDC(diag)-48

Detailed
code
0EB8H
Front outlet solenoid <Ref. to VDC(diag)-60, DTC C0032 FR PRESSURE
0EC0H FR Pressure Reduc-
C0032 valve RH malfunction in REDUCING VALVE MALFUNCTION, Diagnostic Procedure
0EC1H ing Valve Malfunction
VDCCM&H/U with Diagnostic Trouble Code (DTC).>
0ED0H
0BB8H
Front inlet solenoid <Ref. to VDC(diag)-60, DTC C0033 FL HOLD VALVE MAL-
0BC0H FL Hold Valve Mal-
C0033 valve LH malfunction in FUNCTION, Diagnostic Procedure with Diagnostic Trouble
0BC1H function
0BD0H
0CB8H
Front outlet solenoid <Ref. to VDC(diag)-60, DTC C0034 FL PRESSURE
0CC0H FL Pressure Reduc-
C0034 valve LH malfunction in REDUCING VALVE MALFUNCTION, Diagnostic Procedure
0CC1H ing Valve Malfunction
0CD0H
11B8H
Rear inlet solenoid <Ref. to VDC(diag)-61, DTC C0035 RR HOLD VALVE MAL-
11C0H RR Hold Valve Mal-
C0035 valve RH malfunction in FUNCTION, Diagnostic Procedure with Diagnostic Trouble
11C1H function
11D0H
12B8H
Rear outlet solenoid <Ref. to VDC(diag)-61, DTC C0036 RR PRESSURE
12C0H RR Pressure Reduc-
C0036 valve RH malfunction in REDUCING VALVE MALFUNCTION, Diagnostic Procedure
12C1H ing Valve Malfunction
12D0H
0FB8H
Rear inlet solenoid <Ref. to VDC(diag)-61, DTC C0037 RL HOLD VALVE MAL-
0FC0H RL Hold Valve Mal-
C0037 valve LH malfunction in FUNCTION, Diagnostic Procedure with Diagnostic Trouble
0FC1H function
0FD0H
10B8H
Rear outlet solenoid <Ref. to VDC(diag)-61, DTC C0038 RL PRESSURE
10C0H RL Pressure Reduc-
C0038 valve LH malfunction in REDUCING VALVE MALFUNCTION, Diagnostic Procedure
10C1H ing Valve Malfunction
10D0H
Solenoid valve malfunc- <Ref. to VDC(diag)-61, DTC C0039 ANY ONE OF FOUR
0FB5H Any One of Four
C0039 tion in one of four SOLENOID VALVES, Diagnostic Procedure with Diagnostic
11B5H Solenoid Valves
wheels Trouble Code (DTC).>
VDC control module <Ref. to VDC(diag)-64, DTC C0041 ECM, Diagnostic Proce-
— ECM
malfunction dure with Diagnostic Trouble Code (DTC).>
C0041 1630H VDC control module <Ref. to VDC(diag)-66, DTC C0041 PARAMETER SELEC-
Parameter Selection
1645H parameter selection fail- TION ERROR, Diagnostic Procedure with Diagnostic Trou-
Error
16C0H ure ble Code (DTC).>
0316H
<Ref. to VDC(diag)-67, DTC C0042 POWER SUPPLY
031CH Power Supply Volt- Power voltage malfunc-
C0042 VOLTAGE FAILURE, Diagnostic Procedure with Diagnostic
0322H age Failure tion
0324H
Incorrect VDC Con- <Ref. to VDC(diag)-69, DTC C0045 INCORRECT VDC
2922H Different VDC control
C0045 trol Module Specifi- CONTROL MODULE SPECIFICATIONS, Diagnostic Proce-
2932H module specification
cations dure with Diagnostic Trouble Code (DTC).>
VDC(diag)-49

Detailed
code
1504H
1505H
1506H
1507H
1508H
150EH
1512H
1514H
<Ref. to VDC(diag)-70, DTC C0047 CAN COMMUNICA-
1518H Improper CAN commu-
C0047 CAN Communication TION, Diagnostic Procedure with Diagnostic Trouble Code
1519H nication
(DTC).>
151AH
151DH
151EH
151FH
1520H
1531H
1540H
15C0H
021FH
0220H
0221H
0280H <Ref. to VDC(diag)-71, DTC C0051 VALVE RELAY, Diag-
C0051 Valve Relay Valve Relay
0281H nostic Procedure with Diagnostic Trouble Code (DTC).>
02B0H
02B1H
02C0H
0562H <Ref. to VDC(diag)-73, DTC C0052 MOTOR AND MOTOR
Motor and Motor Motor/motor relay OFF
0574H RELAY OFF FAILURE, Diagnostic Procedure with Diagnos-
Relay Off Failure malfunction
0580H tic Trouble Code (DTC).>
<Ref. to VDC(diag)-75, DTC C0052 MOTOR AND MOTOR
Motor and Motor Motor/motor relay ON
C0052 05A0H RELAY ON FAILURE, Diagnostic Procedure with Diagnostic
Relay On Failure malfunction
<Ref. to VDC(diag)-76, DTC C0052 MOTOR MALFUNC-
0560H Motor Malfunction Motor TION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to VDC(diag)-77, DTC C0054 BLS CIRCUIT OPEN,
04B0H BLS Circuit Open BLS open circuit
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-79, DTC C0054 BLS ON MALFUNC-
043CH BLS On Malfunction BLS ON malfunction TION, Diagnostic Procedure with Diagnostic Trouble Code
C0054
(DTC).>
<Ref. to VDC(diag)-81, DTC C0054 BLS OFF MALFUNC-
04C1H BLS Off Malfunction BLS OFF Malfunction TION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
1760H
Abnormal longitudinal <Ref. to VDC(diag)-83, DTC C0056 G SENSOR SIGNAL,
C0056 1770H G Sensor Signal
G sensor output signal Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
1780H
CAN communication <Ref. to VDC(diag)-84, DTC C0057 ECM COMMUNICA-
ECM Communica-
2931H failure of engine control TION CIRCUIT, Diagnostic Procedure with Diagnostic Trou-
tion Circuit
module ble Code (DTC).>
C0057
Coordinate control pro- <Ref. to VDC(diag)-85, DTC C0057 ECM CONTROL SYS-
2930H ECM Control System hibition of engine con- TEM, Diagnostic Procedure with Diagnostic Trouble Code
trol module (DTC).>
19B8H
Secondary cut valve <Ref. to VDC(diag)-61, DTC C0061 NORMAL OPENING
19C0H Normal Opening
C0061 malfunction in VALVE 1 MALFUNCTION, Diagnostic Procedure with Diag-
19C1H Valve 1 Malfunction
VDCCM&H/U nostic Trouble Code (DTC).>
19D0H
VDC(diag)-50

Detailed
code
1AB8H
<Ref. to VDC(diag)-61, DTC C0062 NORMAL OPENING
1AC0H Normal Opening Primary cut valve mal-
C0062 VALVE 2 MALFUNCTION, Diagnostic Procedure with Diag-
1AC1H Valve 2 Malfunction function in VDCCM&H/U
1AD0H
1BB8H
Secondary suction <Ref. to VDC(diag)-61, DTC C0063 NORMAL CLOSING
1BC0H Normal Closing
C0063 valve malfunction in VALVE 1 MALFUNCTION, Diagnostic Procedure with Diag-
1BC1H Valve 1 Malfunction
1BD0H
1CB8H
Primary suction valve <Ref. to VDC(diag)-62, DTC C0064 NORMAL CLOSING
1CC0H Normal Closing
C0064 malfunction in VALVE 2 MALFUNCTION, Diagnostic Procedure with Diag-
1CC1H Valve 2 Malfunction
1CD0H
Excessive steering <Ref. to VDC(diag)-86, DTC C0071 STEERING ANGLE
Steering Angle Sen-
2130H angle sensor output off- SENSOR OFFSET IS TOO BIG, Diagnostic Procedure with
sor Offset Is Too Big
set Diagnostic Trouble Code (DTC).>
Change Range of Excessive variation <Ref. to VDC(diag)-87, DTC C0071 CHANGE RANGE OF
2134H Steering Angle Sen- amount of steering STEERING ANGLE SENSOR IS TOO BIG, Diagnostic Pro-
sor Is Too Big angle sensor output cedure with Diagnostic Trouble Code (DTC).>
212EH
2132H
2136H
2138H
213CH
2150H
C0071 2151H
<Ref. to VDC(diag)-88, DTC C0071 STEER ANGLE SEN-
2152H Steer Angle Sensor Steering angle sensor
SOR OP, Diagnostic Procedure with Diagnostic Trouble
2153H Op output
Code (DTC).>
2154H
2155H
2156H
2157H
2158H
2159H
215AH
Steering angle sensor <Ref. to VDC(diag)-90, DTC C0071 STEERING ANGLE
Steering Angle Sen-
2104H power supply malfunc- SENSOR MALFUNCTION, Diagnostic Procedure with Diag-
sor Malfunction
tion nostic Trouble Code (DTC).>
VDC(diag)-51

Detailed
code
1E1AH
1E1EH
1E22H
1E26H
<Ref. to VDC(diag)-92, DTC C0072 ABNORMAL YAW
1E28H Abnormal Yaw Rate
Yaw rate sensor output RATE SENSOR OUTPUT, Diagnostic Procedure with Diag-
1E2CH Sensor Output
1E34H
1E38H
1E3AH
1E3FH
Voltage Inputted to <Ref. to VDC(diag)-94, DTC C0072 VOLTAGE INPUTTED
Yaw rate sensor power
1EB6H Yaw Rate Sensor TO YAW RATE SENSOR EXCEEDS SPECIFICATION,
supply/output
Exceeds Specification Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Change Range of Excessive variation <Ref. to VDC(diag)-96, DTC C0072 CHANGE RANGE OF
1E30H Yaw Rate Sensor amount of yaw rate sen- YAW RATE SENSOR SIGNAL IS TOO BIG, Diagnostic Pro-
Signal Is Too Big sor output cedure with Diagnostic Trouble Code (DTC).>
1EB7H
C0072 1EBFH
1EB5H
1EBCH
1EBDH
1EBEH
1EC0H
1EC2H <Ref. to VDC(diag)-98, DTC C0072 YAW RATE SENSOR
Yaw Rate Sensor Yaw rate sensor com-
1EC3H COMMUNICATION, Diagnostic Procedure with Diagnostic
Communication munication
1EC4H Trouble Code (DTC).>
1EC6H
1ECEH
1ECFH
1ED0H
1ED3H
1ED4H
1ED5H
<Ref. to VDC(diag)-101, DTC C0072 SENSOR TYPE
1EB9H Sensor Type Abnor- Different yaw rate sen-
ABNORMAL, Diagnostic Procedure with Diagnostic Trouble
1ED6H mal sor specification
Code (DTC).>
Excessive amount of <Ref. to VDC(diag)-101, DTC C0073 LATERAL G SENSOR
1D46H Lateral G Sensor
lateral G sensor output OFFSET IS TOO BIG, Diagnostic Procedure with Diagnostic
1D47H Offset Is Too Big
offset Trouble Code (DTC).>
<Ref. to VDC(diag)-101, DTC C0073 ABNORMAL LAT-
1D44H Abnormal Lateral G
C0073 Lateral G sensor output ERAL G SENSOR OUTPUT, Diagnostic Procedure with
1D45H Sensor Output
<Ref. to VDC(diag)-102, DTC C0073 EXCESSIVE LAT-
Excessive Lateral G Excessive lateral G
1D49H ERAL G SENSOR SIGNAL, Diagnostic Procedure with
Sensor Signal sensor output
1F4EH
<Ref. to VDC(diag)-103, DTC C0074 PRESSURE SEN-
1F4FH
C0074 Pressure Sensor Pressure sensor SOR, Diagnostic Procedure with Diagnostic Trouble Code
1FB1H
(DTC).>
1FC0H
2510H Abnormal reverse sig- <Ref. to VDC(diag)-104, DTC C0075 REVERSE SIGNAL,
C0075 Reverse Signal
2520H nal Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
2610H <Ref. to VDC(diag)-106, DTC C0076 CLUTCH SIGNAL,
C0076 Clutch Signal Abnormal clutch signal
2620H Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
2201H <Ref. to VDC(diag)-109, DTC C0081 SYSTEM FAILURE,
C0081 System Failure System malfunction
2202H Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VDC(diag)-52


A: DTC C0021 FRONT RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT
NOTE:
For the diagnostic procedure, refer to “DTC C0027 REAR LEFT ABS SENSOR CIRCUIT OPEN OR
SHORT”. <Ref. to VDC(diag)-54, DTC C0027 REAR LEFT ABS SENSOR CIRCUIT OPEN OR SHORT, Di-
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)-53

D: DTC C0027 REAR LEFT ABS SENSOR CIRCUIT OPEN OR SHORT

• Defective ABS wheel speed sensor (broken wire, input voltage too high)
• Defective harness connector
TROUBLE SYMPTOM:
• ABS does not operate.
• VDC does not operate.
WIRING DIAGRAM:
B310 VDCCM & H/U
25
26
27
5
6
3
4
2
1
TWISTED PAIR LINE
TWISTED PAIR LINE

TWISTED PAIR LINE
TWISTED PAIR LINE
B99 B98
2
1
3
4
R3 R2
TWISTED PAIR LINE
TWISTED PAIR LINE
B15 B6 R73 R72

2
1
2
1
2
1
2
1
FRONT ABS FRONT ABS REAR ABS REAR ABS

WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED
SENSOR LH SENSOR RH SENSOR LH SENSOR RH
B6 R72 B98 B99 B310
B15 R73 1 2 3 4 5 6 7 8 9 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
10 11 12 13 14 15 16 17 18 19 20 22 23 24 25
6 7 8 9 10 11 12 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
2 1
VDC00529
VDC(diag)-54

Step Check Yes No

1 CHECK POOR CONTACT OF CONNECTOR. Is there poor contact? Repair the connec- Go to step 2.
Check if there is poor contact between tor.
VDCCM&H/U and ABS wheel speed sensor.
2 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 3. Repair the harness
VDCCM&H/U AND ABS WHEEL SPEED connector between
SENSOR. VDCCM&H/U and
1) Disconnect the connector (B310) from the ABS wheel speed
VDCCM&H/U. sensor.
2) Disconnect the connector from ABS wheel
speed sensor.
3) Measure the resistance between
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. 4 — (R72) No. 1:
(B310) No. 3 — (R72) No. 2:
DTC C0027
(B310) No. 27 — (R73) No. 1:
(B310) No. 2 — (R73) No. 2:
Measure the resistance between VDCCM&H/U more? connector between
Connector & terminal ABS wheel speed
DTC C0021 sensor.
DTC C0023
DTC C0025
DTC C0027
4 CHECK ABS WHEEL SPEED SENSOR POW- Is the voltage 5 — 16 V? Go to step 6. Go to step 5.
ER SUPPLY CIRCUIT.
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)-55

Step Check Yes No

5 CHECK VDCCM&H/U POWER SUPPLY CIR- Is the voltage 10 — 15 V? Go to step 6. Check the genera-
CUIT. tor, battery and
2) Disconnect the VDCCM&H/U connector. power supply cir-
3) Turn the ignition switch to ON. cuit.
4) Measure the voltage between VDCCM&H/U
connector terminals.
(B310) No. 28 (+) — (B310) No. 25 (–):
6 CHECK ABS WHEEL SPEED SENSOR SIG- Is the pattern the same wave- Go to step 7. Replace the ABS
NAL. form as shown in the figure? wheel speed sen-
1) Install the ABS wheel speed sensor. sor. <Ref. to VDC-
2) Prepare an oscilloscope. 24, Front ABS
3) Check the ABS wheel speed sensor. <Ref. Wheel Speed Sen-
to VDC-24, ABS WHEEL SPEED SENSOR, sor.>
INSPECTION, Front ABS Wheel Speed Sen-
sor.>
7 CHECK VDCCM&H/U. Is the same DTC displayed? Replace the Go to step 8.
1) Connect all connectors. VDCCM only.
2) Clear the memory. <Ref. to VDC(diag)-27, <Ref. to VDC-12,
Clear Memory Mode.> REPLACEMENT,
3) Perform the Inspection Mode. <Ref. to VDC Control Mod-
VDC(diag)-26, Inspection Mode.> ule and Hydraulic
4) Read the DTC. Control Unit
(VDCCM&H/U).>
8 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- It results from a
nosis according to temporary noise
DTC. <Ref. to interference.
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
E: DTC C0022 FRONT RIGHT ABS SENSOR SIGNAL

NOTE:
For the diagnostic procedure, refer to “DTC C0028 REAR LEFT ABS SENSOR SIGNAL”. <Ref. to VDC(di-
ag)-57, 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).>
VDC(diag)-56

H: DTC C0028 REAR LEFT ABS SENSOR SIGNAL

• Defective ABS wheel speed sensor signal (noise, irregular signal, etc.)
TROUBLE SYMPTOM:
Step Check Yes No
1 CHECK OUTPUT OF ABS WHEEL SPEED Does the speed indicated on Go to step 2. Go to step 7.
SENSOR USING SUBARU SELECT MONI- the display change in response
TOR. to the speedometer reading
1) Select “Current Data Display & Save” on the during acceleration/decelera-
Subaru Select Monitor. tion when the steering wheel is
2) Read the defective ABS wheel speed sen- in the straight-ahead position?
sor output.
2 CHECK POOR CONTACT OF CONNECTOR. Is there poor contact of connec- Repair the connec- Go to step 3.
Turn the ignition switch to OFF. tors between VDCCM&H/U and tor.
ABS wheel speed sensor?
3 CHECK CAUSE OF SIGNAL NOISE. Are the radio wave devices and Go to step 4. Install the radio
Make sure the radio wave devices and elec- electronic components wave devices and
tronic components are installed correctly. installed correctly? electronic compo-
nents properly.
4 CHECK CAUSE OF SIGNAL NOISE. Are noise sources installed? Install the noise Go to step 5.
Check if the noise sources (such as an sources apart from
antenna) are installed near the sensor harness. sensor harness.
(VDCCM&H/U).>
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
7 CHECK INSTALLATION OF ABS WHEEL Is the ABS wheel speed sensor Go to step 8. Tighten the ABS
SPEED SENSOR. installation bolt tightened to 7.5 wheel speed sen-
N·m (0.76 kgf-m, 5.5 ft-lb)? sor installation
bolts.
8 CHECK ABS WHEEL SPEED SENSOR SIG- Does the oscilloscope indicate Go to step 10. Go to step 9.
NAL. the waveform pattern like
1) Install the ABS wheel speed sensor. shown in the figure when the
2) Prepare an oscilloscope. tire is slowly turned? Does the
3) Check the ABS wheel speed sensor. <Ref. oscilloscope indication repeat
to VDC-24, ABS WHEEL SPEED SENSOR, the waveform pattern like
INSPECTION, Front ABS Wheel Speed Sen- shown in the figure when the
sor.> tire is slowly turned in equal
speed for one rotation or more?
VDC(diag)-57

Step Check Yes No

9 CHECK ABS WHEEL SPEED SENSOR OR Are there foreign matter, break-
Remove dirt thor- Go to step 10.
MAGNETIC ENCODER. age or damage at the tip of ABS
oughly. Also
wheel speed sensor or mag- replace the ABS
netic encoder? wheel speed sen-
sor or magnetic
encoder as a unit
with hub unit bear-
ing if it is broken or
damaged.
Make sure the radio wave devices and elec- electronic components wave devices and
tronic components are installed correctly. installed correctly? electronic compo-
nents properly.
11 CHECK CAUSE OF SIGNAL NOISE. Are noise sources installed? Install the noise Go to step 12.
Check if the noise sources (such as an sources apart from
antenna) are installed near the sensor harness. sensor harness.
(VDCCM&H/U).>
VDC(diag)-48, List NOTE:
of Diagnostic Trou- Though the ABS
ble Code (DTC).> warning light re-
mains on at this
time, this 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.
VDC(diag)-58

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:
• EBD may not operate.
NOTE:
Brake warning light comes on as well as ABS warning light when EBD does not operate.
Step Check Yes No
1 WHETHER A WHEEL TURNED FREELY OR Did the wheels turn freely? VDC is normal. Go to step 2.
NOT. Clear the memory.
Check if the wheels have been turned freely for NOTE:
one minute or more, such as when the vehicle is This diagnostic
jacked-up, under full-lock cornering or when the trouble code may
wheels are not in contact with road surface. 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.
2 CHECK TIRE SPECIFICATIONS. Are the tire specifications cor- Go to step 3. Replace the tire.
Turn the ignition switch to OFF. 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.
5 CHECK INSTALLATION OF ABS WHEEL Are the ABS wheel speed sen- Go to step 6. Tighten the ABS
SPEED SENSOR. sor installation bolts tightened wheel speed sen-
to 7.5 N·m (0.76 kgf-m, 5.5 ft- sor installation
lb)? (For four wheels) bolts.
6 CHECK ABS WHEEL SPEED SENSOR SIG- Does the oscilloscope indicate Go to step 8. Go to step 7.
NAL. the waveform pattern like
1) Install the ABS wheel speed sensor. shown in the figure when the
2) Prepare an oscilloscope. tire is slowly turned? Does the
3) Check the ABS wheel speed sensor. <Ref. oscilloscope indication repeat
to VDC-24, ABS WHEEL SPEED SENSOR, the waveform pattern like
INSPECTION, Front ABS Wheel Speed Sen- shown in the figure when the
sor.> tire is slowly turned in equal
speed for one rotation or more?
7 CHECK ABS WHEEL SPEED SENSOR OR Are there foreign matter, break- Remove dirt thor- Go to step 8.
MAGNETIC ENCODER. age or damage at the tip of ABS oughly. Also
wheel speed sensor or mag- replace the ABS
netic encoder? wheel speed sen-
sor or magnetic
encoder as a unit
with hub unit bear-
ing if it is broken or
damaged.
VDC(diag)-59

Step Check Yes No

(VDCCM&H/U).>
VDC(diag)-48, List NOTE:
of Diagnostic Trou- Though the ABS
ble Code (DTC).> warning light re-
mains on at this
12 km/h (7 MPH)
or more in order to
turn ABS warning
drive the vehicle
and check that the
warning light goes
off.
J: DTC C0031 FR HOLD VALVE MALFUNCTION

NOTE:
For the diagnostic procedure, refer to “DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION”. <Ref. to
VDC(diag)-62, DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION, Diagnostic Procedure with Di-
K: DTC C0032 FR PRESSURE REDUCING VALVE MALFUNCTION
NOTE:
L: DTC C0033 FL HOLD VALVE MALFUNCTION
NOTE:
M: DTC C0034 FL PRESSURE REDUCING VALVE MALFUNCTION
NOTE:
VDC(diag)-60

N: DTC C0035 RR HOLD VALVE MALFUNCTION

NOTE:
O: DTC C0036 RR PRESSURE REDUCING VALVE MALFUNCTION
NOTE:
P: DTC C0037 RL HOLD VALVE MALFUNCTION
NOTE:
Q: DTC C0038 RL PRESSURE REDUCING VALVE MALFUNCTION
NOTE:
R: DTC C0039 ANY ONE OF FOUR SOLENOID VALVES
NOTE:
S: DTC C0061 NORMAL OPENING VALVE 1 MALFUNCTION
NOTE:
T: DTC C0062 NORMAL OPENING VALVE 2 MALFUNCTION
NOTE:
U: DTC C0063 NORMAL CLOSING VALVE 1 MALFUNCTION
NOTE:
VDC(diag)-61

V: DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION

• Defective VDCH/U solenoid valve
TROUBLE SYMPTOM:
• EBD does not operate.
WIRING DIAGRAM:
BATTERY
MAIN SBF
GENERATOR
SBF-6
IGNITION
SWITCH
No.33
E
28
25
B310 VDCCM & H/U
B310
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00463
VDC(diag)-62

Step Check Yes No

1 CHECK VDCCM&H/U INPUT VOLTAGE. Is the voltage 10 — 15 V? Go to step 2. Repair the power
1) Turn the ignition switch to OFF. supply circuit.
2) Disconnect the connector from the
VDCCM&H/U.
3) Run the engine at idle.
2 CHECK VDCCM&H/U GROUND CIRCUIT. Is the resistance less than 10 Go to step 3. Repair the
1) Turn the ignition switch to OFF. Ω? VDCCM&H/U
2) Measure the resistance between ground harness.
3 CHECK POOR CONTACT OF CONNEC- Is there poor contact of connec- Repair the connec- Go to step 4.
TORS. tor between generator, battery tor.
and VDCCM&H/U?
1) Connect all connectors. VDCCM&H/U.
Clear Memory Mode.> VDC Control Mod-
3) Perform the Inspection Mode. <Ref. to ule and Hydraulic
VDC(diag)-26, Inspection Mode.> Control Unit
4) Read the DTC. (VDCCM&H/U).>
5 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Temporary poor
nosis according to contact occurs.
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-63

W: DTC C0041 ECM

Defective VDCCM&H/U
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
VDCCM & H/U
25
B310
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00464
VDC(diag)-64

Step Check Yes No

2) Disconnect the connector from the ground harness.
VDCCM&H/U.
VDCCM&H/U and chassis ground.
2 CHECK POOR CONTACT OF CONNEC- Is there poor contact of the con- Repair the connec- Go to step 3.
TORS. nector between the battery, igni- tor.
tion switch and VDCCM&H/U?
electronic components wave devices and
installed correctly? electronic compo-
nents properly.
4 CHECK CAUSE OF SIGNAL NOISE. Is there a noise source (such as Install the noise Go to step 5.
an antenna) installed near the sources apart from
sensor harness? sensor harness.
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-65

X: DTC C0041 PARAMETER SELECTION ERROR

VDCCM parameter selection error
TROUBLE SYMPTOM:
NOTE:
When the VDCCM or VDCCM&H/U is replaced, this DTC may be stored.
Step Check Yes No
1 CHECK VDCCM&H/U REPLACEMENT HIS- Is there history of VDCCM Go to step 2. Go to step 3.
TORY. replacement by itself?
2 CHECK VDCCM IDENTIFICATION SYMBOL. Is the identification symbol cor- Go to step 4. Replace the
Check the identification symbol of the seal rect? VDCCM only.
attached on the side of the VDCCM. <Ref. to <Ref. to VDC-12,
VDC-2, SPECIFICATION, General Descrip- REPLACEMENT,
tion.> VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
3 CHECK VDCCM&H/U IDENTIFICATION Is the identification symbol cor- Go to step 4. Replace the
SYMBOL. rect? VDCCM&H/U.
Check the identification symbol stamped on the <Ref. to VDC-8,
upper part of the H/U. <Ref. to VDC-2, SPECI- VDC Control Mod-
FICATION, General Description.> ule and Hydraulic
Control Unit
(VDCCM&H/U).>
4 CHECK PARAMETER SELECTED IN VDC- Does the parameter registered Replace the Select and register
CM. in the VDCCM match the rele- VDCCM only. the correct param-
<Ref. to VDC(diag)-21, PARAMETER CHECK, vant vehicle? <Ref. to VDC-12, eter. <Ref. to
OPERATION, Subaru Select Monitor.> REPLACEMENT, VDC(diag)-21,
VDC Control Mod- PARAMETER
ule and Hydraulic SELECTION,
Control Unit OPERATION, Sub-
(VDCCM&H/U).> aru Select Moni-
tor.>
VDC(diag)-66

Y: DTC C0042 POWER SUPPLY VOLTAGE FAILURE

Improper VDCCM&H/U power supply voltage
TROUBLE SYMPTOM:
NOTE:
Warning lights go off if voltage returns.
WIRING DIAGRAM:
BATTERY
MAIN SBF
GENERATOR
SBF-6
IGNITION
SWITCH
No.33
E
28
25
B310 VDCCM & H/U
B310
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00463
VDC(diag)-67

Step Check Yes No

1 CHECK GENERATOR. Is the voltage 10 — 15 V? Go to step 2. Repair the genera-
1) Start the engine. tor.
2) Run the engine at idle after warming up.
3) Measure the voltage between generator ter-
minal B and chassis ground.
Terminals
Generator terminal B (+) — Chassis
ground (–):
2 CHECK BATTERY TERMINAL. Are the positive and negative Go to step 3. Tighten the termi-
Turn the ignition switch to OFF. battery terminals clamped nal.
tightly?
1) Disconnect the connector from the supply circuit.
VDCCM&H/U.
3) Operate devices such as headlights, air
conditioner, defogger, etc. which produce an
electrical load.
and VDCCM&H/U?
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-68

Z: 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 history of VDCCM Go to step 2. Go to step 3.
replacement by itself?
2 CHECK VDCCM IDENTIFICATION SYMBOL. Is the identification symbol cor- Go to step 4. Replace the
Check the identification symbol of the seal rect? VDCCM only.
attached on the side of the VDCCM. <Ref. to <Ref. to VDC-12,
VDC-2, SPECIFICATION, General Descrip- REPLACEMENT,
tion.> VDC Control Mod-
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
3 CHECK VDCCM&H/U IDENTIFICATION Is the identification symbol cor- Go to step 4. Replace the
SYMBOL. rect? VDCCM&H/U.
Check the identification symbol stamped on the <Ref. to VDC-8,
upper part of the H/U. <Ref. to VDC-2, SPECI- VDC Control Mod-
FICATION, General Description.> ule and Hydraulic
Control Unit
(VDCCM&H/U).>
4 CHECK PARAMETER SELECTED IN VDC- Does the parameter registered Go to step 5. Select and register
CM. in the VDCCM match the rele- the correct param-
<Ref. to VDC(diag)-21, PARAMETER CHECK, vant vehicle? eter. <Ref. to
OPERATION, Subaru Select Monitor.> VDC(diag)-21,
PARAMETER
SELECTION,
OPERATION, Sub-
aru Select Moni-
tor.>
5 CHECK ECM SPECIFICATION. Is the specification of ECM Go to step 6. Replace the ECM.
Check the ECM specification. same as vehicle specification? <Ref. to FU(STI)-
59, Engine Control
Module (ECM).>
<Ref. to FU(w/o
STI)-57, Engine
Control Module
(ECM).>
(VDCCM&H/U).>
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-69

AA:DTC C0047 CAN COMMUNICATION

CAN communication line circuit is open or shorted.
TROUBLE SYMPTOM:
Step Check Yes No
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK POOR CONTACT OF CONNEC- Is there poor contact of Repair the connec- Go to step 3.
TORS. VDCCM&H/U connector? tor.
3 CHECK OUTPUT OF STEERING ANGLE Does the output signal change? Go to step 4. Check output of
SENSOR WITH SUBARU SELECT MONI- the steering angle
TOR. sensor. <Ref. to
1) Select “Current Data Display & Save” on the VDC(diag)-88,
Subaru Select Monitor. <Ref. to VDC(diag)-19, DTC C0071
READ CURRENT DATA, OPERATION, Subaru STEER ANGLE
Select Monitor.> SENSOR OP,
2) Check the steering angle sensor output. Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
4 CHECK OUTPUT OF YAW RATE & G SEN- Does the output signal change? Go to step 5. Check output of
SOR WITH SUBARU SELECT MONITOR. the yaw rate & G
1) Select “Current Data Display & Save” on the sensor. <Ref. to
Subaru Select Monitor. <Ref. to VDC(diag)-19, VDC(diag)-98,
READ CURRENT DATA, OPERATION, Subaru DTC C0072 YAW
Select Monitor.> RATE SENSOR
2) Check the yaw rate & G sensor output. COMMUNICA-
TION, Diagnostic
Procedure with
Diagnostic Trouble
Code (DTC).>
5 CHECK VDCCM&H/U. Is the same DTC displayed? Replace the Temporary poor
1) Connect all connectors. VDCCM only. contact occurs.
(VDCCM&H/U).>
VDC(diag)-70

AB:DTC C0051 VALVE RELAY

Defective valve relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
MAIN SBF
SBF-6
No.1
E
IGNITION
SWITCH
No.33
B310
25
24
28
MOTOR RELAY
SECONDARY SUCTION
SOLENOID VALVE
PRIMARY SUCTION
PUMP MOTOR
SECONDARY CUT
RR OUTLET
FR OUTLET
RL OUTLET
FL OUTLET
RR INLET
FR INLET
RL INLET
FL INLET
VDCCM & H/U

PRIMARY CUT
VALVE RELAY
B310
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00466
VDC(diag)-71

Step Check Yes No

2) Disconnect the connector from the
VDCCM&H/U.
2 CHECK VDCCM&H/U INPUT VOLTAGE. Is the voltage difference Repair the power Go to step 3.
Calculate the voltage difference measured in between A and B 2 V or more? supply circuit.
step 1.
A: (B310) No. 28 (+) — Chassis ground (–):
B: (B310) No. 24 (+) — Chassis ground (–):
4 CHECK VDCCM&H/U VALVE RELAY. Is the resistance 1 MΩ or Go to step 5. Replace the
Measure the resistance between VDCCM&H/U more? VDCCM&H/U.
terminals. <Ref. to VDC-8,
Terminals VDC Control Mod-
No. 24 — No. 25: ule and Hydraulic
Control Unit
(VDCCM&H/U).>
and VDCCM&H/U?
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-72

AC:DTC C0052 MOTOR AND MOTOR RELAY OFF FAILURE

• Defective motor and motor relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1 MAIN SBF
SBF-6
IGNITION
E
SWITCH
No.33
B310
25
22
23
28
MOTOR RELAY
SECONDARY SUCTION
SOLENOID VALVE
PRIMARY SUCTION
PUMP MOTOR
SECONDARY CUT
RR OUTLET
FR OUTLET
RL OUTLET
FL OUTLET
RR INLET
FR INLET
RL INLET
FL INLET
VDCCM & H/U

PRIMARY CUT
VALVE RELAY
E E
B310
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00467
VDC(diag)-73

Step Check Yes No

1 CHECK VDCCM&H/U INPUT VOLTAGE. Is the voltage 10 — 15 V? Go to step 2. Repair the
2) Disconnect the connector from the power supply cir-
VDCCM&H/U. cuit.
2 CHECK INSTALLATION OF MOTOR Is the motor ground terminal Go to step 3. Tighten the motor
GROUND. installation bolt tightened 33 ground terminal
N·m (3.4 kgf-m, 24.3 ft-lb)? installation bolt.
4 CHECK VDCCM&H/U MOTOR RELAY. Is the resistance 1 MΩ or Go to step 5. Replace the
Measure the resistance between VDCCM&H/U more? VDCCM&H/U.
terminals. <Ref. to VDC-8,
Terminals VDC Control Mod-
No. 23 — No. 22: ule and Hydraulic
Control Unit
(VDCCM&H/U).>
Turn the ignition switch to OFF. and VDCCM&H/U?
1) Connect all connectors. VDCCM&H/U.
DTC. <Ref. to NOTE:
VDC(diag)-48, List Though the ABS
of Diagnostic Trou- warning light re-
ble Code (DTC).> mains on at this
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)-74
gi13usen005.fm 75 ページ２０１２年１１月１６日　金曜日　午後１時４４分

AD:DTC C0052 MOTOR AND MOTOR RELAY ON FAILURE

• Defective motor relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1 MAIN SBF
SBF-6
IGNITION
E
SWITCH
No.33
B310
25
22
23
28
MOTOR RELAY
SECONDARY SUCTION
SOLENOID VALVE
PRIMARY SUCTION
PUMP MOTOR
SECONDARY CUT
RR OUTLET
FR OUTLET
RL OUTLET
FL OUTLET
RR INLET
FR INLET
RL INLET
FL INLET
VDCCM & H/U

PRIMARY CUT
VALVE RELAY
E E
B310
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00467
Step Check Yes No

1 CHECK INSTALLATION OF MOTOR Is the motor ground terminal Go to step 2. Tighten the motor
GROUND. installation bolt tightened 33 ground terminal
VDC(diag)-75
gi13usen005.fm 76 ページ２０１２年１１月１６日　金曜日　午後１時４４分

Step Check Yes No

2 CHECK VDCCM&H/U MOTOR RELAY. Is the resistance 1 M or Go to step 3. Replace the
1) Turn the ignition switch to OFF. more? VDCCM&H/U.
2) Disconnect the connector from the <Ref. to VDC-8,
VDCCM&H/U. VDC Control Mod-
3) Measure the resistance between ule and Hydraulic
VDCCM&H/U terminals. Control Unit
Terminals (VDCCM&H/U).>
No. 23 — No. 22:
(VDCCM&H/U).>
DTC. <Ref. to NOTE:
VDC(diag)-48, List Though the ABS
of Diagnostic Trou- warning light re-
ble Code (DTC).> mains on at this
12 km/h (7 MPH)
or more in order to
turn ABS warning
drive the vehicle
and check that the
warning light goes
off.
AE:DTC C0052 MOTOR MALFUNCTION

• Defective motor
• Defective motor relay
TROUBLE SYMPTOM:
NOTE:
For the diagnostic procedure, refer to “DTC C0052 MOTOR AND MOTOR RELAY OFF FAILURE”. <Ref. to
VDC(diag)-73, DTC C0052 MOTOR AND MOTOR RELAY OFF FAILURE, Diagnostic Procedure with Diag-
VDC(diag)-76

AF:DTC C0054 BLS CIRCUIT OPEN

Defective stop light switch
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
No. 8 SBF-2 MAIN SBF
STOP LIGHT &

BRAKE SWITCH
E
* 12
*
B65
FUSE & RELAY BOX
(F/B)
R3 B99 B159 R168
6 4Dr 5Dr 9 15
B99 R3
7 4Dr 5Dr 7
1
(RELAY BLOCK)
FUSE
B225
7.5A
2
B434 4Dr : 4 DOOR MODEL

2
5Dr : 5 DOOR MODEL
*1 : 4 DOOR MODEL : 3
2
B435 5 DOOR MODEL : 1
5 DOOR MODEL : 2
30
B310 VDCCM & H/U
4Dr : B65 5Dr : B65 B310 B225
1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 9 13 17 21
1 2 22 23 24 25
3 4 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 10 14 18 22
3 4 3 4
11 12 15 16 19 20 23 24
5 6
7 8 25 29 33 37
26 30 34 38
B159 B434 B435 R168 B99 27 28 31 32 35 36 39 40
1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 7 8 9 1 2 3 4 5
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 6 7 8 9 10 11 12
VDC00819
VDC(diag)-77

Step Check Yes No

1 CHECK OUTPUT OF STOP LIGHT SWITCH Is “OFF” displayed on the Go to step 2. Go to step 3.
WITH SUBARU SELECT MONITOR. screen?
1) Select “Current Data Display & Save” on the
Subaru Select Monitor. <Ref. to VDC(diag)-19,
READ CURRENT DATA, OPERATION, Subaru
Select Monitor.>
2) Release the brake pedal.
3) Read the stop light switch output in Subaru
Select Monitor.
2 CHECK OUTPUT OF STOP LIGHT SWITCH Is “ON” displayed on the Go to step 6. Go to step 3.
WITH SUBARU SELECT MONITOR. screen?
1) Depress the brake pedal.
2) Read the stop light switch output in Subaru
Select Monitor.
3 CHECK IF STOP LIGHTS ILLUMINATE. Does the stop light illuminate? Go to step 4. Repair the stop
Depress the brake pedal. light circuit.
4 CHECK FUSE. Is the fuse OK? Go to step 5. Replace the fuse.
Check the fuse (B225) in the relay block.
5 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage 10 — 15 V? Go to step 6. Repair the harness
1) Turn the ignition switch to OFF. between stop light
2) Disconnect the connector from the switch and
VDCCM&H/U. VDCCM&H/U con-
3) Depress the brake pedal. nector.
TORS. tor between stop light switch tor.
and VDCCM&H/U?
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-78

AG:DTC C0054 BLS ON MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
STOP LIGHT &

BRAKE SWITCH
E
* 12
*
B65
FUSE & RELAY BOX
(F/B)
R3 B99 B159 R168
6 4Dr 5Dr 9 15
B99 R3
7 4Dr 5Dr 7
1
(RELAY BLOCK)
FUSE
B225
7.5A
2

2
5Dr : 5 DOOR MODEL
2
5 DOOR MODEL : 2
30
B310 VDCCM & H/U
4Dr : B65 5Dr : B65 B310 B225
1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 9 13 17 21
1 2 22 23 24 25
3 4 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 10 14 18 22
3 4 3 4
11 12 15 16 19 20 23 24
5 6
7 8 25 29 33 37
26 30 34 38
B159 B434 B435 R168 B99 27 28 31 32 35 36 39 40
1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 7 8 9 1 2 3 4 5
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 6 7 8 9 10 11 12
VDC00819
VDC(diag)-79

Step Check Yes No

1 CHECK STOP LIGHT SWITCH. Is the resistance 1 MΩ or more Go to step 2. Replace the stop
1) Turn the ignition switch to OFF. when switch is OFF (when light switch. <Ref.
2) Disconnect the stop light switch connector. pedal is not depressed)? to BR-47, Stop
3) Measure the resistance of stop light switch Light Switch.>
terminals.
4 door model
(B65) No. 3 — No. 4:
5 door model
(B65) No. 1 — No. 2:
2 INTERVIEW CUSTOMERS. Were the acceleration pedal System is normal. Go to step 3.
Make sure that the operation was performed in and brake pedal depressed (DTC may be
which accelerator pedal and brake pedal were simultaneously? recorded while
depressed simultaneously (with depressing brake is applied
brake pedal with left foot). during driving.)
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-80

AH:DTC C0054 BLS OFF MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
STOP LIGHT &

BRAKE SWITCH
E
* 12
*
B65
FUSE & RELAY BOX
(F/B)
R3 B99 B159 R168
6 4Dr 5Dr 9 15
B99 R3
7 4Dr 5Dr 7
1
(RELAY BLOCK)
FUSE
B225
7.5A
2

2
5Dr : 5 DOOR MODEL
2
5 DOOR MODEL : 2
30
B310 VDCCM & H/U
4Dr : B65 5Dr : B65 B310 B225
1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 9 13 17 21
1 2 22 23 24 25
3 4 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 10 14 18 22
3 4 3 4
11 12 15 16 19 20 23 24
5 6
7 8 25 29 33 37
26 30 34 38
B159 B434 B435 R168 B99 27 28 31 32 35 36 39 40
1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 7 8 9 1 2 3 4 5
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 6 7 8 9 10 11 12
VDC00819
VDC(diag)-81

Step Check Yes No

1 CHECK STOP LIGHT SWITCH. Is the resistance 1 Ω or less Go to step 2. Replace the stop
1) Turn the ignition switch to OFF. when the switch is ON (when light switch. <Ref.
2) Disconnect the stop light switch connector. pedal is depressed)? to BR-47, Stop
3) Measure the resistance of stop light switch Light Switch.>
terminals.
4 door model
(B65) No. 3 — No. 4:
5 door model
(B65) No. 1 — No. 2:
2 CHECK STOP LIGHT POWER SUPPLY. Is the voltage 10 — 15 V? Go to step 3. Repair the stop
Measure the voltage between stop light switch light power supply
terminal and chassis ground. circuit.
4 door model
5 door model
3 CHECK STOP LIGHT SWITCH HARNESS. Is the resistance less than 1 Ω? Go to step 4. Repair the stop
1) Disconnect the connector from the light switch circuit.
VDCCM&H/U.
VDCCM&H/U and stop light switch.
4 door model
(B65) No. 4 — (B310) No. 30:
5 door model
(B65) No. 2 — (B310) No. 30:
TORS. tor between stop light switch tor.
and VDCCM&H/U?
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-82

AI: DTC C0056 G SENSOR SIGNAL

Defective longitudinal G sensor output signal
TROUBLE SYMPTOM:
Hill start assist does not operate.
Step Check Yes No
1 WHETHER A WHEEL TURNED FREELY OR Did the wheels turn freely? VDC is normal. Go to step 2.
NOT. Clear the memory.
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.
2 CHECK OUTPUT OF LONGITUDINAL G Is the indicated reading on the Go to step 3. Replace the yaw
SENSOR USING SUBARU SELECT MONI- monitor display –1.2 — 1.2 m/s2? rate & G sensor.
TOR. <Ref. to VDC-20,
1) Park the vehicle on a level surface. Yaw Rate and G
2) Select “Current Data Display & Save” on the Sensor.>
Select Monitor.>
3) Read the indication of longitudinal G sensor
output.
3 CHECK OUTPUT OF LONGITUDINAL G When the yaw rate & G sensor is Go to step 4. Replace the yaw
SENSOR USING SUBARU SELECT MONI- inclined 90° to the front, is the rate & G sensor.
TOR. indicated value 6.8 — 12.8 m/s2? <Ref. to VDC-20,
1) Turn the ignition switch to OFF. Yaw Rate and G
2) Remove the yaw rate & G sensor from vehi- Sensor.>
cle. <Ref. to VDC-20, Yaw Rate and G Sensor.>
3) Turn the ignition switch to ON, and select the
“Current Data Display & Save” in Subaru Select
Monitor. <Ref. to VDC(diag)-19, READ CUR-
RENT DATA, OPERATION, Subaru Select
Monitor.>
4) Read the indication of longitudinal G sensor
output.
4 CHECK OUTPUT OF LONGITUDINAL G When the yaw rate & G sensor Go to step 5. Replace the yaw
SENSOR USING SUBARU SELECT MONI- is inclined 90° to the rear, is the rate & G sensor.
TOR. indicated value –6.8 — –12.8 <Ref. to VDC-20,
Read the indication of longitudinal G sensor m/s2? Yaw Rate and G
output. Sensor.>
5 CHECK POOR CONTACT OF CONNECTOR. Is there poor contact of connec- Repair the connec- Go to step 6.
Turn the ignition switch to OFF. tor between VDCCM&H/U and tor.
yaw rate & G sensor?
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-83

AJ:DTC C0057 ECM COMMUNICATION CIRCUIT

No CAN signal from ECM.
TROUBLE SYMPTOM:
Step Check Yes No
tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK POOR CONTACT OF CONNEC- Is there poor contact of ECM Repair the connec- Go to step 3.
TORS. connector? tor.
3 CHECK ECM. Is ECM normal? Go to step 4. Replace the ECM.
Refer to the basic diagnostic procedure for
Engine (diagnostics).
(VDCCM&H/U).>
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-84

AK:DTC C0057 ECM CONTROL SYSTEM

Cooperation control prohibition of ECM
TROUBLE SYMPTOM:
NOTE:
Warning lights go off if the cooperation control of ECM returns.
Step Check Yes No
1 CHECK WARNING LIGHT. Does the VDC warning light illu- Go to step 2. VDC is normal.
Check whether the VDC warning light illumi- minate? Perform the Clear
nates after driving for 1 minute or more at a Memory Mode.
speed of 10 km/h or more. NOTE:
DTC may be re-
corded if cranking
is performed dur-
ing driving.
2 CHECK POOR CONTACT OF CONNEC- Is there poor contact of ECM Repair the connec- Go to step 3.
TORS. connector? tor.
3 CHECK ECM. Is ECM normal? Go to step 4. Replace the ECM.
Refer to the basic diagnostic procedure for
Engine (diagnostics).
2) Perform the Clear Memory Mode. <Ref. to <Ref. to VDC-12,
VDC(diag)-27, Clear Memory Mode.> REPLACEMENT,
(VDCCM&H/U).>
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-85

AL:DTC C0071 STEERING ANGLE SENSOR OFFSET IS TOO BIG

Defective steering angle sensor
TROUBLE SYMPTOM:
VDC does not operate.
Step Check Yes No
1 CHECK STEERING WHEEL. Is the deviation from the center Go to step 2. Perform the cen-
1) Drive the vehicle on a flat road. of steering wheel less than 5°? tering adjustment
2) Park the vehicle straight. of steering wheel.
3) Check the steering wheel for deviation from
center.
1) Turn the ignition switch to OFF. VDCCM only.
2) Connect all connectors. <Ref. to VDC-12,
3) Clear the memory. <Ref. to VDC(diag)-27, REPLACEMENT,
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-86

AM:DTC C0071 CHANGE RANGE OF STEERING ANGLE SENSOR IS TOO BIG

TROUBLE SYMPTOM:
Step Check Yes No
3) Clear the memory. <Ref. to VDC(diag)-27, REPLACEMENT,
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-87

AN:DTC C0071 STEER ANGLE SENSOR OP

Signal does not come from steering angle sensor.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
MAIN SBF
B310 VDCCM & H/U
SBF-6
35
10
25
TWISTED PAIR LINE E
IGNITION SWITCH
No.33
TWISTED PAIR LINE
TWISTED PAIR LINE

2
1
3
4
3
2
4
B231
STEERING
ANGLE
YAW RATE & E E
G SENSOR
SENSOR
B230
B231 B230 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
1 22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
2
3
4
VDC00702
Step Check Yes No

1 CHECK POWER SUPPLY FOR STEERING Is the voltage 10 — 15 V? Go to step 2. Repair the steering
ANGLE SENSOR. angle sensor
1) Turn the ignition switch to OFF. power supply cir-
2) Disconnect the connector from steering cuit.
angle sensor.
4) Measure the voltage between steering
angle sensor and chassis ground.
VDC(diag)-88

Step Check Yes No

2 CHECK GROUND CIRCUIT OF STEERING Is the resistance less than 10 Go to step 3. Repair ground cir-
ANGLE SENSOR. Ω? cuit in the steering
Measure the resistance between steering angle angle sensor.
sensor and chassis ground.
3 CHECK STEERING ANGLE SENSOR HAR- Is the resistance less than 1 Ω? Go to step 4. Repair the harness
NESS. between the steer-
1) Disconnect the connector from the ing angle sensor
VDCCM&H/U. and VDCCM&H/U.
VDCCM&H/U and steering angel sensor.
(B231) No. 1 — (B310) No. 10:
(B231) No. 2 — (B310) No. 35:
4 CHECK GROUND SHORT CIRCUIT OF Is the resistance 1 MΩ or Go to step 5. Repair the harness
STEERING ANGLE SENSOR HARNESS. more? between the steer-
Measure the resistance between steering angle ing angle sensor
sensor and chassis ground. and VDCCM&H/U.
5 CHECK STEERING ANGLE SENSOR. Is the same DTC displayed? Go to step 6. Go to step 7.
3) Clear the memory. <Ref. to VDC(diag)-27,
Clear Memory Mode.>
VDC(diag)-26, Inspection Mode.>
5) Read the DTC.
2) Replace the steering angle sensor. <Ref. to <Ref. to VDC-12,
VDC-22, Steering Angle Sensor.> REPLACEMENT,
3) Clear the memory. <Ref. to VDC(diag)-27, VDC Control Mod-
Clear Memory Mode.> ule and Hydraulic
4) Perform the Inspection Mode. <Ref. to Control Unit
VDC(diag)-26, Inspection Mode.> (VDCCM&H/U).>
5) Read the DTC.
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
8 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Original steering
nosis according to angle sensor mal-
DTC. <Ref. to function
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-89

AO: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:
BATTERY
MAIN SBF
B310 VDCCM & H/U
SBF-6
35
10
25
TWISTED PAIR LINE E

IGNITION SWITCH
No.33
TWISTED PAIR LINE
TWISTED PAIR LINE

2
1
3
4
3
2
4
B231
STEERING
ANGLE
YAW RATE & E E
G SENSOR
SENSOR
B230
B231 B230 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
1 22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
2
3
4
VDC00702
VDC(diag)-90

Step Check Yes No

1 CHECK POWER SUPPLY FOR STEERING Is the voltage 10 — 15 V? Go to step 2. Repair the steering
ANGLE SENSOR. angle sensor
1) Turn the ignition switch to OFF. power supply cir-
2) Disconnect the connector from steering cuit.
angle sensor.
4) Measure the voltage between steering
angle sensor and chassis ground.
2 CHECK GROUND CIRCUIT OF STEERING Is the resistance less than 10 Go to step 3. Repair ground cir-
ANGLE SENSOR. Ω? cuit in the steering
Measure the resistance between steering angle angle sensor.
3 CHECK STEERING ANGLE SENSOR. Is the same DTC displayed? Go to step 4. Go to step 5.
Clear Memory Mode.>
5) Read the DTC.
2) Replace the steering angle sensor. <Ref. to <Ref. to VDC-12,
VDC-22, Steering Angle Sensor.> REPLACEMENT,
5) Read the DTC.
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
6 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Original steering
nosis according to angle sensor mal-
DTC. <Ref. to function
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-91

AP:DTC C0072 ABNORMAL YAW RATE SENSOR OUTPUT

Defective yaw rate sensor
TROUBLE SYMPTOM:
Step Check Yes No
1 INTERVIEW CUSTOMERS. Did the vehicle run the road VDCCM&H/U may Go to step 2.
Check if the vehicle ran the road with banks or with banks or sandy surface record DTC when
sandy surface (which does not mean a dirt (which does not mean a dirt the vehicle ran the
road). road)? road with banks or
sandy surface
(which does not
mean a dirt road).
2 CHECK YAW RATE & G SENSOR INSTAL- Is the yaw rate & G sensor Go to step 3. Tighten the yaw
LATION. installation bolt tightened to 7.5 rate & G sensor
3 CHECK OUTPUT OF YAW RATE & G SEN- Is the reading indicated on Go to step 4. Replace the yaw
SOR WITH SUBARU SELECT MONITOR. monitor display –4 — 4 deg/s? rate & G sensor.
1) Drive the vehicle on a flat road. <Ref. to VDC-20,
2) Park the vehicle straight. Yaw Rate and G
Select Monitor.>
4) Read the yaw rate output displayed on dis-
play.
4 CHECK OUTPUT OF STEERING ANGLE Is the reading indicated on Go to step 5. Perform the cen-
SENSOR WITH SUBARU SELECT MONI- monitor display –5 — 5°? tering adjustment
TOR. of steering wheel.
1) Drive the vehicle on a flat road.
2) Park the vehicle straight.
3) Select “Current Data Display & Save” on the
Select Monitor.>
4) Read the steering angle sensor output dis-
played on display.
5 CHECK YAW RATE & G SENSOR. Is the same DTC displayed? Go to step 6. Go to step 7.
Clear Memory Mode.>
5) Read the DTC.
2) Replace the yaw rate & G sensor. <Ref. to <Ref. to VDC-12,
VDC-20, Yaw Rate and G Sensor.> REPLACEMENT,
5) Read the DTC.
VDC(diag)-92

Step Check Yes No

DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
8 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Malfunction is
nosis according to found in original
DTC. <Ref. to yaw rate & G sen-
VDC(diag)-48, List sor.
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-93

AQ:DTC C0072 VOLTAGE INPUTTED TO YAW RATE SENSOR EXCEEDS SPEC-

IFICATION
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
MAIN SBF
B310 VDCCM & H/U
SBF-6
35
10
25
TWISTED PAIR LINE E
IGNITION SWITCH
No.33
TWISTED PAIR LINE
TWISTED PAIR LINE

2
1
3
4
3
2
4
B231
STEERING
ANGLE
YAW RATE & E E
G SENSOR
SENSOR
B230
B231 B230 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
1 22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
2
3
4
VDC00702
VDC(diag)-94

Step Check Yes No

1 CHECK POWER SUPPLY OF YAW RATE & G Is the voltage 10 — 15 V? Go to step 2. Repair the yaw rate
SENSOR. & G sensor power
sensor.
4) Measure the voltage between yaw rate & G
2 CHECK YAW RATE & G SENSOR GROUND Is the resistance less than 10 Go to step 3. Repair the yaw rate
CIRCUIT. Ω? & G sensor ground
Measure the resistance between yaw rate & G circuit.
3 CHECK YAW RATE & G SENSOR. Is the same DTC displayed? Replace the yaw Go to step 4.
1) Turn the ignition switch to OFF. rate & G sensor.
3) Clear the memory. <Ref. to VDC(diag)-27, Yaw Rate and G
Clear Memory Mode.> Sensor.>
5) Read the DTC.
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-95

AR:DTC C0072 CHANGE RANGE OF YAW RATE SENSOR SIGNAL IS TOO BIG
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
MAIN SBF
B310 VDCCM & H/U
SBF-6
35
10
25
TWISTED PAIR LINE E
IGNITION SWITCH
No.33
TWISTED PAIR LINE
TWISTED PAIR LINE

2
1
3
4
3
2
4
B231
STEERING
ANGLE
YAW RATE & E E
G SENSOR
SENSOR
B230
B231 B230 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
1 22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
2
3
4
VDC00702
Step Check Yes No

1 INTERVIEW CUSTOMERS. Did the vehicle run the road VDCCM&H/U may Go to step 2.
Check if the vehicle ran the road with banks or with banks or sandy surface record DTC when
sandy surface (which does not mean a dirt (which does not mean a dirt the vehicle ran the
road). road)? road with banks or
sandy surface
(which does not
mean a dirt road).
VDC(diag)-96

Step Check Yes No

3 CHECK POWER SUPPLY OF YAW RATE & G Is the voltage 10 — 15 V? Go to step 4. Repair the yaw rate
SENSOR. & G sensor power
sensor.
5 CHECK OUTPUT OF YAW RATE & G SEN- Is the reading indicated on Go to step 6. Replace the yaw
SOR WITH SUBARU SELECT MONITOR. monitor display –4 — 4 deg/s? rate & G sensor.
1) Drive the vehicle on a flat road. <Ref. to VDC-20,
2) Park the vehicle straight. Yaw Rate and G
Select Monitor.>
4) Read the yaw rate output displayed on dis-
play.
Clear Memory Mode.>
5) Read the DTC.
5) Read the DTC.
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-97

AS:DTC C0072 YAW RATE SENSOR COMMUNICATION

Communication failure between yaw rate sensor and VDCCM
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
MAIN SBF
B310 VDCCM & H/U
SBF-6
35
10
25
TWISTED PAIR LINE E
IGNITION SWITCH
No.33
TWISTED PAIR LINE
TWISTED PAIR LINE

2
1
3
4
3
2
4
B231
STEERING
ANGLE
YAW RATE & E E
G SENSOR
SENSOR
B230
B231 B230 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
1 22 23 24 25
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
2
3
4
VDC00702
VDC(diag)-98

Step Check Yes No

1 CHECK POWER SUPPLY FOR YAW RATE & Is the voltage 10 — 15 V? Go to step 2. Repair the yaw rate
G SENSOR. & G sensor power
sensor.
3 CHECK YAW RATE & G SENSOR HARNESS. Is the resistance less than 1 Ω? Go to step 4. Repair the harness
1) Disconnect the connector from the between yaw rate
VDCCM&H/U. & G sensor and
2) Measure the resistance between VDCCM&H/U.
VDCCM&H/U and yaw rate & G sensor.
(B230) No. 3 — (B310) No. 10:
(B230) No. 2 — (B310) No. 35:
4 CHECK GROUND SHORT CIRCUIT IN YAW Is the resistance 1 MΩ or Go to step 5. Repair the harness
RATE & G SENSOR HARNESS. more? between yaw rate
Measure the resistance between yaw rate & G & G sensor and
sensor and chassis ground. VDCCM&H/U.
Clear Memory Mode.>
5) Read the DTC.
6 CHECK YAW RATE & G SENSOR. Is the same DTC displayed? Replace the Go to step 8.
5) Read the DTC.
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-99

Step Check Yes No

of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-100

AT:DTC C0072 SENSOR TYPE ABNORMAL

Different yaw rate sensor specification
TROUBLE SYMPTOM:
• Hill start assist does not operate.
Step Check Yes No
1 CHECK YAW RATE & G SENSOR IDENTIFI- Is the identification symbol cor- Go to step 2. Replace the yaw
CATION MARK. rect? rate & G sensor
Check the identification mark on the sticker MT: R with a genuine
applied on the top of the yaw rate & G sensor. part. <Ref. to VDC-
20, Yaw Rate and
G Sensor.>
2 CHECK VDCCM&H/U IDENTIFICATION Is the identification symbol cor- Replace the Replace the
SYMBOL. rect? VDCCM only. VDCCM&H/U.
Check the identification mark stamped on the <Ref. to VDC-12, <Ref. to VDC-8,
upper side of the H/U. <Ref. to VDC-2, SPECI- REPLACEMENT, VDC Control Mod-
FICATION, General Description.> VDC Control Mod- ule and Hydraulic
ule and Hydraulic Control Unit
Control Unit (VDCCM&H/U).>
(VDCCM&H/U).>
AU: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)-102, DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL, Diagnostic Procedure with Diag-
AV: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)-102, DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL, Diagnostic Procedure with Diag-
VDC(diag)-101

AW:DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL

Defective lateral G sensor
TROUBLE SYMPTOM:
Step Check Yes No
2 CHECK OUTPUT OF LATERAL G SENSOR Is the indicated reading on the Go to step 3. Replace the yaw
WITH SUBARU SELECT MONITOR. monitor display –1.5 — 1.5 m/s2? rate & G sensor.
1) Park the vehicle on a level surface. <Ref. to VDC-20,
2) Select “Current Data Display & Save” on the Yaw Rate and G
Subaru Select Monitor. <Ref. to VDC(diag)-19, Sensor.>
Select Monitor.>
3) Read the lateral G sensor output displayed
on screen.
3 CHECK OUTPUT OF LATERAL G SENSOR When the yaw rate & G sensor is Go to step 4. Replace the yaw
WITH SUBARU SELECT MONITOR. inclined 90° to the right, is the rate & G sensor.
1) Turn the ignition switch to OFF. indicated value 6.8 — 12.8 m/s2? <Ref. to VDC-20,
2) Remove the yaw rate & G sensor from vehi- Yaw Rate and G
cle. Sensor.>
3) Turn the ignition switch to ON, and select the
“Current Data Display & Save” in Subaru Select
Monitor. <Ref. to VDC(diag)-19, READ CUR-
RENT DATA, OPERATION, Subaru Select
Monitor.>
4) Read the lateral G sensor output displayed
on screen.
4 CHECK LATERAL G SENSOR WITH SUBA- When the yaw rate & G sensor Go to step 5. Replace the yaw
RU SELECT MONITOR. is inclined 90° to the left, is the rate & G sensor.
Read the lateral G sensor output displayed on indicated value –6.8 — –12.8 <Ref. to VDC-20,
screen. m/s2? Yaw Rate and G
Sensor.>
TORS. tor between VDCCM&H/U and tor.
Turn the ignition switch to OFF. yaw rate & G sensor?
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-102

AX:DTC C0074 PRESSURE SENSOR

Defective pressure sensor
TROUBLE SYMPTOM:
Step Check Yes No
1 CHECK STOP LIGHT SWITCH CIRCUIT. Is the stop light switch circuit Go to step 2. Repair the stop
Check stop light switch open circuit. OK? light switch circuit.
NOTE:
If there is malfunc-
tion in the stop light
circuit, DTC may
be recorded in the
memory.
2 CHECK OUTPUT OF PRESSURE SENSOR When the brake pedal is Go to step 3. Replace the
WITH SUBARU SELECT MONITOR. released, is the displayed value VDCCM&H/U.
1) Select {Current Data Display & Save} in –40 — 40 bar? <Ref. to VDC-8,
Subaru Select Monitor. <Ref. to VDC(diag)-19, VDC Control Mod-
READ CURRENT DATA, OPERATION, Subaru ule and Hydraulic
Select Monitor.> Control Unit
2) Read the pressure sensor output displayed (VDCCM&H/U).>
on display.
3 CHECK OUTPUT OF PRESSURE SENSOR When the brake pedal is oper- Go to step 4. Replace the
WITH SUBARU SELECT MONITOR. ated, does the pressure sensor VDCCM&H/U.
1) Select {Current Data Display & Save} in output value displayed on the <Ref. to VDC-8,
Subaru Select Monitor. <Ref. to VDC(diag)-19, screen change in accordance VDC Control Mod-
READ CURRENT DATA, OPERATION, Subaru with the brake pedal? ule and Hydraulic
Select Monitor.> Control Unit
2) Read the pressure sensor output displayed (VDCCM&H/U).>
on display.
4 CHECK PRESSURE SENSOR. Is the same DTC displayed? Replace the Go to step 5.
1) Clear the memory. <Ref. to VDC(diag)-27, VDCCM&H/U.
Clear Memory Mode.> <Ref. to VDC-8,
(VDCCM&H/U).>
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-103

AY:DTC C0075 REVERSE SIGNAL

Abnormal reverse signal
TROUBLE SYMPTOM:
WIRING DIAGRAM:
Back-up light system <Ref. to WI-95, Back-up Light System.>
BATTERY
MAIN SBF
E
SBF-8
IG 2 RELAY
No. 18
BACK-UP
LIGHT SWITCH
*1 1 2
*2
B128 T9 T13 T1 T1 T13 T9 B128
5M : 5MT MODEL
5 5
6M : 6MT MODEL
B436 B434
: 5MT MODEL : 2
*1 6MT MODEL : 3
: 5MT MODEL : 4
*2 6MT MODEL : 6
B18
10
35
B3
B9
B: B280 BODY INTEGRATED UNIT B310 VDCCM & H/U
6M : B128 5M : B128 B434 B436 B310 T1 B: B280
1 2 3 4 5 1 2 1 2 3 4 5 6
1 2 3 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 7 8 9 10 11 12 13 14 15 16 17
4 5 6 3 4 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
18 19 20 21 22 23 24 25 26
VDC00890
VDC(diag)-104

Step Check Yes No

tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK REVERSE SIGNAL USING SUBARU Is “OFF” displayed when the Go to step 5. Go to step 3.
SELECT MONITOR. shift lever is placed in any posi-
1) Select “Current Data Display & Save” on the tion other than reverse, and is
Subaru Select Monitor. <Ref. to VDC(diag)-19, “ON” displayed in reverse posi-
READ CURRENT DATA, OPERATION, Subaru tion?
Select Monitor.>
2) Read the indication of reverse signal.
3 CHECK BACK-UP LIGHT ILLUMINATION. Does the back-up light illumi- Go to step 4. Repair the back-up
1) Turn the ignition switch to ON. nate? light circuit.
2) Place the shift lever in reverse position.
4 CHECK HARNESS BETWEEN BODY INTE- Is the resistance less than 1 Ω? Replace the back- Repair the harness
GRATED UNIT AND BACK-UP LIGHT up light switch. between body inte-
SWITCH. <Ref. to 5MT-32, grated unit and
1) Turn the ignition switch to OFF. Switches and Har- back-up light
2) Disconnect the connectors from body inte- ness.> <Ref. to switch connector.
grated unit and back-up light switch. 6MT-39, Back-up
3) Measure the resistance of harness between Light Switch.>
body integrated unit and back-up light switch
connector.
(B280) No. 18 — (T13) No. 2:
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-105

AZ:DTC C0076 CLUTCH SIGNAL

Abnormal clutch signal
TROUBLE SYMPTOM:
NOTE:
Depending on the user clutch operation patterns, the hill start assist warning light may illuminate for a while,
and then go off.
Illumination condition:
While the vehicle speed is above 10 km/h, and the clutch switch signal ON (depressed) condition continues
five minutes or more, if the vehicle speed lowers below 10 km/h, the module judge as abnormal (clutch switch
stuck ON), and then turn on the warning light.
Turning off condition:
If the clutch switch signal OFF (foot released) condition continues for 1 second, the module turns off the
warning light.
The hill start assist function does not operate, while the warning light illuminates.
VDC(diag)-106

WIRING DIAGRAM:
Engine electrical system <Ref. to WI-32, Engine Electrical System.>
BATTERY
MAIN SBF
E
SBF-8
IG 2 RELAY
No. 4
B440
1
1
B441 CLUTCH SWITCH
1
2
B107
C17
C28
10
35
B9
B: B135 C: B136 ECM B310 VDCCM & H/U
B107 B440 B441 B310 B: B135 C: B136
1 2 1 2 3 4 5 1 2 3 4 5 6 7 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35
VDC00891
VDC(diag)-107

Step Check Yes No

tem. <Ref. to
LAN(diag)-32, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK CLUTCH SIGNAL USING SUBARU Is “OFF” displayed when the Go to step 5. Go to step 3.
SELECT MONITOR. clutch pedal is not depressed,
1) Select “Current Data Display & Save” on the and is “ON” displayed when
Subaru Select Monitor. <Ref. to VDC(diag)-19, depressed?
Select Monitor.>
2) Read the indication of clutch switch signal.
3 CHECK CLUTCH SIGNAL OF ECM USING Is “OFF” displayed when the Go to step 5. Go to step 4.
SUBARU SELECT MONITOR. clutch pedal is not depressed,
1) Select “Current Data Display & Save” on and is “ON” displayed when
Subaru Select Monitor. <Ref. to depressed?
EN(H4DOTC)(diag)-40, READ CURRENT
DATA FOR ENGINE (NORMAL MODE),
2) Read the indication of clutch switch signal.
4 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Repair the power Repair the harness
CLUTCH SWITCH. supply circuit of between ECM and
1) Turn the ignition switch to OFF. clutch switch. Or clutch switch con-
2) Disconnect the connectors from ECM and replace the clutch nector.
clutch switch. switch. <Ref. to
3) Measure the resistance of harness between CL-33, Clutch
ECM and clutch switch connector. Switch.>
(B135) No. 9 — (B107) No. 2:
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-48, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-108

BA:DTC C0081 SYSTEM FAILURE

VDC long time sequential control
TROUBLE SYMPTOM:
Step Check Yes No
1 CHECK POOR CONTACT OF CONNECTOR. Is there poor contact of the Repair the connec- Go to step 2.
VDCCM&H/U and yaw rate & G tor.
sensor connector?
2 CHECK VDCCM&H/U. Is the same DTC displayed? Replace the Malfunction is
1) Replace the yaw rate & G sensor. <Ref. to VDCCM&H/U. found in original
VDC-20, Yaw Rate and G Sensor.> <Ref. to VDC-8, yaw rate & G sen-
2) Connect all connectors. VDC Control Mod- sor.
3) Clear the memory. <Ref. to VDC(diag)-27, ule and Hydraulic
Clear Memory Mode.> Control Unit
4) Perform the Inspection Mode. <Ref. to (VDCCM&H/U).>
5) Read the DTC.
VDC(diag)-109


A: INSPECTION
Symptoms Main probable cause Other probable cause
Poor brake per- Long braking/ • VDCCM&H/U • Defective ABS wheel speed sensor or sensor
formance stopping dis- • Brake pad gap
tance • Aeration to brake line • Defective steering angle sensor or improper
• Tire specifications, tire wear and air neutral position
pressures • Defective yaw rate & G sensor or improper
• Incorrect wiring or piping connections installation
• Master cylinder
• Brake caliper
• Disc rotor
• Brake pipe
• Brake booster
Wheel lock • VDCCM&H/U • Defective steering angle sensor or improper
• Defective ABS wheel speed sensor or neutral position
sensor gap • Defective yaw rate & G sensor or improper
• Incorrect wiring or piping connections installation
• Brake caliper
• Brake pipe
Brake drag • VDCCM&H/U • Defective steering angle sensor or improper
• Defective ABS wheel speed sensor or neutral position
sensor gap • Defective yaw rate & G sensor or improper
• Master cylinder installation
• Brake caliper • Brake pad
• Parking brake • Brake pipe
• Axle and wheels
• Brake pedal play
Long brake • Aeration to brake line • VDCCM&H/U
pedal stroke • Brake pedal play • Master cylinder
• Brake caliper
• Brake pad
• Brake pipe
• Brake booster
Vehicle vertical • VDCCM&H/U • Defective ABS wheel speed sensor or sensor
pitching • Road surface (uneven) gap
• Suspension play or fatigue (reduced • Defective steering angle sensor or improper
damping) neutral position
• Incorrect wiring or piping connections • Defective yaw rate & G sensor or improper
installation
Poor brake per- Unstable or • VDCCM&H/U • Defective ABS wheel speed sensor or sensor
formance uneven braking • Defective ABS wheel speed sensor or gap
sensor gap • Defective steering angle sensor or improper
• Brake caliper neutral position
• Brake pad • Defective yaw rate & G sensor or improper
• Road surface (uneven) installation
• Tire specifications, tire wear and air • Master cylinder
pressures • Disc rotor
• Incorrect wiring or piping connections • Brake pipe
• Axle and wheels
• Road with crowns or banks
• Suspension play or fatigue (reduced damping)
VDC(diag)-110


Vibration or Excessive • Road surface (uneven) • VDCCM&H/U
noise brake pedal • Incorrect wiring or piping connections • Brake booster
• When braking vibration • Suspension play or fatigue (reduced damping)
suddenly Noise from • VDCCM&H/U (mount bushing) • VDCCM&H/U
• When accel- VDCH/U • Defective ABS wheel speed sensor or • Defective steering angle sensor or improper
erating sud- sensor gap neutral position
denly • Brake pipe • Defective yaw rate & G sensor or improper
• While driving installation
on a slippery
Noise from the • VDCCM&H/U (mount bushing) • Axle and wheels
road
front side of • Defective ABS wheel speed sensor or • Tire specifications, tire wear and air pressures
vehicle sensor gap
• Master cylinder
• Brake caliper
• Brake pad
• Disc rotor
• Brake pipe
• Brake booster
• Suspension play or fatigue (reduced
damping)
Noise from the • Defective ABS wheel speed sensor or • Axle and wheels
rear side of sensor gap • Tire specifications, tire wear and air pressures
vehicle • Brake caliper
• Brake pad
• Disc rotor
• Parking brake
• Brake pipe
damping)
Engine does not accelerate or • VDCCM&H/U • Defective steering angle sensor or improper
goes into a stall when accelerat- • Defective ABS wheel speed sensor or neutral position
ing suddenly or driving on a slip- sensor gap • Defective yaw rate & G sensor or improper
pery surface. • Master cylinder installation
• Brake caliper • Brake pad
• Parking brake • Brake pipe
• Incorrect wiring or piping
VDC(diag)-111


Poor change- Deviation to • VDCCM&H/U • Disc rotor
direction-opera- right or left • Defective ABS wheel speed sensor or • Brake pipe
tion stability of direction sensor gap • Axle and wheels
TCS • Defective steering angle sensor or • Suspension play or fatigue (reduced damping)
improper neutral position
• Defective yaw rate & G sensor or
improper installation
• Brake caliper
• Brake pad
• Wheel alignment
• Road surface (uneven)
• Tire specifications, tire wear and air
pressures
• Incorrect wiring or piping connections
Vehicle spin • VDCCM&H/U • Brake caliper
• Defective ABS wheel speed sensor or • Brake pipe
sensor gap
• Defective steering angle sensor or
• Brake pad
pressures
Steering wheel drag while driving • VDCCM&H/U • Brake caliper
• Defective ABS wheel speed sensor or • Brake pad
sensor gap • Disc rotor
• Defective steering angle sensor or • Wheel alignment
improper neutral position • Road surface (uneven)
• Defective yaw rate & G sensor or • Road with crowns or banks
improper installation • Suspension play or fatigue (reduced damping)
• Incorrect wiring or piping connections • Tire specifications, tire wear and air pressures
• Power steering system
VDC operates while driving nor- • VDCCM&H/U
mally. • Defective ABS wheel speed sensor or
sensor gap
• Defective steering angle sensor or
• Wheel alignment
• Road surface (uneven)
damping)
pressures
• Power steering system
VDC(diag)-112


VDC OFF indicator light does not • Harness
illuminate when the VDC OFF • Combination meter
switch is depressed. (5MT model) • VDC OFF switch
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 re-
stored.
VDC traction mode indicator light • Harness
does not illuminate when the VDC • Combination meter
OFF switch is depressed. (6MT • VDC OFF switch
model)
NOTE:
When the VDC OFF switch is
pressed for 10 seconds or more,
the VDC traction mode indicator
light goes off, and operation can-
not be continued. When turning
the ignition switch from OFF to
ON, the previous status is re-
stored.
VDC(diag)-113
BRAKE
BR
Page
2. Front Brake Pad .......................................................................................14
3. Front Disc Rotor .......................................................................................17
4. Front Disc Brake Assembly ......................................................................18
5. Rear Brake Pad ........................................................................................23
6. Rear Disc Rotor ........................................................................................26
7. Rear Disc Brake Assembly ......................................................................28
8. Master Cylinder ........................................................................................32
9. Brake Booster ..........................................................................................34
10. Brake Fluid ...............................................................................................38
11. Air Bleeding ..............................................................................................39
12. Brake Hose ..............................................................................................41
13. Brake Pipe ................................................................................................44
14. Brake Pedal ..............................................................................................45
15. Stop Light Switch .....................................................................................47
16. Hill Start Assist .........................................................................................49
General Description
BRAKE
A: SPECIFICATION
Size Brembo 17-inch type 16-inch type
Type Disc (Opposed type, ventilated) Disc (Floating type, ventilated)
Effective disc diameter mm (in) 268 (10.55) 244 (9.61)
Disc thickness × Diameter mm (in) 30 × 326 (1.18 × 12.83) 24 × 294 (0.94 × 11.57)
Front disc
brake 40.0 × 2, 46.0 × 2
Effective cylinder diameter mm (in) 42.8 (1.685) × 2
(1.575 × 2, 1.811 × 2)
Pad dimensions 131.8 × 60.5 × 8.9 117.8 × 50.5 × 11.0
mm (in)
(Length × Width × Thickness) (5.189 × 2.382 × 0.35) (4.638 × 1.988 × 0.433)
Clearance adjustment Automatic adjustment
Size Brembo 17-inch type 15-inch type
Type Disc (Opposed type, ventilated) Disc (Floating type, solid)
Effective disc diameter mm (in) 268 (10.55) 250 (9.84)
20 × 316
Rear disc Disc thickness × Diameter mm (in) 10 × 286 (0.39 × 11.26)
(0.79 × 12.44 )
brake
Effective cylinder diameter mm (in) 40.0 (1.575) × 2 38.1 (1.500)
Pad dimensions 76.8 × 45.0 × 9.0 92.0 × 33.0 × 9.0
mm (in)
(Length × Width × Thickness) (3.024 × 1.772 × 0.354) (3.622 × 1.299 × 0.354)
Clearance adjustment Automatic adjustment
Type Tandem
Master Effective diameter mm (in) 23.8 (15/16)
cylinder Reservoir type Sealed type
Brake fluid reservoir capacity cm3 (cu in) 205 (12.51)
Brake Type Vacuum suspended
booster Effective diameter mm (in) 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.
FMVSS No. 116, DOT3, or DOT4
• 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.
BR-2
General Description
BRAKE
NOTE:
Refer to “PB” section for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General Descrip-
tion.>
Item Standard Limit
16-inch type 11 (0.43) 1.5 (0.059)
Pad thickness mm (in)
Brembo 17-inch type 8.9 (0.35) 1.2 (0.047)
16-inch type 24 (0.94) 22 (0.87)
Front brake Disc thickness mm (in)
Brembo 17-inch type 30 (1.18) 28 (1.10)
16-inch type — 0.050 (0.0020)
Disc runout mm (in)
Brembo 17-inch type — 0.075 (0.0030)
15-inch type 9.0 (0.354) 1.5 (0.059)
Pad thickness mm (in)
Brembo 17-inch type 9.0 (0.354) 1.2 (0.047)
15-inch type 10 (0.39) 8.5 (0.335)
Rear brake Disc thickness mm (in)
Brembo 17-inch type 20 (0.79) 18 (0.71)
15-inch type — 0.050 (0.0020)
Disc runout mm (in)
Brembo 17-inch type — 0.070 (0.0028)
Inside diameter mm (in) 190 (7.48) 191 (7.52)
Parking brake Lining thickness mm (in) 2.8 (0.11) 1.5 (0.059)
Lever stroke 7 — 8 notches/200 N (20 kgf, 45 lbf)
Brake pedal force Fluid pressure kPa (kgf/cm2, psi)

N (kgf, lbf) Brembo 17-inch type 16-inch type
Brake fluid pressure with engine 147 (15, 33) 545 (6, 79)
stopped 294 (30, 66) 1,564 (16, 227)
Brake booster Brake fluid pressure with engine run- 147 (15, 33) 4,984 (51, 723) 6,003 (61, 871)
ning and vacuum pressure at 66.7
kPa (500 mmHg, 19.69 inHg) 294 (30, 66) 10,249 (105, 1,486) 11,273 (115, 1,635)
0.5 — 2 (0.020 — 0.079)

Brake pedal Free play mm (in) [When pulling the brake pedal upward with a force of less than 10 N
(1 kgf, 2 lbf)]
BR-3
General Description
BRAKE
B: COMPONENT
1. FRONT DISC BRAKE (BREMBO-TYPE)
(1)
(5)
T3 (3) T2
(2)
(4)
(6)
(11) (10)
(9)
(12) (8)
(8) (7)
(14) (9)
(10)
(13)
(12)
(11)
(16)
T1
(15)
BR-00781
(1) Housing (8) Piston boot (15) Disc rotor

(2) Caliper body (9) Piston (16) Disc cover
(3) Air bleeder screw (10) Piston seal
(4) Guide plate (11) Pad shim (outer) Tightening torque: N·m (kgf-m, ft-lb)
(5) Cross spring (12) Pad shim (inner) T1: 18 (1.84, 13.3)
(6) Clip (13) Pad (outside) T2: 20 (2.04, 14.8)
(7) Pad pin (14) Pad (inside) T3: 155 (15.81, 114.3)
BR-4
General Description
BRAKE
2. FRONT DISC BRAKE (EXCEPT FOR BREMBO-TYPE)
T2 T1
(2)
(3)
(4)
(1)
(5)
(6)
T3 (7)
(11)
(9)
(8)
(4)
(10)
(12)
(1 3)
(14)
(16)
(15)
(14)
(13)
(1 8 )
(17)
BR-00884
(1) Caliper body (9) Lock pin (17) Disc rotor

(2) Air bleeder screw (10) Support (18) Disc cover
(3) Guide pin (11) Pad clip upper
(4) Pin boot (12) Pad clip lower Tightening torque: N·m (kgf-m, ft-lb)
(5) Piston seal (13) Outer shim T1: 8 (0.82, 5.9)
(6) Piston (14) Inner shim T2: 27 (2.75, 19.9)
(7) Piston boot (15) Pad (outside) T3: 80 (8.16, 59)
(8) Bushing (16) Pad (inside)
BR-5
General Description
BRAKE
3. REAR DISC BRAKE (BREMBO-TYPE)
(2) T1
(3)
(4)
T2 (7)
(6)
(5)
(1) (10)
(5)
(12)
(6)
(11) (7)
(10)
(8)
(15)
(9)
(16)
(17)
(18)
(1 3 ) (19) (21)
(3 0 )
(22)
(23)
(24)
(25)
(20)
(27)
(26)
(14) (29) (28)
BR-00696
(1) Caliper body (13) Shoe hold-down pin (25) Primary shoe return spring
(2) Air bleeder screw (14) Adjusting hole cover (26) Adjusting spring
(3) Guide plate (15) Back plate (27) Adjusting screw
(4) Cross spring (16) Retainer (28) Shoe hold-down cup
(5) Piston boot (17) Wave washer (29) Shoe hold-down spring
(6) Piston (18) Parking brake lever (30) Disc rotor
(7) Piston seal (19) Parking brake shoe (secondary)
(8) Clip (20) Parking brake shoe (primary) Tightening torque: N·m (kgf-m, ft-lb)
(9) Pad pin (21) Strut T1: 20 (2.04, 14.8)
(10) Pad shim (22) Strut shoe spring T2: 65 (6.63, 47.9)
(11) Pad (outside) (23) Shoe guide plate
(12) Pad (inside) (24) Secondary shoe return spring
BR-6
General Description
BRAKE
4. REAR DISC BRAKE (EXCEPT FOR BREMBO-TYPE)
(2) T1
T2
(3)
(4)
(1) (5)
T3 (8)
(6)
(7)
(11)
(9)
(12) (10)
(13)
(4)
(14)
(15)
(11) (16)
(17)
(18)
(19)
(20)
(3 2 ) (21) (23)
(22)
(24)
(25)
(26)
(31)
(34) (30) (2 7 )
(3 3 ) (29) (28)
BR-00887
(1) Caliper body (14) Inner pad (27) Adjusting screw

(2) Air bleeder screw (15) Outer pad (28) Shoe hold-down cup
(3) Guide pin (black) (16) Shim (29) Shoe hold-down spring
(4) Pin boot (17) Back plate (30) Adjusting spring
(5) Piston seal (18) Retainer (31) Parking brake shoe (primary)
(6) Piston (19) Wave washer (32) Shoe hold-down pin
(7) Piston boot (20) Lever (33) Disc rotor
(8) Support (21) Parking brake shoe (secondary) (34) Adjusting hole cover
(9) Lock pin (silver) (22) Strut spring
(10) Bushing (23) Strut Tightening torque: N·m (kgf-m, ft-lb)
(11) Pad clip (24) Shoe guide plate T1: 8 (0.82, 5.9)
(12) Outer shim (25) Secondary shoe return spring T2: 27 (2.75, 19.9)
(13) Inner shim (26) Primary shoe return spring T3: 66 (6.73, 48.7)
BR-7
General Description
BRAKE
5. MASTER CYLINDER
(1)
(2)
(10) (3)
(9) T
(8)
(11)
(4)
(5)
(6)
(7)
BR-00371
(1) Cap (6) Secondary piston (11) O-ring

(2) Filter (7) Cylinder body
(3) Reservoir tank (8) Cylinder pin Tightening torque: N·m (kgf-m, ft-lb)
(4) C-ring (9) Seal T: 13 (1.33, 9.6)
(5) Primary piston (10) Pin
BR-8
General Description
BRAKE
6. FRONT BRAKE PIPES AND HOSES
(8) (2)
T2
T1
T1
(1)
T2
T1
(5)
T4
(9)
(7) T3 T3 (5)
(3)
(6) (4)
T1
T2
T4
T2
(6)
BR-00805
(1) Front brake pipe ASSY (6) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(2) Two-way connector (7) VDC control module and hydraulic T1: 15 (1.53, 11.1)
control unit (VDCCM&H/U)
(3) Front brake hose RH (8) Bracket T2: 18 (1.84, 13.3)
(4) Front brake hose LH (9) Master cylinder T3: 19 (1.94, 14)
(5) Clamp T4: 33 (3.36, 24.3)
BR-9
General Description
BRAKE
7. CENTER AND REAR BRAKE PIPES & HOSES
T1
(6)
(4)
T3
(8) (7)
T2
T2
(3)
T1
T1 (6)
(2) (5)
T2
(7)
T1 T3
T1
T2
(1)
BR-00707
(1) Center brake pipe ASSY (5) Rear brake hose LH Tightening torque: N·m (kgf-m, ft-lb)
(2) Two-way connector (6) Clamp T1: 15 (1.53, 11.1)
(3) Rear brake pipe ASSY (7) Gasket T2: 18 (1.84, 13.3)
(4) Rear brake hose RH (8) Bracket T3: 33 (3.36, 24.3)
8. BRAKE BOOSTER
(1)
BR-00827
(1) Brake booster Tightening torque: N·m (kgf-m, ft-lb)

T: 18 (1.84, 13.3)
BR-10
General Description
BRAKE
9. BRAKE PEDAL
• 6MT model
T2
T1 T2
T2
(1)
T2 (2)
(6)
T1
T1
(7)
(3)
(4)
(5)
BR-00714
(1) Brake pedal ASSY (5) Clutch pedal pad Tightening torque: N·m (kgf-m, ft-lb)
(2) Stop light switch (6) Clutch switch (cruise control) T1: 8 (0.82, 5.9)
(3) Brake pedal pad (7) Clutch switch (clutch start) T2: 18 (1.84, 13.3)
(4) Clutch pedal
BR-11
General Description
BRAKE
• 5MT model
T2
T1
T2
T2
(1)
T2 (2)
(6)
T1
T1
(7)
(3)
(4)
(5)
BR-00730
(1) Brake pedal ASSY (5) Clutch pedal pad Tightening torque: N·m (kgf-m, ft-lb)
(2) Stop light switch (6) Clutch switch (cruise control) T1: 8 (0.82, 5.8)
(3) Brake pedal pad (7) Clutch switch (clutch start) T2: 18 (1.84, 13.3)
(4) Clutch pedal
BR-12
General Description
BRAKE
C: CAUTION
• Wear appropriate work clothing, including a helmet, protective goggles and protective shoes when per-
forming any work.
turers.
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 2. EXCEPT FOR BREMBO TYPE

A: REMOVAL wheels.
1. BREMBO TYPE 2) Remove the caliper bolt.
wheels.
2) Remove clips (1).
(1) BR-00339
3) Raise the caliper body and support it.

NOTE:
BR-00292 Do not disconnect the brake hose from the caliper
3) Remove the pad pins (1) and cross spring (2). body.
4) Remove the pads.
(2)
(1)
BR-00293
BR-00849
4) Spread apart the pads using a pair of wrenches
and push back the piston. B: INSTALLATION
1. BREMBO TYPE
1) Apply a thin coat of Molykote M7439 (Part No.
003602001) or grease contained in the pad kit to
the side of the pad.
BR-00290
5) Remove the pads.
BR-00782
BR-00291
BR-14
Front Brake Pad

BRAKE
2) Apply a thin coat of Molykote AS880N (Part No. • Correctly install the pad return spring to the
K0777YA010) or grease contained in the pad kit to supporting surface of the pad clip as shown in
the pad and pad shim. the figure.
• If the pad return spring is deformed or dam-
aged, replace the brake pad.
(1)
(2)
BR-00783
3) Install the pads to the caliper body. (3)

BR-00885
4) Install the cross spring.
5) Install the pad pins. (1) Pad return spring
6) Install the clips. (2) Supporting surface of pad clip
2. EXCEPT FOR BREMBO TYPE (3) Direction of brake rotor rotation
003602001) or grease contained in the pad kit to NOTE:
the pad clip. Install the pad indicator in proper direction.
(1)
(5)
(6)
(2)
(5)
BR-00596
(6)
2) Apply a thin coat of Molykote AS880N (Part No. (3)
K0777YA010) or grease contained in the pad kit to (5)
both surfaces of the pad and inner shim.
(6)
(4)
(5)
(6)
BR-00886
(1) LH — IN
BR-00837 (2) LH — OUT
3) Install the pad to support. (3) RH — IN
(4) RH — OUT
CAUTION:
(5) Pad indicator
• Be sure to install so that the pad return
spring faces the input side of the direction of (6) Pad return spring
brake rotor rotation, as shown in the figure.
4) Install the caliper body to the support.
Tightening torque:
27 N·m (2.75 kgf-m, 19.9 ft-lb)
BR-15
Front Brake Pad

BRAKE
C: INSPECTION
Check the pad thickness A.
• Brembo type
A
BR-00296
Pad thickness A Standard 8.9 (0.35)

mm (in) Wear limit 1.2 (0.047)
• Except for brembo type
BR-00888
Pad thickness A Standard 11 (0.433)

NOTE:
• Always replace the pads of both wheels and both
sides as a set.
• Replace the cross spring and pad pins if they are
twisted or worn. (Brembo type)
• A wear indicator is installed on the outer disc
brake pad. (Brembo type)
• Wear indicators are installed on the inner and
outer disc brake pads. (Except for brembo type)
• If the pad is worn to the limit, the end of wear in-
dicator contacts disc rotor, and a squeaking sound
is heard as the wheel rotates. If the sound is heard,
replace the pad.
• Replace the pad if there is oil or grease on it.
BR-16
Front Disc Rotor

BRAKE
3. Front Disc Rotor Tightening torque:

Brembo type
A: REMOVAL 155 N·m (15.81 kgf-m, 114.3 ft-lb)
1) Lift up the vehicle, and then remove the front Except for brembo type
wheels. 80 N·m (8.16 kgf-m, 59 ft-lb)
2) Remove the caliper body assembly from hous- 3) Install the front wheels.
ing, and suspend it from the strut using a wire. C: INSPECTION
CAUTION: 1) Check the front wheel bearing play and axle hub
Be careful not to stretch the brake hose. runout before the inspection of disc rotor runout
• Brembo type limit. <Ref. to DS-17, INSPECTION, Front Axle.>
2) Secure the disc rotor by tightening the five wheel
nuts.
3) Set a dial gauge 10 mm (0.39 in) inward from the
disc rotor outer circumference. Rotate the disc rotor
to check runout. If the disc rotor runout exceeds the
limit, resurface the disc rotor. After grinding, check
the thickness of the disc rotor according to the pro-
cedure in step 4).
BR-00297
BR-00019
Disc rotor runout limit:

Brembo type
BR-00017 0.075 mm (0.0030 in)
3) Remove the disc rotor. Except for brembo type
0.050 mm (0.0020 in)
NOTE: 4) Set a micrometer 10 mm (0.39 in) inward from
If it is difficult to remove the disc rotor from the hub, the disc rotor outer perimeter, and then measure
drive an 8 mm bolt into the threaded section (B) of the disc rotor thickness. If the thickness A of the
the rotor, then remove the rotor. disc rotor exceeds the service limit, replace with a
new disc rotor.
B
A B
A
BR-00018
4) Remove mud and foreign matter from the caliper BR-00018

body assembly.
Disc rotor thickness A Disc rotor
Standard Limit
B: INSTALLATION mm (in) diameter
1) Install the disc rotor. Brembo type 30 (1.18) 28 (1.10) 326 (12.83)
2) Install the caliper body assembly to the housing. Except for brembo
24 (0.94) 22 (0.87) 294 (11.57)
type
BR-17
Front Disc Brake Assembly

BRAKE
4. Front Disc Brake Assembly 3) Remove the bolts which secure the caliper body.
A: REMOVAL
1. BREMBO TYPE
CAUTION:
Do not allow brake fluid to come in contact with
the painted surface of the vehicle body. If it
does, wash off with water immediately and wipe
away completely.
BR-00022
wheels.
2) Remove the union bolt (1) and brake hose from 4) Raise the caliper body, and then move it toward
the caliper body. vehicle center to separate it from the support.
3) Remove the mounting bolts (2) from the hous- 5) Remove the brake pad, and then remove the
ing. support from the housing.
NOTE:
(1) Remove the support only when replacing the rotor
or support. It is not necessary to remove it when
servicing the caliper body.
(2)
BR-00299
4) Remove mud and foreign matter from the caliper

body assembly.
2. EXCEPT FOR BREMBO TYPE BR-00023
CAUTION: 6) Remove mud and foreign matter from the caliper
Do not allow brake fluid to come in contact with body and the support.
does, wash off with water and wipe away com- B: INSTALLATION
pletely. 1. BREMBO TYPE
wheels. 1) Install the caliper body assembly to the housing.
2) Remove the union bolt, and disconnect the Tightening torque:
brake hose from the caliper body. 155 N·m (15.81 kgf-m, 114.3 ft-lb)
BR-00021
BR-00782
BR-18

BRAKE
3) Apply a thin coat of Molykote AS880N (Part No. 3) Apply a thin coat of Molykote M7439 (Part No.
K0777YA010) or grease contained in the pad kit to 003602001) or grease contained in the pad kit to
the pad and pad shim. the pad clip.
BR-00783 BR-00596
4) Install the pads to the caliper body. 4) Apply a thin coat of Molykote AS880N (Part No.
5) Install the cross spring. K0777YA010) or grease contained in the pad kit to
6) Install the pad pins. both surfaces of the pad and inner shim.
7) Install the clips.
8) Connect the brake hose using a new brake hose
gasket.
Tightening torque:
18 N·m (1.84 kgf-m, 13.3 ft-lb)
9) Bleed air from the brake system. <Ref. to BR-39,
PROCEDURE, Air Bleeding.>
2. EXCEPT FOR BREMBO TYPE
1) Apply a thin coat of Molykote M7439 (Part No. BR-00837
003602001) or the grease included with pad kit to 5) Install the pad to support.
the support.
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.
BR-00597
2) Install the support to the housing.

Tightening torque: (1)
80 N·m (8.16 kgf-m, 59 ft-lb)
(2)
(3)
BR-00885
(1) Pad return spring

(2) Supporting surface of pad clip
(3) Direction of brake rotor rotation
BR-19

BRAKE
NOTE: C: DISASSEMBLY
Install the pad indicator in proper direction.
1. BREMBO TYPE
(1) 1) Remove mud and foreign matter from the caliper
(5)
body.
CAUTION:
(6)
the brake hose connector.
(2)
2) Remove the piston boots from each piston end.
(5)
(6)
(3)
(5)
(6)
(4)
(5) BR-00303
3) Place a wooden block in the caliper body as

shown in the figure to prevent the piston from jump-
(6)
ing out and being damaged.
BR-00886
4) Gradually apply compressed air via the brake
(1) LH — IN hose installation hole to push the piston out.
(2) LH — OUT
(3) RH — IN
(4) RH — OUT
(5) Pad indicator
(6) Pad return spring
(1)

Tightening torque:
27 N·m (2.75 kgf-m, 19.9 ft-lb) BR-00304
7) Connect the brake hose using a new brake hose
gasket. (1) Place a wooden block of 30 mm (1.18 in) width.
Tightening torque: 5) Remove the piston seal (1) from the caliper body
18 N·m (1.84 kgf-m, 13.3 ft-lb) cylinder.
8) Bleed air from the brake system. <Ref. to BR-39,
PROCEDURE, Air Bleeding.> CAUTION:
Do not damage the cylinder and piston seal
groove.
(1)
BR-00305
BR-20

BRAKE
2. EXCEPT FOR BREMBO TYPE D: ASSEMBLY

body and the support.
1. BREMBO TYPE
1) Clean the inside of the caliper body using brake
CAUTION: fluid.
Be careful not to allow foreign matter to enter 2) Apply a coat of brake fluid to piston seal and in-
the brake hose connector. stall the piston seal to the caliper body groove.
2) Place a wooden block in the caliper body as 3) Apply a coat of brake fluid to the inner surface of
shown in the figure to prevent the piston from jump- cylinder and the entire outer surface of the piston.
ing out and being damaged. 4) Apply NIGLUBE RX-2 (Part No. K0779GA102)
3) Gradually apply compressed air via the brake or the piston kit grease to the boot, and install to the
hose installation hole to push the piston out. piston groove.
5) Insert the piston into the cylinder.
CAUTION:
Do not force the piston into cylinder.
(1)
BR-00026
(1) Place a wooden block of 30 mm (1.18 in) width.
4) Remove the piston boot. BR-00307
6) Position the boot in the grooves on cylinder and

piston.
(1)
(2)
(3)
BR-00240
5) Remove the piston seal (1) from the caliper body

cylinder. BR-00309
CAUTION:
(1) Piston seal
Do not damage the cylinder and piston seal
groove. (2) Piston boot
(3) Piston
(1)
BR-00027
6) Remove the guide pin and boot from caliper

body.
BR-21

BRAKE
2. EXCEPT FOR BREMBO TYPE 8) Insert the lock pin and guide pin boot into the
1) Clean the inside of the caliper body using brake support.
fluid. CAUTION:
2) Apply a coat of brake fluid to piston seal and in- After inserting the pin into the given place,
stall the piston seal to the caliper body groove. move the caliper by hand to make sure that it
3) Apply a coat of brake fluid to the inner surface of moves smoothly without obstacles or exces-
cylinder and the entire outer surface of the piston. sive friction.
4) Apply grease contained in the piston seal kit to
: (3)
the boot, and install it to the groove at the end of the (1)
cylinder. (2)
5) Insert the piston into cylinder.

CAUTION:
Do not force the piston into cylinder.
(2)
BR-00362
(1)
(1) Pin boot

(2) Lock pin or guide pin
(3) Grease applied area
BR-00242
E: INSPECTION
1) Repair or replace the faulty parts.
(1) Piston 2) Check the caliper body and piston for uneven
(2) Piston boot wear, damage or rust.
3) Check the rubber parts for damage or deteriora-
6) Position the boot in the grooves on cylinder and tion.
piston.
(3)
(4)
(2)
(1)
BR-00243
(1) Piston
(2) Piston boot
(3) Caliper body
(4) Piston seal
7) Apply a coat of the grease included with the pis-

ton kit to the lock pin and guide pin outer surface,
cylinder inner surface, and boot grooves.
BR-22
Rear Brake Pad

BRAKE
5. Rear Brake Pad 2. EXCEPT FOR BREMBO TYPE

A: REMOVAL wheels.
1. BREMBO TYPE 2) Remove the brake hose bracket.
wheels.
2) Remove clips (1).
(1)
RS-00264
3) Remove the caliper bolt.
BR-00698
3) Remove the pad pins (1) and cross spring (2).
(1)
(2) BR-00660
4) Raise the caliper body and support it.

NOTE:
BR-00699 Do not disconnect the brake hose from the caliper
4) Spread apart the pads using a pair of wrenches body.
and push back the piston. 5) Remove the pads.
5) Remove the pads.
BR-00032
BR-00700
BR-23
Rear Brake Pad

BRAKE
B: INSTALLATION 2) Apply a thin coat of Molykote AS880N (Part No.

K0777YA010) or grease contained in the pad kit
1. BREMBO TYPE between the outer pad and shim.
BR-00875
3) Apply a thin coat of Molykote AS880N (Part No.

K0777YA010) or grease contained in the pad kit to
BR-00784 both surfaces of the inner pad inner shim.
2) Apply a thin coat of Molykote AS880N (Part No.
K0777YA010) or the grease contained in the pad
kit to the contact surface between the pad and pad
shim.
BR-00876
4) Install the pad to support.

BR-00785 Tightening torque:
27 N·m (2.75 kgf-m, 19.9 ft-lb)
3) Install the pads to the caliper body.
6) Install the brake hose bracket.
4) Install the cross spring and pad pins.
5) Install the clips. Tightening torque:
33 N·m (3.36 kgf-m, 24.3 ft-lb)
2. EXCEPT FOR BREMBO TYPE
the pad clip.
BR-00599
BR-24
Rear Brake Pad

BRAKE
C: INSPECTION
Check the pad thickness A.
• Brembo type
A
BR-00314

BR-00889

NOTE:
• Always replace the pads of both wheels and both
sides as a set.
• Replace the cross spring and pad pins if they are
twisted or worn. (Brembo type)
• A wear indicator is installed on the outer disc
brake pad. (Brembo type)
• Wear indicators are installed on the inner and
outer disc brake pads. (Except for brembo type)
• If the pad is worn to the limit, the end of wear in-
dicator contacts disc rotor, and a squeaking sound
is heard as the wheel rotates. If the sound is heard,
replace the pad.
• Replace the pad if there is oil or grease on it.
BR-25
Rear Disc Rotor

BRAKE
6. Rear Disc Rotor 5) Remove the disc rotor.

NOTE:
A: REMOVAL If it is difficult to remove the disc rotor, perform the
1) Lift up the vehicle, and then remove the rear following two methods in order.
wheels. (1) Turn the adjusting screw using a flat tip
2) Release the parking brake. screwdriver until the brake shoe is far enough
3) Remove the brake hose bracket. away to allow removal of the disc rotor.
(2)
(1)
(3)
RS-00264 BR-00734
4) Remove the caliper body assembly from hous-

(1) Adjusting screw
ing, and suspend it from the strut using a wire.
(2) Flat tip screwdriver
CAUTION: (3) Disc rotor
Be careful not to stretch the brake hose.
• Brembo type (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
BR-00703
A
BR-00018
B: INSTALLATION
Tightening torque:
Brake hose bracket
33 N·m (3.36 kgf-m, 24.3 ft-lb)
Caliper body assembly (17-inch type)
65 N·m (6.63 kgf-m, 47.9 ft-lb)
BR-00743 Caliper body assembly (15-inch type)
66 N·m (6.73 kgf-m, 48.7 ft-lb)
2) Adjust the parking brake. <Ref. to PB-8, AD-
JUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>
BR-26
Rear Disc Rotor

BRAKE
C: INSPECTION
1) Check the rear wheel bearing play and axle hub
runout before inspecting the disc rotor runout.
<Ref. to DS-26, 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 disc rotor runout exceeds the
limit, resurface the disc rotor. After grinding, check
the thickness of the disc rotor according to the pro-
cedure in step 4).
BR-00037
Disc rotor runout limit:

Brembo type
0.070 mm (0.0028 in)
Except for brembo type
0.050 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 A of the
disc rotor exceeds the service limit, replace with a
new disc rotor.
B
A
BR-00018
Disc rotor thickness A Disc rotor

Standard Limit
mm (in) diameter
Brembo type 20 (0.79) 18 (0.71) 316 (12.44)
Except for brembo 8.5
10 (0.39) 286 (11.26)
type (0.335)
BR-27
Rear Disc Brake Assembly

BRAKE
7. Rear Disc Brake Assembly 4) Remove the caliper mounting bolts.
A: REMOVAL
1. BREMBO TYPE
CAUTION:
Do not allow brake fluid to come in contact with
does, wash off with water and wipe away com-
pletely.
BR-00660
wheels.
2) Remove the union bolt and brake hose from the 5) Raise the caliper body, and then move it toward
caliper body. vehicle center to separate it from the support.
3) Remove the caliper body assembly. 6) Remove the brake pad, and then remove the
support from the housing.
NOTE:
Remove the support only when replacing the rotor
or support. It is not necessary to remove it when
servicing the caliper body.
body and the support.
CAUTION:
BR-00704 the brake hose connector.
4) Remove mud and foreign matter from the caliper B: INSTALLATION
body assembly.
CAUTION: 1. BREMBO TYPE
Be careful not to allow foreign matter to enter 1) Install the caliper body to the housing.
the brake hose connector. Tightening torque:
2. EXCEPT FOR brembo TYPE 65 N·m (6.63 kgf-m, 47.9 ft-lb)
CAUTION: 003602001) or grease contained in the pad kit to
Do not allow brake fluid to come in contact with the side of the pad.
does, wash off with water and wipe away com-
pletely.
wheels.
2) Remove the brake hose bracket.
3) Disconnect the brake hose.
BR-00784
BR-00662
BR-28

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book 329 ページ ２０１２年６月１２日 火曜日 午後２時４０分

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

TUMBLE GENERATOR TUMBLE GENERATOR

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

EB:DTC P2022 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

TUMBLE GENERATOR TUMBLE GENERATOR

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

EC:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

INTAKE OIL FLOW INTAKE OIL FLOW

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

ED:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

INTAKE OIL FLOW INTAKE OIL FLOW

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

EE:DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-

EXHAUST OIL FLOW EXHAUST OIL FLOW

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

EF:DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-

EXHAUST OIL FLOW EXHAUST OIL FLOW

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

EG:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

INTAKE OIL FLOW INTAKE OIL FLOW

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

EH:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

INTAKE OIL FLOW INTAKE OIL FLOW

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

EI: DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-

EXHAUST OIL FLOW EXHAUST OIL FLOW

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

EJ:DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIR-

EXHAUST OIL FLOW EXHAUST OIL FLOW

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

: TERMINAL No. OPTIONAL ARRANGEMENT

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A/F, OXYGEN SENSOR B220 FUSE B19 B83

: TERMINAL No. OPTIONAL ARRANGEMENT 28 29 30 31 32 33 34 35

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

: TERMINAL No. OPTIONAL ARRANGEMENT 1 2 3 4 5 6 7

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A/F, OXYGEN SENSOR FUSE

Step Check Yes No

Diagnostic Procedure with Diagnostic Trouble Code (DTC)

Step Check Yes No

book 329 ページ２０１２年６月１２日　火曜日　午後２時４０分