Page 1: Body Section
HVAC SYSTEM (AUTO A/C) (DIAGNOSTIC) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTIC) This service manual has been prepared to provide SUBARU service personnel SEAT BELT SYSTEM with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. LIGHTING SYSTEM...
Page 2 2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(H4SO) (DIAGNOSTIC) CRUISE CONTROL SYSTEM CC(H4DOTC) (DIAGNOSTIC) CRUISE CONTROL SYSTEM CC(H4DOTC 2.5) (DIAGNOSTIC) IMMOBILIZER (DIAGNOSTIC) G8080GE7...
Page 3: Table Of Contents
HVAC SYSTEM (HEATER, VENTILATOR AND A/C) Page General Description ..................2 Refrigerant Pressure with Manifold Gauge Set.........25 Refrigerant Recovery Procedure...............26 Refrigerant Charging Procedure ...............27 Refrigerant Leak Check ................30 Compressor Oil ..................31 Blower Motor Unit Assembly ..............32 Blower Resistor (Manual A/C Model) ............33 Heater Core....................34 Control Unit ....................35 Compressor....................36...
Page 4: General Description
General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 1. General Description A: SPECIFICATION 1. HEATER SYSTEM Item Specifications Condition • Mode selector switch: HEAT • Temperature control switch: FULL HOT • Temperature difference between hot water 5.0 kW (4,300 kcal/h, Heating capacity 17,062 BTU/h) or more and inlet air: 65°C (149°F)
Page 5 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) Item Specifications Motor type Magnet 2.5 L turbo model and turbo AT model for EC and Condenser fan (Sub fan) Power consumption 120 W at 12 V Other model than above: 70 W at 12 V Fan outer diameter 320 mm (12.6 in) Motor type...
Page 6 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) Item Specifications Type Corrugated fin (Sub cool type) Core face area 0.234 m (2.52 sq ft) Condenser Core thickness 16 mm (0.63 in) Radiation area 5.6 m (6.26 sq ft) Receiver drier Effective inner capacity 220 cm (13.42 cu in)
Page 7 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) B: COMPONENT 1. HEATER COOLING UNIT • LHD MODEL WITH AUTO A/C (19) (18) (19) (17) (20) (23) (21) (22) (15) (13) (12) (14) (16) (10) (11) AC-00358 Evaporator cover (10) Heater core (19) O-ring Mode actuator...
Page 8 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • RHD MODEL WITH AUTO A/C (22) (18) (21) (20) (20) (24) (23) (17) (19) (15) (13) (12) (14) (16) (10) (11) AC-00001 Evaporator cover (10) Heater core (19) Cooling unit pipe Mode actuator (11) Drain hose...
Page 9 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • LHD MODEL WITH MANUAL A/C (16) (15) (16) (14) (17) (20) (18) (19) (13) (11) (12) (10) AC-00359 Evaporator cover Heater core (17) Expansion valve Mode main lever (10) Drain hose (18) Evaporator Vent door lever...
Page 10 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • RHD MODEL WITH MANUAL A/C (20) (16) (19) (18) (18) (22) (21) (17) (15) (13) (12) (14) (10) (11) AC-00084 Evaporator cover (10) Heater core (19) Expansion valve Side rod (11) Drain hose (20) Evaporator...
Page 11 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 2. BLOWER MOTOR UNIT • LHD MODEL WITH AUTO A/C AC-00334 Upper case Link lever Lower case Air inlet select actuator Filter cover Blower motor ASSY Air inlet select link Cover AC-9...
Page 12 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • RHD MODEL WITH AUTO A/C AC-00332 Upper case Link lever Lower case Air inlet select actuator Filter cover Blower motor ASSY Air inlet select link Cover AC-10...
Page 13 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • LHD MODEL WITH MANUAL A/C AC-00209 Upper case Link rod Cover Air inlet select actuator Filter cover Lower case Air inlet select link Blower resistor Blower motor ASSY AC-11...
Page 14 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • RHD MODEL WITH MANUAL A/C AC-00085 Upper case Air inlet select link Cover Air inlet select actuator Filter cover Lower case Air inlet select lever Blower resister Blower motor ASSY AC-12...
Page 15 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 3. CONTROL UNIT • AUTO A/C MODEL AC-00210 Panel Control case (front) Control case (rear) Control dial Bulb Switch Control unit circuit AC-13...
Page 16 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • LHD MODEL WITH MANUAL A/C (11) (10) AC-00211 Panel A/C switch Mode control cable Temperature control dial Air inlet select switch (10) Temperature control cable Fan dial Rear defogger switch (11) Bulb Mode control dial Switch circuit board...
Page 17 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • RHD MODEL WITH MANUAL A/C (11) (10) AC-00333 Panel A/C switch Mode control cable Mode control dial Rear defogger switch (10) Temperature control cable Fan dial Air inlet select switch (11) Bulb Temperature control dial Switch circuit board...
Page 18 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 4. AIR CONDITIONING UNIT • LHD MODEL AC-00866 Condenser Compressor Tightening torque: N·m (kgf-m, ft-lb) High-pressure hose O-ring T1: 7.4 (0.75, 5.4) Low-pressure hose Triple pressure switch T2: 15 (1.5, 10.8) Pipe AC-16...
Page 19 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • RHD MODEL AC-00243 Condenser Compressor Tightening torque: N·m (kgf-m, ft-lb) High-pressure hose O-ring T1: 7.4 (0.75, 5.4) Low-pressure hose Triple pressure switch T2: 15 (1.5, 10.8) Pipe AC-17...
Page 20 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 5. COMPRESSOR AC-00335 Idler pulley bracket Compressor belt cover (Non-turbo Tightening torque: N·m (kgf-m, ft-lb) model) Idler pulley adjuster T1: 4.0 (0.40, 2.95) Idler pulley Compressor stay T2: 22.6 (2.3, 16.6) Compressor bracket T3: 23.0 (2.35, 17.0) Compressor T4: 28.9 (2.95, 21.3)
Page 21 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 6. HEATER DUCT AC-00212 Front defroster nozzle Side defroster duct (RH) Side ventilation duct (RH) Side defroster duct (LH) Side ventilation duct (LH) Rear heater duct AC-19...
Page 22 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) C: CAUTION 4. HANDLING OF REFRIGERANT • The refrigerant boils at approx. −30°C (−22°F). 1. HFC-134a A/C SYSTEM When handling it, be sure to wear safety goggles • The cooling system components for the HFC- and protective gloves.
Page 23 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 5. O-RING CONNECTIONS • Use compressor oil specified in the service man- ual to lubricate the O-rings. • Use new O-rings. Apply the oil to the top and sides of the O-rings be- •...
Page 24 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) Illustration Tools and Equipment Wrench Various WRENCHES will be required to service any A/C system. A 7 to 40 N·m (0.7 to 4.1 kgf-m, 5 to 30 ft-lb) torque wrench and various crow- foot wrenches will be needed.
Page 25 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) Illustration Tools and Equipment Syringe A graduated plastic SYRINGE will be needed to add oil back into the system. The syringe can be available at a pharmacy or a drug store. AC-00015 Vacuum pump A VACUUM PUMP (in good working condition) is necessary, and can be available at either a refrigerant supplier or an automotive equipment...
Page 26 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) Illustration Tools and Equipment Electronic leak detector An ELECTRONIC LEAK DETECTOR can be available at either a spe- cialty tool supplier or an A/C equipment supplier. AC-00019 Weight scale A WEIGHT SCALE such as an electronic charging scale or a bath- room scale with digital display will be needed, if a 13.6 kg (30 lb) refrig- erant container is used.
Page 27: Refrigerant Pressure With Manifold Gauge Set
Refrigerant Pressure with Manifold Gauge Set HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 2. Refrigerant Pressure with Manifold Gauge Set A: OPERATION 1) Place the vehicle in the shade and draftless condition. 2) Connect the manifold gauge set. 3) Open the front windows and close all doors. 4) Open the hood.
Page 28: Refrigerant Recovery Procedure
Refrigerant Recovery Procedure HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 3. Refrigerant Recovery Proce- 4) Install the low-/high-pressure hoses to the ser- vice ports on the low-/high-pressure sides of the dure vehicle respectively. A: OPERATION CAUTION: • During operation, be sure to wear safety gog- gles and protective gloves.
Page 29: Refrigerant Charging Procedure
Refrigerant Charging Procedure HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 4. Refrigerant Charging Proce- 2) Install the low-/high-pressure hoses to corre- sponding service ports on vehicle. dure A: OPERATION CAUTION: • During operation, be sure to wear safety gog- gles and protective gloves. •...
Page 30 Refrigerant Charging Procedure HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 6) Leave it at least 5 to 10 minutes after closing the 13) Loosen the center hose connection on manifold valves on low-/high-pressure sides, and then check gauge (if applicable, press a purge valve on mani- the low-pressure gauge reading for any changes.
Page 31 Refrigerant Charging Procedure HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 22) Set up the vehicle to the following status: • A/C switch ON • Engine running at 1,500 rpm • Blower speed setting to “HI” • Temperature setting to “MAX COOL” •...
Page 32: Refrigerant Leak Check
Refrigerant Leak Check HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 5. Refrigerant Leak Check CAUTION: Carefully check the external surface of hoses A: INSPECTION and tubes at approx. 25 mm (0.98 in) per sec- 1) Operate the A/C system for approx. 10 minutes, ond.
Page 33: Compressor Oil
Compressor Oil HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 6. Compressor Oil A: OPERATION NOTE: Before making repairs, conduct the oil return oper- ation to return the compressor oil in circulation with the refrigerant to the compressor. 1) Increase the engine speed to 1,500 rpm. 2) Turn ON the A/C switch.
Page 34: Blower Motor Unit Assembly
Blower Motor Unit Assembly HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 7. Blower Motor Unit Assembly B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. Refer to COMPONENT in General Descrip- 2) Remove the glove box.
Page 35: Blower Resistor (Manual A/C Model)
Blower Resistor (Manual A/C Model) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 8. Blower Resistor (Manual A/C Model) A: REMOVAL 1) Remove the glove box. <Ref. to EI-37, REMOV- AL, Glove Box.> 2) Disconnect the blower resistor connector. 3) Remove the two screws to remove blower resis- tor.
Page 36: Heater Core
Heater Core HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 9. Heater Core 6) Remove the screws to remove lower case. A: REMOVAL 1) Remove the heater cooling unit. <Ref. to AC-39, REMOVAL, Heater Cooling Unit.> 2) Remove the screws to remove the heater core pipe cover (RHD model).
Page 37: Control Unit
Control Unit HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 10.Control Unit 6) Insert the flat tip screwdriver to the position (A) and release the claw with pulling out the lower por- A: REMOVAL tion of center console panel. 1) Disconnect the ground cable from battery. CAUTION: 2) In case of manual A/C, remove the mode cable Do not insert the flat tip screwdriver into any...
Page 38: Compressor
Compressor HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 11.Compressor 9) Remove the bolts to remove compressor brack- A: INSPECTION 1. MAGNETIC CLUTCH CLEARANCE 1) Check the clearance of the entire circumference around the drive plate and pulley. Standard: 0.3 — 0.6 mm (0.0118 — 0.0236 in) 2.
Page 39: Condenser
Condenser HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 12.Condenser B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Using the refrigerant recovery system, discharge Replace the O-rings on hoses or pipes with new refrigerant. <Ref. to AC-26, OPERATION, Refriger- ones, and then apply compressor oil.
Page 40: Condenser (Sub Fan)
Condenser (Sub Fan) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 13.Condenser (Sub Fan) A: REMOVAL <Ref. to CO(H4SO)-35, REMOVAL, Radiator Main Fan and Fan Motor.> B: INSTALLATION <Ref. to CO(H4SO)-37, INSTALLATION, Radiator Main Fan and Fan Motor.> AC-38...
Page 41: Heater Cooling Unit
Heater Cooling Unit HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 14.Heater Cooling Unit A: REMOVAL 1) Disconnect the ground cable from battery. 2) Using the refrigerant recovery system, dis- charge refrigerant. <Ref. to AC-26, OPERATION, Refrigerant Recovery Procedure.> 3) Drain the engine coolant from radiator. 4) Remove the bolt securing expansion valve and pipe in engine compartment.
Page 42: Evaporator
Evaporator HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 15.Evaporator A: REMOVAL 1) Perform the refrigerant recovery operation, and then disconnect the toe board area A/C pipe. <Ref. to AC-26, OPERATION, Refrigerant Recovery Pro- cedure.> 2) Remove the glove box. 3) Remove blower motor unit assembly. <Ref. to AC-32, REMOVAL, Blower Motor Unit Assembly.>...
Page 43: Hose And Tube
Hose and Tube HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 16.Hose and Tube B: INSTALLATION CAUTION: A: REMOVAL • When disconnecting/connecting hoses, do CAUTION: not apply an excessive force to them. Confirm • When disconnecting/connecting hoses, do not that no torsion and excessive tension exists af- apply excessive force to them.
Page 44: Relay And Fuse
Relay and Fuse HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 17.Relay and Fuse B: INSPECTION A: LOCATION AC-00093 (1) — (2) Continuity exists. AC-00834 (3) — (4) Continuity exists. (1) Main fuse box (M/B) (3) — (5) No continuity. (2) Main fan relay While applying battery voltage between the termi- (3) Sub fan relay nals (1) and (2), check continuity between the ter-...
Page 45: Pressure Switch (Triple Pressure Switch)
Pressure Switch (Triple Pressure Switch) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 18.Pressure Switch (Triple Pres- sure Switch) A: INSPECTION 1) Connect the manifold gauge to the service valve on the high-pressure side. 2) Remove the pressure switch harness connector. Using a circuit tester, inspect the ON-OFF opera- tion of the pressure switch.
Page 46: Ambient Sensor (Auto A/C Model)
Ambient Sensor (Auto A/C Model) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 19.Ambient Sensor (Auto A/C Model) A: REMOVAL 1) Open the front hood. 2) Disconnect the ground cable from battery. 3) Disconnect the ambient sensor connector. 4) Remove the ambient sensor from radiator lower panel.
Page 47: Sunload Sensor (Auto A/C Model)
Sunload Sensor (Auto A/C Model) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 20.Sunload Sensor (Auto A/C Model) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the sunload sensor connector. AC-00126 CAUTION: Be careful not to damage the sensors and inte- rior trims when removing them.
Page 48: Air Vent Grille
Air Vent Grille HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 21.Air Vent Grille A: REMOVAL 1. CENTER GRILLE 1) Disconnect the ground cable from battery. 2) Remove the center console panel. <Ref. to EI- 40, REMOVAL, Instrument Panel Assembly.> 3) Loosen the two screws to remove the center air vent grille.
Page 49: Heater Duct
Heater Duct HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 22.Heater Duct A: REMOVAL 1) Remove the front seat. <Ref. to SE-6, REMOV- AL, Front Seat.> 2) Remove the front side sill cover. 3) Pull off the floor mat, remove the cover, and then remove the heater duct.
Page 50: Heater Vent Duct
Heater Vent Duct HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 23.Heater Vent Duct A: REMOVAL 1) Remove the instrument panel. <Ref. to EI-40, REMOVAL, Instrument Panel Assembly.> 2) Remove the screws. 3) Remove the heater vent duct. AC-00224 B: INSTALLATION Install in the reverse order of removal. AC-48...
Page 51: Heater Cock Solenoid Valve
Heater Cock Solenoid Valve HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 24.Heater Cock Solenoid Valve C: INSPECTION 1) Remove the heater cock solenoid valve. <Ref. to A: REMOVAL AC-49, REMOVAL, Heater Cock Solenoid Valve.> 1) Drain the engine coolant. 2) Connect the positive terminal of battery to No. 1 <Ref.
Page 52: General Diagnostics
General Diagnostics HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 25.General Diagnostics A: INSPECTION Symptom Repair order Fuse Blower motor relay Wiring harness Does not run. Blower motor Blower motor Blower motor resistor (Manual A/C model) Blower switch Noise Blower motor Refrigerant Fuse A/C relay Wiring harness...
Page 53 General Diagnostics HVAC SYSTEM (HEATER, VENTILATOR AND A/C) Symptom Repair order Wiring harness Air mix actuator (Auto A/C), Temperature control cable (Manual Temperature of air from vents does not change. A/C) Temperature adjustment switch Wiring harness Unable to switch blow vents. Mode actuator (Auto A/C), Mode control cable (Manual A/C) Mode switch Wiring harness...
Page 54 General Diagnostics HVAC SYSTEM (HEATER, VENTILATOR AND A/C) AC-52...
Page 55 HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Page Basic Diagnostics Procedure ..............2 General Description ..................3 Electrical Component Location ..............5 Auto A/C Control Module I/O Signal............7 Diagnostic Chart for Self-Diagnosis ............9 Diagnostics for A/C System Malfunction ...........12 Diagnostic Procedure for Actuators ............21 Diagnostic Procedure for Sensors ............32 General Diagnostic Table................41...
Page 56: Basic Diagnostics Procedure
Basic Diagnostics Procedure HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 1. Basic Diagnostics Procedure A: PROCEDURE Step Check START INSPECTIONS. Does the self-diagnosis oper- Go to step 2. <Ref. to AC-12, A/ 1) Perform the pre-inspection. <Ref. to AC-3, ate? C OR SELF-DIAG- INSPECTION, General Description.>...
Page 57: General Description
General Description HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 2. General Description 5) Approach a strip of paper (b) in front of the in-ve- hicle sensor suction port (a) located in the instru- A: CAUTION ment lower cover, and check that air is being 1) Never connect the battery in reverse polarity.
Page 58: Control Switches
General Description HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 5. CONTROL SWITCHES Start and warm-up the engine completely. 1) Inspection using switches Point to check Switch operation Judgment standard Fan speed changes 1st → 2nd → 3rd → 4th Fan speed control dial Turn the fan speed control dial clockwise. as dial turn.
Page 59: Electrical Component Location
Electrical Component Location HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 3. Electrical Component Location A: LOCATION 1. ENGINE COMPARTMENT AC-00097 A/C compressor Pressure switch Ambient sensor A/C relay AC-5...
Page 60 Electrical Component Location HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 2. PASSENGER COMPARTMENT AC-00098 Mode door actuator Intake door actuator Air mix door actuator In-vehicle sensor Blower motor Sunload sensor Evaporator sensor AC-6...
Page 61: Auto A/C Control Module I/O Signal
Auto A/C Control Module I/O Signal HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 4. Auto A/C Control Module I/O Signal A: ELECTRICAL SPECIFICATION AC-00099 Specified Terminal No. Content Measuring condition value Changes outlet from VENT to DEF. Mode door actuator power supply Changes outlet from DEF to VENT. Changes air mix door from COOL to HOT.
Page 62 Auto A/C Control Module I/O Signal HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Specified Terminal No. Content Measuring condition value Combination meter (ambient temperature sig- nal) VENT, BI-LEVEL, HEAT Mode door actuator position detection signal Outlet DEF/HEAT, DEF VENT, DEF/HEAT Mode door actuator position detection signal Outlet BI-LEVEL, HEAT, DEF A/C: ON...
Page 63: Diagnostic Chart For Self-Diagnosis
Diagnostic Chart for Self-Diagnosis HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 5. Diagnostic Chart for Self-Diagnosis A: OPERATION AC-00250 Temperature control dial A/C switch Rear window defogger switch OFF/BRIGHT switch Defroster switch FRESH/RECIRC switch AUTO switch Air flow control switch Fan speed control dial A / C AUTO FRESH / RECIRC...
Page 64 Diagnostic Chart for Self-Diagnosis HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check SELECT CONTROL PANEL TO SELF-DIAG- Does the self-diagnosis mode Go to step 2. <Ref. to AC-12, A/ NOSIS MODE. operate? C OR SELF-DIAG- 1) Turn the ignition switch to OFF. NOSIS SYS- 2) Start the engine while pressing defroster TEMS DO NOT...
Page 65 Diagnostic Chart for Self-Diagnosis HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 1. SENSOR CHECK TABLE NOTE: When the sunload sensor is checked indoors or in the shade, open circuit might be indicated. Always check the sunload sensor at a place where sun shines directly on it. Present Stored Open circuit...
Page 66: Diagnostics For A/C System Malfunction
Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 6. Diagnostics for A/C System Malfunction A: A/C OR SELF-DIAGNOSIS SYSTEMS DO NOT OPERATE TROUBLE SYMPTOM: • Switch LEDs are faulty and switches do not operate. • Self-diagnosis system does not operate. WIRING DIAGRAM: IGNITION BATTERY...
Page 67 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK FUSE. Is the fuse blown-out? Replace the fuse. Go to step 2. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 2 from main fuse box. 3) Check the condition of fuse.
Page 68 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) B: BLOWER FAN DOES NOT ROTATE. TROUBLE SYMPTOM: • Blower motor does not rotate. • Blower motor does not change. WIRING DIAGRAM: BATTERY F/B NO.1 SBF-3 SBF-1 F/B NO.2 IGNITION SWITCH F/B NO.17 SBF-4 BLOWER...
Page 69 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK FUSE. Is any fuse blown-out? Replace the fuse. Go to step 2. 1) Remove the fuse No. 1, 2 and 17 from fuse & relay box. 2) Check the condition of fuse. CHECK POWER SUPPLY FOR BLOWER Is the voltage more than 8 V (at Go to step 3.
Page 70 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) C: COMPARTMENT TEMPERATURE DOES NOT CHANGE, OR A/C SYSTEM DOES NOT RESPOND PROMPTLY. TROUBLE SYMPTOM: • Compartment temperature is not changed. (No cool air is discharged.) • A/C system does not respond quickly. WIRING DIAGRAM: •...
Page 71 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) • RHD model IGNITION BATTERY A/C RELAY HOLDER SWITCH F/B NO.17 SBF-4 SBF-1 SUB FAN FUSE F/B NO.18 MAIN FAN FUSE MAIN FAN MOTOR FAN RELAY MAIN FAN MOTOR FAN MODE RELAY SUB FAN MOTOR FAN RELAY SUB FAN MOTOR...
Page 72 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK FUSE. Is the fuse blown out? Replace the fuse. Go to step 2. 1) Turn the ignition switch to OFF. 2) Remove the main fan fuse and sub fan fuse in main fuse box.
Page 73 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK OPERATION OF MAIN FAN MOTOR. Does the main fan motor oper- Go to step 14. Go to step 10. 1) Start the engine and turn the A/C switch to ate normally? 2) Check the operation of main fan motor.
Page 74 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK POWER SUPPLY TO SUB FAN MO- Is the voltage more than 10 V? Go to step 16. Repair the har- TOR. ness for sub fan motor power sup- CAUTION: ply circuit.
Page 75: Diagnostic Procedure For Actuators
Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 7. Diagnostic Procedure for Actuators A: INTAKE DOOR ACTUATOR TROUBLE SYMPTOM: FRESH/RECIRC mode is not changed. WIRING DIAGRAM: IGNITION BATTERY SWITCH F/B NO.17 SBF-4 SBF-1 AUTO A/C CONTROL MODULE B202 : B201 : : LHD MODEL : RHD MODEL : LHD MODEL : 2...
Page 76 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK POWER SUPPLY FOR INTAKE Is the voltage 7 V (at normal Go to step 2. Check open or DOOR ACTUATOR. temperature)? short circuit in har- 1) Turn the ignition switch to OFF. ness between 2) Disconnect the intake door actuator con- intake door actua-...
Page 77 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) B: MODE DOOR ACTUATOR TROUBLE SYMPTOM: Air flow outlet is not changed. WIRING DIAGRAM: AUTO A/C CONTROL MODULE B202 : LHD MODEL : RHD MODEL MODE ACTUATOR B202 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 8 9 10 11...
Page 78 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK POWER SUPPLY FOR AUTO A/C Is the voltage more than 12 V? Go to step 2. Replace the auto CONTROL MODULE SIDE. A/C control mod- 1) Turn the ignition switch to ON. ule.
Page 79 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK AUTO A/C CONTROL MODULE SIG- Is the voltage 5 V when HEAT, Go to step 9. Go to step 7. NAL VOLTAGE. D/H, DEF position and 0 V 1) Turn the ignition switch to ON. when VENT, BI-LEVEL posi- 2) Turn the mode control dial and measure tion?
Page 80 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK HARNESS BETWEEN AUTO A/C Is the resistance less than 1 Replace the auto Repair the har- Ω? CONTROL MODULE AND MODE DOOR AC- A/C control mod- ness between auto TUATOR.
Page 81 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK AUTO A/C CONTROL MODULE SIG- Is the voltage 5 V? Go to step 18. Go to step 17. NAL POWER SUPPLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from mode door actuator.
Page 82 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) C: AIR MIX DOOR ACTUATOR TROUBLE SYMPTOM: Outlet air temperature does not change. WIRING DIAGRAM: • LHD model AUTO A/C CONTROL MODULE AIR MIX DOOR ACTUATOR 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 3 4 5 6 9 10 11 12 13 14 15 16...
Page 83 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) • RHD model AUTO A/C CONTROL MODULE B202 B293 AIR MIX DOOR ACTUATOR B293 B202 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 8 9 10 11 3 4 5 6 9 10 11 12 13 14 15 16...
Page 84 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK POWER SUPPLY FOR AIR MIX Is the voltage approx. 5 V? Go to step 2. Replace the auto DOOR ACTUATOR POSITION SWITCH. A/C control mod- 1) Turn the ignition switch to OFF. ule.
Page 85 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK AIR MIX DOOR ACTUATOR POSI- Does the voltage change Go to step 6. Replace the air TION SWITCH SIGNAL. between 0.5 (Max. HOT) — 4.5 mix door actuator. 1) Connect the connector of auto A/C control (Max.
Page 86: Diagnostic Procedure For Sensors
Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 8. Diagnostic Procedure for Sensors A: AMBIENT SENSOR TROUBLE SYMPTOM: • Fan speed is not switched when the fan speed control dial is in AUTO position. • Malfunction related to ambient sensor is indicated in self diagnosis. WIRING DIAGRAM: •...
Page 87 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) • RHD model COMBINATION METER AMBIENT SENSOR B202 B100 : MT MODEL : AT MODEL AUTO A/C CONTROL MODULE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30...
Page 88 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 2. Repair the har- Ω? AUTO A/C CONTROL MODULE AND COM- ness between auto BINATION METER. A/C control mod- 1) Turn the ignition switch to OFF.
Page 89 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) B: IN-VEHICLE SENSOR TROUBLE SYMPTOM: • Blower fan speed, outlet port and inlet port do not change after turning the AUTO switch to ON. • Malfunction related to ambient sensor is indicated in self diagnosis. WIRING DIAGRAM: i55 : B314 :...
Page 90 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK IN-VEHICLE SENSOR. Is the resistance approx. 2.7 Go to step 2. Replace the in- 1) Turn the ignition switch to OFF. kΩ at 20°C (68°F)? vehicle sensor. 2) Remove the instrument panel lower cover. 3) Disconnect the connector from in-vehicle sensor.
Page 91 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) C: EVAPORATOR SENSOR WIRING DIAGRAM: B256 EVAPORATOR SENSOR B202 : LHD MODEL : RHD MODEL AUTO A/C CONTROL MODULE B256 B202 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16...
Page 92 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK EVAPORATOR SENSOR. Is the resistance approx. 2.7 Go to step 2. Replace the evap- 1) Turn the ignition switch to OFF. kΩ at 20°C (68°F)? orator sensor. 2) Remove the glove box. 3) Disconnect the connector from evaporator sensor.
Page 93 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) D: SUNLOAD SENSOR TROUBLE SYMPTOM: • Sensor identifies that sunlight is at maximum. Then, A/C system is controlled to COOL side. • Sensor identifies that sunlight is at minimum. Then, A/C system is controlled to HOT side. NOTE: When the sunload sensor check is conducted indoors or in the shade, open circuit might be indicated.
Page 94 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) Step Check CHECK POWER SUPPLY VOLTAGE FOR Is the voltage approx. 5 V? Go to step 4. Go to step 2. SUNLOAD SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from sunload sensor.
Page 95: General Diagnostic Table
General Diagnostic Table HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) 9. General Diagnostic Table A: INSPECTION Symptom Problem parts • Fuse • Connector (Poor contact) • Ground • Auto A/C control module A/C system fails to operate. • Blower fan motor • Blower fan relay •...
Page 96 General Diagnostic Table HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC) AC-42...
Page 97 AIRBAG SYSTEM Page General Description ..................2 Airbag Connector ..................9 Inspection Locations After a Collision ............12 Driver’s Airbag Module................14 Passenger’s Airbag Module ..............15 Side Airbag Module...................16 Airbag Control Module ................18 Side Airbag Sensor ...................19 Roll Connector ..................20 Front Sub Sensor ..................21 Airbag Module Disposal (Deployment Processing On Vehicle) ....22 Disposal of Airbag Module (Deploying After Removal from Vehicle) ..26...
Page 98: General Description
General Description AIRBAG SYSTEM 1. General Description A: COMPONENT 1. SRS AIRBAG (11) (10) AB-00685 Combination switch ASSY with roll Airbag control module Tightening torque: N·m (kgf-m, ft-lb) connector Side airbag sensor T1: 5.9 (0.59, 4.4) ® Wiring harness rear T2: 7.4 (0.75, 5.4) TORX bolt T30...
Page 99 General Description AIRBAG SYSTEM B: CAUTION • When checking, use a test harness (1). Do not directly apply the tester probe to any connector ter- • When servicing a vehicle, be sure to turn the ig- minal of the airbag. Damage to the connector termi- nition switch to OFF, disconnect the ground cable nal may cause the airbag to activate erroneously.
Page 100 General Description AIRBAG SYSTEM • Do not drop the airbag modulator parts, subject • Do not allow water or oil to come in contact with them to high temperature over 93°C (199°F), or let the connector terminals. Do not touch the connec- water, oil, or grease get on them;...
Page 101 General Description AIRBAG SYSTEM • When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wire harness of the airbag system.
Page 102 General Description AIRBAG SYSTEM • When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result.
Page 103 General Description AIRBAG SYSTEM C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FC030 DEPLOYMENT • Used for deploying the side airbag module. ADAPTER A • Used with DEPLOYMENT TOOL (98299PA030). ST98299FC030 98299SA010 TEST HARNESS • Used for deploying the driver’s airbag module ADAPTER D and seat belt pretensioner.
Page 104 General Description AIRBAG SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299PA030 DEPLOYMENT • Used for deploying the airbag module. TOOL • Used with DEPLOYMENT ADAPTER A (98299FC030). ST98299PA030 2. GENERAL TOOL TOOL NAME REMARKS ® Used for removal/installation of driver’s airbag module. TORX AB-8...
Page 105: Airbag Connector
Airbag Connector AIRBAG SYSTEM 2. Airbag Connector 2. DRIVER’S AIRBAG (BETWEEN AIRBAG HARNESS AND ROLL CONNECTOR), PAS- A: OPERATION SENGER’S AIRBAG AND SIDE AIRBAG 1. POWER SUPPLY 1) How to disconnect: (1) Push the lock arm (A). 1) How to disconnect: (2) With the lock arm (A) pushed in, move the (1) Move the slide lock (A) in the direction of ar- slide lock (B) in the direction of arrow.
Page 106 Airbag Connector AIRBAG SYSTEM 3. DRIVER’S AIRBAG MODULE AND PRE- 4. FRONT SUB-SENSOR AND SIDE AIR- TENSIONER BAG SENSOR 1) How to disconnect: 1) How to disconnect: (1) Using a flat tip screwdriver, pry the push Holding outer part (A), pull it in the direction of ar- lock upward to unlock.
Page 107 Airbag Connector AIRBAG SYSTEM (2) With the slide lock pushed, pull the connec- (2) Pull the connector to disconnect from lap tor in the direction of arrow and disconnect it. seat belt pretensioner. AB-00022 AB-00026 CAUTION: CAUTION: When pulling, be sure to hold onto the connec- When pulling, be sure to hold onto the connec- tor and not the wire.
Page 108: Inspection Locations After A Collision
Inspection Locations After a Collision AIRBAG SYSTEM 3. Inspection Locations After a • The clearance between the driver’s airbag mod- ule and steering wheel is not constant. Collision • The steering wheel deformation in axial and radi- al directions exceed limits. A: REPLACEMENT When airbag system is deployed, replace the fol- Specifications:...
Page 109 Inspection Locations After a Collision AIRBAG SYSTEM 5. FRONT SUB SENSOR 8. STEERING SHAFT If the front section of vehicle as shown in the figure Check for the following, and replace damaged is damaged: parts with new ones. • Overall length of steering column should be with- in specifications.
Page 110: Driver's Airbag Module
Driver’s Airbag Module AIRBAG SYSTEM 4. Driver’s Airbag Module B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: CAUTION: Do not allow harness and connectors to inter- Refer to “CAUTION” in General Description be- fere or get tangled up with other parts. fore handing the airbag module.
Page 111: Passenger's Airbag Module
Passenger’s Airbag Module AIRBAG SYSTEM 5. Passenger’s Airbag Module A: REMOVAL CAUTION: Refer to “CAUTION” in General Description be- fore handing the airbag module. <Ref. to AB-3, CAUTION, General Description.> 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work.
Page 112: Side Airbag Module
Side Airbag Module AIRBAG SYSTEM 6. Side Airbag Module 7) Remove the side airbag module (A) from back- rest frame assembly. A: REMOVAL CAUTION: Before working on the airbag module, refer to the “CAUTION” in General Description. <Ref. to AB-3, CAUTION, General Description.> NOTE: Remove the passenger’s side by referring to driv- er’s side.
Page 113 Side Airbag Module AIRBAG SYSTEM 3) Install the side airbag harness to backrest frame C: INSPECTION assembly. CAUTION: NOTE: Before working on the airbag module, refer to Secure the harness to its original position of seat. the “CAUTION” in General Description. <Ref. to AB-3, CAUTION, General Description.>...
Page 114: Airbag Control Module
Airbag Control Module AIRBAG SYSTEM 7. Airbag Control Module A: REMOVAL CAUTION: • Do not disassemble the airbag control mod- ule. • If the airbag control module is deformed or if water damage is suspected, replace the airbag control module with a new part. •...
Page 115: Side Airbag Sensor
Side Airbag Sensor AIRBAG SYSTEM 8. Side Airbag Sensor A: REMOVAL 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3) Remove the outer belt (FRONT). <Ref. to SB- 10, FRONT OUTER BELT, REMOVAL, Front Seat Belt.>...
Page 116: Roll Connector
Roll Connector AIRBAG SYSTEM 9. Roll Connector A: REMOVAL 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3) Remove the driver’s airbag module. <Ref. to AB- 14, Driver’s Airbag Module.>...
Page 117: Front Sub Sensor
Front Sub Sensor AIRBAG SYSTEM 10.Front Sub Sensor A: REMOVAL 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3) Remove the front grille and front grille side. <Ref.
Page 118: Airbag Module Disposal (Deployment Processing On Vehicle)
(Tool number 98299PA030) • If circumstances do not permit the airbag (B) Deployment adapter A: module deployment, contact the SUBARU deal- (Tool number 98299SA030) 7) Connect the deployment adapter A to airbag 1. DRIVER’S AIRBAG MODULE connector (AB30).
Page 119 Airbag Module Disposal (Deployment Processing On Vehicle) AIRBAG SYSTEM 8) Extend the wiring of deployment tool to the limit, 2. PASSENGER’S AIRBAG MODULE and make sure that the vehicle is empty. Close all 1) Turn the ignition switch to OFF. the windows, sunroof and rear gate completely.
Page 120 Airbag Module Disposal (Deployment Processing On Vehicle) AIRBAG SYSTEM 8) Extend the wiring of deployment tool to the limit, 3. SIDE AIRBAG MODULE and make sure that the vehicle is empty. Close all 1) Turn the ignition switch to OFF. the windows, sunroof and rear gate completely.
Page 121 Airbag Module Disposal (Deployment Processing On Vehicle) AIRBAG SYSTEM 8) Extend the wiring of deployment tool to the limit, and make sure that the vehicle is empty. Close all the windows, sunroof and rear gate completely. SB-00017 9) Move the battery at least 5 m (16 ft) from vehicle, and secure the nearby area.
Page 122: Disposal Of Airbag Module (Deploying After Removal From Vehicle)
• If circumstances do not permit the airbag module deployment, contact the SUBARU deal- 1. DRIVER’S AIRBAG MODULE 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work.
Page 123 Disposal of Airbag Module (Deploying After Removal from Vehicle) AIRBAG SYSTEM 9) Install the airbag module with pad side facing up- 12) Connect the other cable of deployment tool to ward on a wheel with tire. the battery positive (+) terminal, and deploy the air- bag module.
Page 124 Disposal of Airbag Module (Deploying After Removal from Vehicle) AIRBAG SYSTEM 5) Short the terminal to alligator clip furnished as 10) Move the battery at least 5 m (16 ft) from vehi- deployment tool (A) cle, and secure the nearby area. Connect the de- ployment tool alligator clip to the battery negative (−...
Page 125 Disposal of Airbag Module (Deploying After Removal from Vehicle) AIRBAG SYSTEM 3. SIDE AIRBAG MODULE 9) Install the airbag module on 14-inch or greater size tire without wheel. 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work.
Page 126 Disposal of Airbag Module (Deploying After Removal from Vehicle) AIRBAG SYSTEM 12) Connect the other cable of deployment tool to the battery positive (+) terminal, and deploy the air- bag module. SB-00018 CAUTION: • After deployment, the airbag module will be especially hot, leave it unattended for 40 min- utes, and discard it.
Page 127 AIRBAG SYSTEM (DIAGNOSTIC) Page Basic Diagnostic Procedure ................2 Check List for Interview................3 General Description ..................4 Electrical Components Location..............19 Airbag Control Module I/O Signal..............21 Airbag Connector ..................27 Airbag Warning Light Illumination Pattern..........30 Read Diagnostic Trouble Code (DTC) ............31 Inspection Mode..................32 Clear Memory Mode..................33 Airbag Warning Light Failure..............34 List of Diagnostic Trouble Code (DTC) .............43 Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....46...
Page 128: Basic Diagnostic Procedure
Basic Diagnostic Procedure AIRBAG SYSTEM (DIAGNOSTIC) 1. Basic Diagnostic Procedure A: PROCEDURE Step Check READ DTC. Is the normal code detected? Finish the diagno- Go to step 2. <Ref. to AB-31, Read Diagnostic Trouble Code sis. (DTC).> READ DTC. Is DTC displayed? Go to step 3.
Page 129: Check List For Interview
Check List for Interview AIRBAG SYSTEM (DIAGNOSTIC) 2. Check List for Interview A: CHECK Customer’s Name Inspector’s Name Date Vehicle Brought In Registration No. Odometer Reading miles Date Problem Occurred Registration Year ❏ Fine ❏ Cloudy ❏ Rainy ❏ Snowy ❏...
Page 130: General Description
General Description AIRBAG SYSTEM (DIAGNOSTIC) 3. General Description • When checking, use a test harness. Do not di- rectly apply the tester probe to any connector termi- A: CAUTION nal of the airbag. • When servicing a vehicle, be sure to turn the ig- nition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work.
Page 131 General Description AIRBAG SYSTEM (DIAGNOSTIC) • If any damage, opening, or rust is found on the • Either of the airbag modules for driver, passen- airbag system wiring harness, do not attempt to re- ger or side, or pretensioner must not be disassem- pair using soldering equipment.
Page 132 General Description AIRBAG SYSTEM (DIAGNOSTIC) • The removed front seat with the airbag module must be kept at least 200 mm (8 in) away from walls and other objects. AB-00128 (1) More than 200 mm (8 in) • When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, re- move the front sub sensors and wire harness of the...
Page 133 General Description AIRBAG SYSTEM (DIAGNOSTIC) • When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result.
Page 134 General Description AIRBAG SYSTEM (DIAGNOSTIC) B: INSPECTION Before diagnosing, check the following items that might be related to the engine problem: 1. BATTERY Measure the battery voltage and specific gravity of electrolyte. Standard voltage: 12 V Specific gravity: Above 1.260 C: PREPARATION TOOL 1.
Page 135 General Description AIRBAG SYSTEM (DIAGNOSTIC) • TEST HARNESS F ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FC010 TEST HARNESS F Used when measuring voltage, resistance of air- bag module harness. ST98299FC010 3 4 5 6 AB-00719 AB-9...
Page 136 General Description AIRBAG SYSTEM (DIAGNOSTIC) • TEST HARNESS G ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FC020 TEST HARNESS G Used when measuring voltage, resistance of side airbag sensor. ST98299FC020 4 5 6 7 8 AB-00428 AB-10...
Page 137 General Description AIRBAG SYSTEM (DIAGNOSTIC) • TEST HARNESS H ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FA030 TEST HARNESS H Used when measuring voltage, resistance of front sub-sensor. ST98299FA030 3 4 5 6 AB-00720 AB-11...
Page 138 General Description AIRBAG SYSTEM (DIAGNOSTIC) • TEST HARNESS L ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FE000 TEST HARNESS L Used when measuring voltage, resistance of seat belt pretensioner. ST98299FE000 AB-00430 AB-12...
Page 139 General Description AIRBAG SYSTEM (DIAGNOSTIC) • TEST HARNESS R ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FE030 TEST HARNESS R Used when measuring voltage, resistance of air- bag control module. ST98299FE030 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 5 6 7...
Page 140 General Description AIRBAG SYSTEM (DIAGNOSTIC) • TEST HARNESS P ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299SA020 TEST HARNESS P Used when measuring voltage, resistance of driver’s airbag module harness and passenger airbag module harness. ST98299SA020 AB-00679 AB-14...
Page 141 General Description AIRBAG SYSTEM (DIAGNOSTIC) • TEST HARNESS N ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299SA000 TEST HARNESS N Used when measuring voltage, resistance of driver’s airbag module and seat belt preten- sioner. ST98299SA000 AB-00675 AB-15...
Page 142 General Description AIRBAG SYSTEM (DIAGNOSTIC) • TEST HARNESS T ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299SA060 TEST HARNESS T • Used when measuring voltage, resistance of airbag system. • Used with test harness M (98299FE020). ST98299SA060 3 4 5 6 AB-00607 AB-16...
Page 143 General Description AIRBAG SYSTEM (DIAGNOSTIC) • TEST HARNESS Q ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299SA040 TEST HARNESS Q Used when measuring voltage, resistance of driver’s airbag module. ST98299SA040 AB-00678 AB-17...
Page 144 General Description AIRBAG SYSTEM (DIAGNOSTIC) • AIRBAG RESISTOR ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299PA040 AIRBAG RESISTOR Used in replacement of airbag module which resistance value is same as airbag module. ST98299PA040 AB-00433 AB-18...
Page 145: Electrical Components Location
Electrical Components Location AIRBAG SYSTEM (DIAGNOSTIC) 4. Electrical Components Location A: LOCATION 1. LHD MODEL AB18 AB15 AB14 AB13 AB21 AB26 (10) (11) AB20 AB11 AB19 AB10 AB12 (14) (15) (12) (13) AB-00737 To body harness To seat belt pretensioner (LH) To seat belt pretensioner (RH) Front sub sensor (LH) Passenger’s airbag inflator...
Page 146 Electrical Components Location AIRBAG SYSTEM (DIAGNOSTIC) 2. RHD MODEL AB18 AB15 AB14 AB13 AB21 AB26 (11) (10) AB25 (16) AB19 AB11 AB20 AB10 AB12 (13) (12) (14) (15) AB-00738 To body harness To seat belt pretensioner (LH) To seat belt pretensioner (RH) Front sub sensor (LH) Passenger’s airbag inflator (13)
Page 147: Airbag Control Module I/O Signal
Airbag Control Module I/O Signal AIRBAG SYSTEM (DIAGNOSTIC) 5. Airbag Control Module I/O Signal A: WIRING DIAGRAM 1. LHD MODEL TO POWER SUPPLY ROUTING FB-33 FB-20 FB-21 F/B FUSE No. 14 IGNITION RELAY F/B FUSE No. 11 F/B FUSE No. 6 (IG) (IG) (IG)
Page 148 Airbag Control Module I/O Signal AIRBAG SYSTEM (DIAGNOSTIC) FRONT SUB SENSOR LH FRONT SUB SENSOR RH AB18 AB15 AB14 AB13 AIRBAG CONTROL MODULE AB21 AB26 STEERING ROLL CONNECTOR GAB-1 INFLATOR (DRIVER SIDE) INFLATOR (PASSENGER SIDE) (YELLOW) (YELLOW) AB13 (YELLOW) (BLACK) AB15 (YELLOW) (YELLOW)
Page 149 Airbag Control Module I/O Signal AIRBAG SYSTEM (DIAGNOSTIC) AIRBAG CONTROL MODULE AB19 AB10 AB12 AB11 AB20 PRETENSIONER SIDE AIR BAG SIDE AIR BAG PRETENSIONER SENSOR LH SENSOR RH INFLATOR INFLATOR (SIDE LH) (SIDE RH) (YELLOW) AB11 (YELLOW) AB10 (YELLOW) (YELLOW) (YELLOW) (YELLOW) AB19...
Page 150 Airbag Control Module I/O Signal AIRBAG SYSTEM (DIAGNOSTIC) 2. RHD MODEL TO POWER SUPPLY ROUTING FB-36 FB-20 FB-21 F/B FUSE No. 14 IGNITION RELAY F/B FUSE No. 11 F/B FUSE No. 6 (IG) (IG) (IG) (IG) COMBINATION METER CHECK CONNECTOR AIRBAG WARNING LED LIGHT AIRBAG...
Page 151 Airbag Control Module I/O Signal AIRBAG SYSTEM (DIAGNOSTIC) FRONT SUB SENSOR LH FRONT SUB SENSOR RH AB18 AB15 AB14 AB13 AIRBAG CONTROL MODULE AB21 AB26 STEERING ROLL CONNECTOR INFLATOR (DRIVER SIDE) INFLATOR (PASSENGER SIDE) (YELLOW) (YELLOW) AB13 (YELLOW) (BLACK) AB15 (YELLOW) (YELLOW) AB21...
Page 152 Airbag Control Module I/O Signal AIRBAG SYSTEM (DIAGNOSTIC) AIRBAG CONTROL MODULE AB19 AB10 AB12 AB11 AB25 AB20 PRETENSIONER SIDE AIRBAG SIDE AIRBAG PRETENSIONER SENSOR LH SENSOR RH SEAT BELT INFLATOR INFLATOR PRETENSIONER (SIDE LH) (SIDE RH) (YELLOW) AB25 (YELLOW) AB10 (YELLOW) (YELLOW) (YELLOW)
Page 153: Airbag Connector
Airbag Connector AIRBAG SYSTEM (DIAGNOSTIC) 6. Airbag Connector 2. DRIVER’S AIRBAG (AIRBAG MAIN HAR- NESS AND ROLL CONNECTOR), SIDE AIR- A: OPERATION BAG AND PRETENSIONER 1. POWER SUPPLY 1) How to disconnect: (1) Push the lock arm (A). 1) How to disconnect: (2) With the lock arm (A) pushed in, move the (1) Move the slide lock (A) in the direction of the slide lock (B) in the direction of the arrow.
Page 154 Airbag Connector AIRBAG SYSTEM (DIAGNOSTIC) 3. DRIVER’S AIRBAG, PRETENSIONER 4. PASSENGER’S AIRBAG 1) How to disconnect: 1) How to disconnect: (1) Using a flat tip screwdriver, pry the push (1) Push the lock arm (A). lock upward to unlock. (2) With the lock arm (A) pushed in, pull the connector in direction of arrow to separate.
Page 155 Airbag Connector AIRBAG SYSTEM (DIAGNOSTIC) 5. FRONT SUB-SENSOR AND SIDE AIR- 6. LAP PRETENSIONER BAG SENSOR 1) How to disconnect: 1) How to disconnect: (1) Using a flat tip screwdriver, pry the push lock (A) upward to unlock. Holding outer part (A), pull it in the direction of the arrow.
Page 156: Airbag Warning Light Illumination Pattern
Airbag Warning Light Illumination Pattern AIRBAG SYSTEM (DIAGNOSTIC) 7. Airbag Warning Light Illumi- nation Pattern A: INSPECTION Keep the ignition switch to ON, and confirm that the airbag warning light remains off approx. 6 seconds after being turned on. AB-00135 (1) Airbag warning light (2) Approx.
Page 157: Read Diagnostic Trouble Code (Dtc)
Read Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) 8. Read Diagnostic Trouble 3) Read the DTC by identifying the way airbag warning light flashes. Code (DTC) The airbag warning light flashes a code corre- sponding to the faulty parts. A: OPERATION The long segment (1.2 sec on) indicates a “ten”, 1) Turn the ignition switch to ON.
Page 158: Inspection Mode
Inspection Mode AIRBAG SYSTEM (DIAGNOSTIC) 9. Inspection Mode A: OPERATION Recreate the circumstance by referring to the con- ditions described in the checklist. AB-32...
Page 159: Clear Memory Mode
Clear Memory Mode AIRBAG SYSTEM (DIAGNOSTIC) 10.Clear Memory Mode A: OPERATION 1) Turn the ignition switch to ON. 2) Connect the ground terminal (ground, terminal “A”) to diagnosis connector terminal No. 1 in the in- strument panel lower cover area. 3 4 5 6 AB-00138 (1) Diagnosis connector...
Page 160: Airbag Warning Light Failure
Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTIC) 11.Airbag Warning Light Failure A: AIRBAG WARNING LIGHT REMAINS ON. DIAGNOSIS: • Airbag warning light unit is faulty. • Airbag control module to airbag warning light circuit is shorted or open. • Grounding circuit is faulty. •...
Page 161 Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTIC) 1. LHD MODEL WIRING DIAGRAM: COMBINATION METER IGNITION SWITCH NO.14 AIRBAG WARNING LIGHT AIRBAG CIRCUIT AIRBAG CONTROL MODULE 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 3 4 5 6...
Page 162 Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK AIRBAG WARNING LIGHT. Is the airbag warning light Go to step 4. Go to step 3. 1) Turn the ignition switch to OFF, disconnect turned off? the battery ground cable, and wait more than 20 seconds.
Page 163 Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTIC) 2. RHD MODEL WIRING DIAGRAM: COMBINATION METER IGNITION SWITCH NO.14 AIRBAG WARNING LIGHT AIRBAG CIRCUIT AIRBAG CONTROL MODULE 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 3 4 5 6...
Page 164 Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK AIRBAG WARNING LIGHT. Is the airbag warning light Go to step 4. Go to step 3. 1) Turn the ignition switch to OFF, disconnect turned off? the battery ground cable, and wait more than 20 seconds.
Page 165 Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTIC) B: AIRBAG WARNING LIGHT REMAINS OFF. DIAGNOSIS: • Fuse No. 14 (in fuse box) is blown. • Body harness circuit is open. • Airbag warning light is faulty. • Airbag main harness is faulty. •...
Page 166 Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK COMBINATION METER. Do the warning lights not for Go to step 2. Repair the combi- Turn the ignition switch to ON, and confirm that airbag turn on? nation meter warning lights equipped in the combination power supply.
Page 167 Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTIC) 2. RHD MODEL WIRING DIAGRAM: COMBINATION METER IGNITION SWITCH NO.14 AIRBAG WARNING LIGHT AIRBAG CIRCUIT AIRBAG CONTROL MODULE 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 3 4 5 6...
Page 168 Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK COMBINATION METER. Do the warning lights not for Go to step 2. Repair the combi- Turn the ignition switch to ON, and confirm that airbag turn on? nation meter warning lights equipped in the combination power supply.
Page 169: List Of Diagnostic Trouble Code (Dtc)
List of Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) 12.List of Diagnostic Trouble Code (DTC) A: LIST Memory func- Contents of diagnosis Index No. tion • Airbag main harness circuit is open, shorted or <Ref. to AB-46, DTC 11, shorted to ground. Diagnostic Procedure •...
Page 170 List of Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Memory func- Contents of diagnosis Index No. tion • Front sub-sensor harness circuit (LH) is shorted, <Ref. to AB-69, DTC 32, opened or shorted to power supply. Diagnostic Procedure • Airbag main harness circuit is shorted, opened or with Diagnostic Trouble Provided.
Page 171 List of Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Memory func- Contents of diagnosis Index No. tion • Seat belt pretensioner circuit (LH) is shorted to <Ref. to AB-91, DTC 66, power supply. Diagnostic Procedure Provided. • Pretensioner is faulty. with Diagnostic Trouble •...
Page 172: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)
Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) 13.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC 11 DIAGNOSIS: • Airbag main harness circuit is open, shorted or shorted to ground. • Airbag module harness circuit (Driver) is open, shorted or shorted to ground. •...
Page 173 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK DRIVERS AIRBAG MODULE. Is the airbag warning light Replace the Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? driver’s airbag the battery ground cable, and wait more than module.
Page 174 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) B: DTC 12 DIAGNOSIS: • Airbag main harness circuit is open, shorted or shorted to ground. • Airbag module harness circuit (Passenger) is open, shorted or shorted to ground. • Passenger’s airbag module is faulty. •...
Page 175 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK PASSENGERS AIRBAG MODULE. Is the airbag warning light Replace the pas- Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? senger airbag the battery ground cable, and wait more than module.
Page 176 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) C: DTC 15 DIAGNOSIS: • Airbag main harness circuit (Driver) is shorted to the power supply. • Airbag module harness (Driver) is shorted to the power supply. • Roll connector is shorted to the power supply. •...
Page 177 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK DRIVERS AIRBAG MODULE. Is the airbag warning light Replace the Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? driver’s airbag the battery ground cable, and wait more than module.
Page 178 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) D: DTC 16 DIAGNOSIS: • Airbag main harness circuit (Passenger) is shorted to the power supply. • Airbag module harness (Passenger) is shorted to the power supply. • Passenger’s airbag module is faulty. •...
Page 179 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK PASSENGERS AIRBAG MODULE. Is the airbag warning light Replace the pas- Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? senger airbag the battery ground cable, and wait more than module.
Page 180 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) E: DTC 21 DIAGNOSIS: Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait more than 20 seconds before starting to work. •...
Page 181 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) F: DTC 22 1. LHD MODEL WIRING DIAGRAM: AIRBAG CONTROL MODULE AB21 AB26 STEERING ROLL CONNECTOR AB19 AB20 INFLATOR INFLATOR (PASSENGER SIDE) PRETENSIONER LH PRETENSIONER RH (DRIVER SIDE) AB19 AB20 1 2 3 4 1 2 3 4 5 6...
Page 182 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) 2. RHD MODEL WIRING DIAGRAM: AIRBAG CONTROL MODULE AB21 AB26 STEERING ROLL CONNECTOR AB19 AB25 AB20 INFLATOR INFLATOR (PASSENGER SIDE) LAP SEAT BELT PRETENSIONER LH (DRIVER SIDE) PRETENSIONER RH PRETENSIONER AB25 AB19 AB20...
Page 183 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) G: DTC 23 DIAGNOSIS: (AB3), (AB7) and (AB8) are not connected properly to airbag control module. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait more than 20 seconds before starting to work.
Page 184 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) H: DTC 24 DIAGNOSIS: • Airbag control module is faulty. • Airbag main harness circuit is open. • Fuse No. 11 (in fuse and relay box) is blown. • Body harness circuit is open. CAUTION: •...
Page 185 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK AIRBAG CONTROL MODULE. Is the voltage more than 10 V? Replace the airbag Go to step 2. 1) Turn the ignition switch to OFF, disconnect control module. the battery ground cable, and wait more than <Ref.
Page 186 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) 2. RHD MODEL WIRING DIAGRAM: IGNITION SWITCH NO.11 AIRBAG CONTROL MODULE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 3 4 5 6 18 19 20 21 22 23 24 25 26 27 28 AB-00745 AB-60...
Page 187 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK AIRBAG CONTROL MODULE. Is the voltage more than 10 V? Replace the airbag Go to step 2. 1) Turn the ignition switch to OFF, disconnect control module. the battery ground cable, and wait more than <Ref.
Page 188 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) I: DTC 25 DIAGNOSIS: • Airbag control module is faulty. • Airbag main harness circuit is open. • Fuse No. 6 (in joint box) is blown. • Body harness circuit is open. CAUTION: •...
Page 189 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK AIRBAG CONTROL MODULE. Is the voltage more than 10 V? Replace the airbag Go to step 2. 1) Turn the ignition switch to OFF, disconnect control module. the battery ground cable, and wait more than <Ref.
Page 190 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) 2. RHD MODEL WIRING DIAGRAM: IGNITION SWITCH NO.6 AIRBAG CONTROL MODULE 1 2 3 4 5 6 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 AB-00746 AB-64...
Page 191 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK AIRBAG CONTROL MODULE. Is the voltage more than 10 V? Replace the airbag Go to step 2. 1) Turn the ignition switch to OFF, disconnect control module. the battery ground cable, and wait more than <Ref.
Page 192 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) J: DTC 31 DIAGNOSIS: • Front sub-sensor harness circuit (RH) is shorted, open or shorted to power supply. • Airbag main harness circuit is shorted, open or shorted to power supply. •...
Page 193 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check Is the resistance 750 Ω and 1 CHECK FRONT SUB-SENSOR (RH) AND Replace the airbag Go to step 2. AIRBAG HARNESS. KΩ? control module. 1) Turn the ignition switch to OFF, disconnect <Ref.
Page 194 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK FRONT SUB-SENSOR HARNESS Is the resistance more than 1 Go to step 8. Replace the front (RH). MΩ? sub-sensor har- Measure the resistance between connector ness (RH) with (3L) in test harness L and the chassis ground.
Page 195 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) K: DTC 32 DIAGNOSIS: • Front sub-sensor harness circuit (LH) is shorted.is shorted, open or shorted to power supply. • Airbag main harness circuit is shorted, open or shorted to power supply. •...
Page 196 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check Is the resistance 750 Ω and 1 CHECK FRONT SUB-SENSOR (LH) AND Replace the airbag Go to step 2. AIRBAG HARNESS. KΩ? control module. 1) Turn the ignition switch to OFF, disconnect <Ref.
Page 197 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK FRONT SUB-SENSOR HARNESS Is the resistance more than 1 Go to step 8. Replace the front (LH). MΩ? sub-sensor har- Measure the resistance between connector ness (LH) with (3L) in test harness L and the chassis ground.
Page 198 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) L: DTC 41 DIAGNOSIS: • Side airbag harness (RH) is faulty. • Side airbag module (RH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait more than 20 seconds before starting to work.
Page 199 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK SIDE AIRBAG MODULE. Is the airbag warning light Replace the front Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? seat with side air- the battery ground cable, and wait more than bag module (RH).
Page 200 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) M: DTC 42 DIAGNOSIS: • Side airbag harness (LH) is faulty. • Side airbag module (LH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait more than 20 seconds before starting to work.
Page 201 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK SIDE AIRBAG MODULE. Is the airbag warning light Replace the front Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? seat with side air- the battery ground cable, and wait more than bag module (LH).
Page 202 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) N: DTC 45 DIAGNOSIS: • Side airbag harness (RH) is shorted to power supply. • Side airbag module (RH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait more than 20 seconds before starting to work.
Page 203 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK SIDE AIRBAG MODULE. Is the airbag warning light Replace the front Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? seat with side air- the battery ground cable, and wait more than bag module (RH).
Page 204 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) O: DTC 46 DIAGNOSIS: • Side airbag harness (LH) is shorted to power supply. • Side airbag module (LH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait more than 20 seconds before starting to work.
Page 205 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK SIDE AIRBAG MODULE. Is the airbag warning light Replace the front Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? seat with side air- the battery ground cable, and wait more than bag module (LH).
Page 206 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) P: DTC 51 DIAGNOSIS: • Side airbag sensor (RH) is faulty. • Side airbag harness is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait more than 20 seconds before starting to work.
Page 207 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK SIDE AIRBAG (RH) HARNESS. Is the resistance less than 10 Go to step 2. Replace the side Ω? 1) Turn the ignition switch to OFF, disconnect airbag harness the battery ground cable, and wait more than with body harness.
Page 208 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Q: DTC 52 DIAGNOSIS: • Side airbag sensor (LH) is faulty. • Side airbag harness (LH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait more than 20 seconds before starting to work.
Page 209 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK SIDE AIRBAG (LH) HARNESS. Is the resistance less than 10 Go to step 2. Replace the side Ω? 1) Turn the ignition switch to OFF, disconnect airbag harness the battery ground cable, and wait more than with body harness.
Page 210 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) R: DTC 53 DIAGNOSIS: • Side airbag sensor (RH) is faulty. When Code 53 is displayed, the circuit within the side airbag sensor (RH) is faulty. Replace the side airbag sensor (RH).
Page 211 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) U: DTC 61 DIAGNOSIS: • Seat belt pretensioner circuit (RH) is open, shorted or shorted to ground. • Airbag control module is faulty. • Pretensioner is faulty. • Pretensioner harness is faulty. CAUTION: •...
Page 212 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK SEAT BELT PRETENSIONER. Is the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? belt pretensioner the battery ground cable, and wait more than (RH).
Page 213 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) V: DTC 62 DIAGNOSIS: • Seat belt pretensioner circuit (LH) is open, shorted or shorted to ground. • Airbag control module is faulty. • Pretensioner is faulty. • Pretensioner harness is faulty. CAUTION: •...
Page 214 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK SEAT BELT PRETENSIONER. Is the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? belt pretensioner the battery ground cable, and wait more than (LH).
Page 215 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) W: DTC 65 DIAGNOSIS: • Seat belt pretensioner circuit (RH) is shorted to the power supply. • Pretensioner is faulty. • Pretensioner harness is faulty. • Airbag control module is faulty. CAUTION: •...
Page 216 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK SEAT BELT PRETENSIONER. Is the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? belt pretensioner the battery ground cable, and wait more than (RH).
Page 217 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) X: DTC 66 DIAGNOSIS: • Seat belt pretensioner circuit (LH) is shorted to the power supply. • Pretensioner is faulty. • Pretensioner harness is faulty. • Airbag control module is faulty. CAUTION: •...
Page 218 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK SEAT BELT PRETENSIONER. Is the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? belt pretensioner the battery ground cable, and wait more than (LH).
Page 219 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Y: DTC 72 DIAGNOSIS: • Airbag harness is open, shorted or shorted to ground. • Airbag module harness circuit (Passenger) is open, shorted or shorted to ground. • Passenger’s airbag module is faulty. •...
Page 220 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK PASSENGERS AIRBAG MODULE. Is the airbag warning light Replace the pas- Go to step 2. 1) Turn the ignition switch OFF, disconnect the turned on normally? senger’s airbag battery ground cable, and wait more than 20 module.
Page 221 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Z: DTC 76 DIAGNOSIS: • Airbag main harness circuit (Passenger) is shorted to the power supply. • Airbag module harness (Passenger) is shorted to the power supply. • Passenger’s airbag module is faulty. •...
Page 222 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK PASSENGERS AIRBAG MODULE. Is the airbag warning light Replace the pas- Go to step 2. 1) Turn the ignition switch OFF, disconnect the turned on normally? senger’s airbag battery ground cable, and wait more than 20 module.
Page 223 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) AA:DTC 81 DIAGNOSIS: • Lap seat belt pretensioner circuit (RH) is open, shorted or shorted to ground. • Lap pretensioner is faulty. • Lap pretensioner harness is faulty. • Airbag control module is faulty. CAUTION: •...
Page 224 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK LAP SEAT BELT PRETENSIONER. Is the airbag warning light Replace the lap Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? seat belt preten- the battery ground cable, and wait more than sioner (RH).
Page 225 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) AB:DTC 85 DIAGNOSIS: • Lap seat belt pretensioner circuit (RH) is shorted to the power supply. • Lap pretensioner is faulty. • Lap pretensioner harness is faulty. • Airbag control module is faulty. CAUTION: •...
Page 226 Diagnostic Procedure with Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTIC) Step Check CHECK LAP SEAT BELT PRETENSIONER. Is the airbag warning light Replace the lap Go to step 2. 1) Turn the ignition switch to OFF, disconnect turned on normally? seat belt preten- the battery ground cable, and wait more than sioner (RH).
Page 227 SEAT BELT SYSTEM Page General Description ..................2 Inspection Locations After a Collision ............6 Seat Belt Warning System ................7 Front Seat Belt ..................10 Rear Seat Belt...................12 Disposal of Pretensioner ................14...
Page 228: General Description
General Description SEAT BELT SYSTEM 1. General Description A: COMPONENT 1. FRONT SEAT BELT SB-00001 ⋅ Adjuster anchor ASSY Outer belt ASSY Tightening torque: N m (kgf-m, ft-lb) Anchor cover Inner belt ASSY T1: 7.5 (0.76, 5.5) Outer belt ASSY with lap preten- T2: 30 (3.1, 22) sioner (For Australia model) T3: 53 (5.4, 39)
Page 229 General Description SEAT BELT SYSTEM 2. REAR SEAT BELT SB-00064 ⋅ Outer seat belt RH Inner seat belt LH Tightening torque: N m (kgf-m, ft-lb) Outer seat belt CENTER Anchor cover T1: 30 (3.1, 22) Outer seat belt LH Adjuster anchor ASSY T2: 53 (5.4, 39) Inner seat belt RH SB-3...
Page 230 General Description SEAT BELT SYSTEM B: CAUTION • Before starting, turn the ignition switch to OFF, disconnect the battery ground cable and wait for 20 seconds or more. • The pretension system has a backup power source. The pretensioner might deploy if you do not wait for 20 seconds or more before starting work.
Page 231 General Description SEAT BELT SYSTEM C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299SA010 DEPLOYMENT • Used for deploying the pretensioner. ADAPTER D • Used with DEPLOYMENT TOOL (98299PA030). ST98299SA010 98299SA050 DEPLOYMENT • Used for deploying the lap seat belt preten- ADAPTER F sioner.
Page 232: Inspection Locations After A Collision
Inspection Locations After a Collision SEAT BELT SYSTEM 2. Inspection Locations After a Collision A: INSPECTION Check for the following, and then replace with new parts if necessary. • Center pillar lower garnish is discolored or cracked. • Wiring harness and/or connector is damaged. SB-6...
Page 233: Seat Belt Warning System
Seat Belt Warning System SEAT BELT SYSTEM 3. Seat Belt Warning System A: WIRING DIAGRAM <Ref. to WI-255, WIRING DIAGRAM, Seat Belt Warning System.> B: INSPECTION TROUBLE SYMPTOM: • Seat belt warning light does not come on or go off. •...
Page 234 Seat Belt Warning System SEAT BELT SYSTEM Step Check CHECK HARNESS BETWEEN SEAT BELT Is the resistance more than 1 Go to step 7. Repair the open SWITCH AND CHASSIS GROUND. MΩ? circuit of harness Measure the resistance of harness between between seat belt seat belt switch and chassis ground.
Page 235 Seat Belt Warning System SEAT BELT SYSTEM Step Check CHECK HARNESS BETWEEN TCU AND Is the resistance less than 10 Go to step 15. Repair the short of Ω? SEAT BELT TIMER MODULE. harness. Measure the resistance between seat belt timer module harness connector and chassis ground.
Page 236: Front Seat Belt
Front Seat Belt SEAT BELT SYSTEM 4. Front Seat Belt CAUTION: • Do not drop or apply any impact to the pre- A: REMOVAL tensioner. • Pretensioner and bracket should be treated as 1. FRONT OUTER BELT an assembly. Do not attempt to disassemble it. 1) Fold backrest all the way forward, and then move 2.
Page 237 Front Seat Belt SEAT BELT SYSTEM 8) Remove the two bolts and adjustable anchor as- B: INSTALLATION sembly. 1. FRONT OUTER BELT Install in the reverse order of removal. CAUTION: • The parts on right and left are not identical. Before installation, make sure that the correct part is used.
Page 238: Rear Seat Belt
Rear Seat Belt SEAT BELT SYSTEM 5. Rear Seat Belt 8) Remove the two bolts and adjustable anchor as- sembly. A: REMOVAL 1. OUTER BELT SIDE 1) Remove the luggage floor mat. <Ref. to EI-50, RE- MOVAL, Luggage Floor Mat.> 2) Remove the rear seat.
Page 239 Rear Seat Belt SEAT BELT SYSTEM 9) Disconnect the harness and connector, and then 3. INNER BELT remove the outer belt center assembly. Install in the reverse order of removal. CAUTION: During installation, make sure that the seat belts are not twisted. Tightening torque: <Ref.
Page 240: Disposal Of Pretensioner
• Wrap the deployed pretensioner in an airtight vi- nyl bag, and then discard it. • If circumstances do not permit pretensioner de- ployment, contact a SUBARU dealer. B: OPERATION 1. DEPLOYING OF PRETENSIONER WHILE INSTALLED IN VEHICLE 1) Fold backrest all the way forward, and then move front seat all the way forward.
Page 241 Disposal of Pretensioner SEAT BELT SYSTEM 15) Extened the deployment tool to the limit, and CAUTION: make sure that the vehicle is empty. Close all win- • After deployment, pretensioner is especially dows, sunroof and rear gate completely. hot. Leave it unattended for 40 minutes or long- •...
Page 242 Disposal of Pretensioner SEAT BELT SYSTEM 2. DEPLOYING OF RETRACTOR PRETEN- 8) Install the pretensioner on a wheel with tire. Then, bundle three wire automotive harness [each SIONER AFTER REMOVAL FROM VEHICLE with a sectional area of 1.25 mm (0.00194 sq in) or 1) Fold backrest all the way forward, then move more], and bind them twofold around the preten- front seat all the way forward.
Page 243 Disposal of Pretensioner SEAT BELT SYSTEM 11) Connect the other cable of deployment tool to 5) Short the terminal to alligator clip furnished as a the battery positive (+) terminal. Then deploy the deployment tool (A). pretensioner. 6) Connect the deployment tool and deployment adapter F (B).
Page 244 Disposal of Pretensioner SEAT BELT SYSTEM 10) Move the battery at least 5 m (16 ft) from the vehicle, and secure the nearby area. Connect the deployment tool alligator clip to the battery negative (−) terminal. SB-00065 (1) 5 m (16 ft) or more 11) Connect the other cable of deployment tool to the battery positive (+) terminal.
Page 245 LIGHTING SYSTEM Page General Description ..................2 Headlight and Tail Light System ..............3 Front Fog Light System................4 Rear Fog Light System ................5 Turn Signal Light and Hazard Light System..........6 Back-up Light System .................7 Stop Light System ..................8 Room Light System..................9 Headlight Beam Leveler System...............10 Combination Switch (Light) ...............11 Headlight Assembly ..................13 Headlight Bulb...................16...
Page 246: General Description
General Description LIGHTING SYSTEM 1. General Description A: SPECIFICATION Headlight 12 V — 55 W/60 W Front turn signal light 12 V — 21 W Clearance light 12 V — 5 W Side marker light 12 V — 5 W Front fog light 12 V —...
Page 247: Headlight And Tail Light System
Headlight and Tail Light System LIGHTING SYSTEM 2. Headlight and Tail Light Sys- 3. TAIL AND ILLUMINATION RELAY Measure the tail and illumination relay resistance between terminals when connecting terminal No. 4 A: WIRING DIAGRAM to battery positive terminal and terminal No. 3 to battery ground terminal.
Page 248: Front Fog Light System
Front Fog Light System LIGHTING SYSTEM 3. Front Fog Light System A: WIRING DIAGRAM 1. FRONT FOG LIGHT <Ref. to WI-219, WIRING DIAGRAM, Front Fog Light System.> B: INSPECTION 1. FRONT FOG LIGHT SWITCH Measure the resistance between front fog light switch terminals.
Page 249: Rear Fog Light System
Rear Fog Light System LIGHTING SYSTEM 4. Rear Fog Light System A: WIRING DIAGRAM 1. REAR FOG LIGHT <Ref. to WI-249, WIRING DIAGRAM, Rear Fog Light System.> B: INSPECTION 1. REAR FOG LIGHT SWITCH 1) Turn the ignition switch to ON. 2) Turn on the headlight or front fog light.
Page 250: Turn Signal Light And Hazard Light System
Turn Signal Light and Hazard Light System LIGHTING SYSTEM 5. Turn Signal Light and Hazard Light System A: WIRING DIAGRAM 1. TURN SIGNAL LIGHT AND HAZARD LIGHT <Ref. to WI-229, WIRING DIAGRAM, Turn Signal Light and Hazard Light System.> B: INSPECTION 1.
Page 251: Back-Up Light System
Back-up Light System LIGHTING SYSTEM 6. Back-up Light System 2. INHIBITOR SWITCH (AT MODEL) Measure the resistance between inhibitor switch ter- A: WIRING DIAGRAM minals. 1. BACK-UP LIGHT <Ref. to WI-209, WIRING DIAGRAM, Back-up Light System.> 4 3 2 1 B: INSPECTION 1.
Page 252: Stop Light System
Stop Light System LIGHTING SYSTEM 7. Stop Light System A: WIRING DIAGRAM 1. STOP LIGHT <Ref. to WI-228, WIRING DIAGRAM, Stop Light System.> B: INSPECTION 1. STOP LIGHT SWITCH Measure the resistance between stop light switch terminals. LI-00064 (A) Without cruise control (B) With cruise control Switch position Terminal No.
Page 253: Room Light System
Room Light System LIGHTING SYSTEM 8. Room Light System A: WIRING DIAGRAM 1. ROOM LIGHT <Ref. to WI-224, WIRING DIAGRAM, In Compart- ment Light System.> B: INSPECTION 1. DOOR SWITCH Measure the resistance between door switch termi- nals. LI-00007 Switch position Terminal No.
Page 254: Headlight Beam Leveler System
Headlight Beam Leveler System LIGHTING SYSTEM 9. Headlight Beam Leveler Sys- A: WIRING DIAGRAM 1. HEADLIGHT BEAM LEVELER <Ref. to WI-191, WIRING DIAGRAM, Headlight Beam Leveler System.> B: INSPECTION 1. HEADLIGHT BEAM LEVELER ACTUA- 1) Turn on the headlights. 2) Confirm the headlight beam level is lowered by changing the switch position to 0 →...
Page 255: Combination Switch (Light)
Combination Switch (Light) LIGHTING SYSTEM 10.Combination Switch (Light) C: INSPECTION Measure the combination switch resistance. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. <Ref. to EI-40, REMOVAL, Instrument Panel Assembly.> 3) Remove the screw which secure upper column cover to lower column cover.
Page 256: Turn Signal Switch
Combination Switch (Light) LIGHTING SYSTEM 2. DIMMER AND PASSING SWITCH LHD and RHD model with rear fog light: Switch position Terminal No. Standard Less than 1 Ω Passing 7, 8 and 16 Less than 1 Ω Low beam 16 and 17 Less than 1 Ω...
Page 257: Headlight Assembly
Headlight Assembly LIGHTING SYSTEM 11.Headlight Assembly 2) Remove the five screws. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the air intake duct (when removing the headlight RH). <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Duct.> 3) Remove the front grille and headlight side cover. <Ref.
Page 258 Headlight Assembly LIGHTING SYSTEM 7) Remove the packing (A) from seal groove. 4) Match the positions of the lens and headlight as- sembly, and then insert the lens into headlight as- CAUTION: sembly. Completely remove the packing not to leave 5) Secure the hook, and then install the clip and any chips behind.
Page 259 Headlight Assembly LIGHTING SYSTEM • This illustration is for LHD model. The pattern for RHD model is symmetrically opposite. 3m (10 ft) LI-00054 (A) Vehicle center (B) Bulb center W mm (in) H mm (in) h mm (in) at 3 m (10 ft) 1,140 (44.88) 733 (28.9) 30 (1.18)
Page 260: Headlight Bulb
Headlight Bulb LIGHTING SYSTEM 12.Headlight Bulb A: REMOVAL CAUTION: • Because the halogen bulb operates at a high temperature, dirt and oil on the bulb surface re- duces the bulb’s service life. Hold the flange portion when replacing the bulb. Never touch the glass portion.
Page 261: Front Turn Signal Light Bulb
Front Turn Signal Light Bulb LIGHTING SYSTEM 13.Front Turn Signal Light Bulb A: REMOVAL 1) Remove the headlight assembly. <Ref. to LI-13, REMOVAL, Headlight Assembly.> 2) Turn the socket and remove the bulb. LI-00021 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Visually check the bulb for blow out.
Page 262: Clearance Light Bulb
Clearance Light Bulb LIGHTING SYSTEM 14.Clearance Light Bulb A: REMOVAL 1) Remove the headlight assembly. <Ref. to LI-13, REMOVAL, Headlight Assembly.> 2) Turn the socket and remove the bulb. LI-00022 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Visually check the bulb for blow out.
Page 263: Front Fog Light Assembly
Front Fog Light Assembly LIGHTING SYSTEM 15.Front Fog Light Assembly A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the two clips and lower mudguard. LI-00023 3) Disconnect the harness connector. 4) Remove the lower bolts. LI-00024 5) Remove the mounting bolts and clip, and then detach the fog light assembly.
Page 264: Front Fog Light Bulb
Front Fog Light Bulb LIGHTING SYSTEM 16.Front Fog Light Bulb A: REMOVAL 1) Remove the front fog light assembly. <Ref. to LI- 19, REMOVAL, Front Fog Light Assembly.> 2) Remove the back cover. LI-00026 3) Remove the spring retainer, and then detach the fog light bulb.
Page 265: Rear Combination Light Assembly
Rear Combination Light Assembly LIGHTING SYSTEM 17.Rear Combination Light As- sembly A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the two bolts, and then turn the socket and disconnect cord assembly to remove rear com- bination light. LI-00028 LI-00029 B: INSTALLATION...
Page 266: Tail/Stop Light Bulb
Tail/Stop Light Bulb LIGHTING SYSTEM 18.Tail/Stop Light Bulb A: REMOVAL 1) Remove the rear combination light assembly. <Ref. to LI-21, REMOVAL, Rear Combination Light Assembly.> 2) Turn the socket and remove the bulb. LI-00056 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Visually check the bulb for blow out.
Page 267: Back-Up Light Bulb
Back-up Light Bulb LIGHTING SYSTEM 19.Back-up Light Bulb A: REMOVAL 1) Remove the rear combination light assembly. <Ref. to LI-21, REMOVAL, Rear Combination Light Assembly.> 2) Turn the socket and remove the bulb. LI-00032 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Visually check the bulb for blow out.
Page 268: Rear Turn Signal Light Bulb
Rear Turn Signal Light Bulb LIGHTING SYSTEM 20.Rear Turn Signal Light Bulb A: REMOVAL 1) Remove the rear combination light assembly. <Ref. to LI-21, REMOVAL, Rear Combination Light Assembly.> 2) Turn the socket and remove the bulb. LI-00031 B: INSTALLATION Install in the reverse order of removal.
Page 269: Rear Fog Light Bulb
Rear Fog Light Bulb LIGHTING SYSTEM 21.Rear Fog Light Bulb A: REMOVAL NOTE: Rear fog light bulb is attached only to driver’s side combination light. 1) Remove the rear combination light assembly. <Ref. to LI-21, REMOVAL, Rear Combination Light Assembly.> 2) Turn the socket and remove the bulb.
Page 270: License Plate Light
License Plate Light LIGHTING SYSTEM 22.License Plate Light A: REMOVAL 1) Remove the license plate light mounting screw (A), and then remove the lens. LI-00034 2) Remove the bulb. B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Visually check the bulb for blow out.
Page 271: High-Mounted Stop Light
High-mounted Stop Light LIGHTING SYSTEM 23.High-mounted Stop Light A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the cap (a) by prying on the edge with screwdriver. 3) Remove the screws (b), and then detach the cover (c). 4) Remove the screws (d), disconnect the connec- tor, and then detach the high-mounted stop light.
Page 272: Side Turn Signal Light
Side Turn Signal Light LIGHTING SYSTEM 24.Side Turn Signal Light A: REMOVAL 1) Disconnect the ground cable from battery. 2) Pull out the light from body while pushing it in di- rection of vehicle front. 3) Disconnect the harness connector and remove the light.
Page 273: Spot Map Light
Spot Map Light LIGHTING SYSTEM 25.Spot Map Light A: REMOVAL 1) Disconnect the ground cable from battery. 2) Insert a flat tip screwdriver to the slot of lens, and then pry the lens to remove. LI-00038 3) Remove the spot map light installation screws. LI-00039 4) Disconnect the harness connectors and remove the spot map light.
Page 274: Room Light
Room Light LIGHTING SYSTEM 26.Room Light A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lens (A) and room light mounting screws (B). LI-00040 3) Disconnect the harness connectors and remove the room light. B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1.
Page 275: Luggage Room Light
Luggage Room Light LIGHTING SYSTEM 27.Luggage Room Light C: INSPECTION A: REMOVAL 1. LUGGAGE ROOM LIGHT BULB 1) Disconnect the ground cable from battery. 1) Visually check the bulb for blow out. 2) Remove the lens (A) and luggage room light 2) Check the bulb specification.
Page 276: Glove Box Light
Glove Box Light LIGHTING SYSTEM 28.Glove Box Light A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box. <Ref. to EI-37, REMOV- AL, Glove Box.> 3) Disconnect the harness connector. 4) Remove the glove box light. LI-00044 B: INSTALLATION Install in the reverse order of removal.
Page 277 WIPER AND WASHER SYSTEM Page General Description ..................2 Wiper and Washer System .................6 Combination Switch (Wiper)................7 Wiper Blade....................9 Washer Tank and Motor................11 Front Wiper Arm..................12 Front Wiper Motor and Link...............13 Front Washer Nozzle ................15 Rear Wiper Arm ..................16 Rear Wiper Motor..................17 Rear Washer .....................18 Wiper Control Relay ..................19 Headlight Washer..................20...
Page 278: General Description
General Description WIPER AND WASHER SYSTEM 1. General Description A: SPECIFICATION Front wiper motor Input 12 V — 72 W or less Rear wiper motor Input 12 V — 42 W or less Pump type Centrifugal Front washer motor Input 12 V —...
Page 279 General Description WIPER AND WASHER SYSTEM 2. REAR WIPER (10) WW-00190 Wiper rubber Spacer B Tightening torque: N·m (kgf-m, ft-lb) Wiper blade ASSY T1: 6.0 (0.61, 4.4) Wiper arm T2: 7.5 (0.76, 5.5) Wiper motor (10) Wiper arm cover T3: 8.0 (0.82, 5.9) Spacer A Cushion WW-3...
Page 280: Motor B
General Description WIPER AND WASHER SYSTEM 3. WASHER TANK (10) (11) (12) (13) WW-00097 Washer nozzle Grommet (13) Valve Washer hose Headlight washer motor Washer tank Motor bracket Tightening torque: N·m (kgf-m, ft-lb) Washer tank cap (10) Headlight washer case T: 6.0 (0.61, 4.4) Front washer motor (11)
Page 281 General Description WIPER AND WASHER SYSTEM C: CAUTION • Reconnect the connectors and hoses securely. After reconnecting, confirm that each function oper- ates normally. • Be careful that wiring harnesses of airbag sys- tem pass near electrical parts and switches. •...
Page 282: Wiper And Washer System
Wiper and Washer System WIPER AND WASHER SYSTEM 2. Wiper and Washer System A: WIRING DIAGRAM 1. WIPER AND WASHER (FRONT) <Ref. to WI-264, WIRING DIAGRAM, Wiper and Washer System (Front).> 2. WIPER AND WASHER (REAR) <Ref. to WI-265, WIRING DIAGRAM, Wiper and Washer System (Rear).> B: INSPECTION Symptom Repair order...
Page 283 Combination Switch (Wiper) WIPER AND WASHER SYSTEM 3. Combination Switch (Wiper) C: INSPECTION 1) Inspect the continuity between each connector A: REMOVAL terminal. 1) Loosen the screw to remove the steering column cover. WW-00004 2) Disconnect the connectors from combination switches.
Page 284: Combination Switch (Wiper)
Combination Switch (Wiper) WIPER AND WASHER SYSTEM RHD except for Europe model: Switch position Terminal No. Standard 3 and 12 Less than 1Ω 3 and 12 Less than 1Ω FRONT 3 and 11 Less than 1Ω 2 and 11 Less than 1Ω Washer ON 8 and 17 Less than 1Ω...
Page 285: Wiper Blade
Wiper Blade WIPER AND WASHER SYSTEM 4. Wiper Blade 2) Make sure the wiper rubber is securely fastened to the pull stopper (A). A: REMOVAL While pushing the locking clip (A) up, pull out the blade from arm to arrow direction. WW-00037 WW-00008 B: INSTALLATION...
Page 286 Wiper Blade WIPER AND WASHER SYSTEM 2. RESIN TYPE WW-00193 1) Insert the wiper rubber through the claw (B). 3) Insert the wiper rubber into the claw (A). WW-00198 WW-00147 2) Insert the wiper rubber top until it protrudes about E: INSPECTION 20 mm (0.79 in) from the stopper (D).
Page 287: Washer Tank And Motor
Washer Tank and Motor WIPER AND WASHER SYSTEM 5. Washer Tank and Motor C: DISASSEMBLY 1) Remove bolt, and then pull out washer motor A: REMOVAL from tank. (Model with headlight washer) 1) Open the hood. 2) Disconnect the ground cable from battery. 3) Remove the two bolts, hose and connector, and then remove the tank.
Page 288: Front Wiper Arm
Front Wiper Arm WIPER AND WASHER SYSTEM 6. Front Wiper Arm A: REMOVAL 1) Open the hood. 2) Remove the cap. 3) Loosen the nut to remove arm. WW-00047 B: INSTALLATION 1) Install in the reverse order of removal. 2) Operate the wiper once. 3) Align the wiper blade to ceramic print point mark (A) of front window panel.
Page 289: Front Wiper Motor And Link
Front Wiper Motor and Link WIPER AND WASHER SYSTEM 7. Front Wiper Motor and Link 6) Install in the reverse order of removal. Tightening torque: A: REMOVAL Refer to COMPONENT in General Descrip- 1) Disconnect the ground cable from battery. tion.
Page 290 Front Wiper Motor and Link WIPER AND WASHER SYSTEM 4) Connect the battery and confirm that the motor stops at automatic stop position after the motor op- erates at low speed again. WW-00227 WW-14...
Page 291: Front Washer Nozzle
Front Washer Nozzle WIPER AND WASHER SYSTEM 8. Front Washer Nozzle A: REMOVAL 1) Remove the washer hose from the washer noz- zle. 2) Open the clips on the underside of the hood with a thin screwdriver or other tool, and remove the washer nozzle.
Page 292: Rear Wiper Arm
Rear Wiper Arm WIPER AND WASHER SYSTEM 9. Rear Wiper Arm C: ADJUSTMENT 1) Operate the rear wiper once. A: REMOVAL 2) Align the blade to the center of rear defogger 1) Remove the wiper arm cover (A). heat wire (A). WW-00191 WW-00200 2) Loosen the nut to remove wiper arm.
Page 293: Rear Wiper Motor
Rear Wiper Motor WIPER AND WASHER SYSTEM 10.Rear Wiper Motor C: INSPECTION 1) Connect the battery to wiper motor connector A: REMOVAL and confirm that the wiper motor operates. 1) Disconnect the ground cable from battery. 2) Remove the rear wiper arm. 3) Remove the cap (A), nut (B), and spacer (C) from rear wiper shaft.
Page 294: Rear Washer
Rear Washer WIPER AND WASHER SYSTEM 11.Rear Washer A: REMOVAL 1) Remove the rear gate upper trim. <Ref. to EI-48, REMOVAL, Rear Gate Trim.> 2) Remove the washer hose from the washer noz- zle. 3) Push the anchor portion of washer nozzle with a thin screwdriver or other tool, and remove the washer nozzle.
Page 295: Wiper Control Relay
Wiper Control Relay WIPER AND WASHER SYSTEM 12.Wiper Control Relay 3) Measure the voltage when the wiper relay is op- erated. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the right quarter lower trim. <Ref. to EI- 45, REMOVAL, Rear Quarter Trim.>...
Page 296: Headlight Washer
Headlight Washer WIPER AND WASHER SYSTEM 13.Headlight Washer B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from the battery. 2) Remove the front grille. <Ref. to EI-18, REMOV- AL, Front Grille.> 3) Remove the headlight. <Ref. to LI-13, REMOV- AL, Headlight Assembly.>...
Page 297 ENTERTAINMENT Page General Description ..................2 Radio System....................3 Front Accessory Power Supply Socket System ..........4 Radio Body....................5 Front Speaker .....................6 Antenna.......................7 Antenna Amplifier..................8 Front Accessory Power Supply Socket ............9...
Page 298: General Description
General Description ENTERTAINMENT 1. General Description A: CAUTION • Before disassembling or reassembling parts, al- ways disconnect the battery ground cable. When re- placing radio, control module and other parts provided with memory functions, record memory con- tents before disconnecting the battery ground cable. Otherwise, the memory will be erased.
Page 299: Radio System
Radio System ENTERTAINMENT 2. Radio System A: WIRING DIAGRAM 1. RADIO <Ref. to WI-101, WIRING DIAGRAM, Audio System.> B: INSPECTION Symptom Repair order No power coming in. (No display and no sound from speakers.) (1) Check the fuse and power supply for radio. (2) Check the radio ground.
Page 300: Front Accessory Power Supply Socket System
Front Accessory Power Supply Socket System ENTERTAINMENT 3. Front Accessory Power Sup- ply Socket System A: WIRING DIAGRAM 1. FRONT ACCESSORY POWER SUPPLY SOCKET SYSTEM <Ref. to WI-190, WIRING DIAGRAM, Front Acces- sory Power Supply System.> ET-4...
Page 301: Radio Body
Radio Body ENTERTAINMENT 4. Radio Body 5) Insert the flat tip screwdriver to the position (A) and release the claw with pulling out the lower por- A: REMOVAL tion of center console panel. 1) Disconnect the ground cable from battery. CAUTION: 2) Remove the front cover.
Page 302: Front Speaker
Front Speaker ENTERTAINMENT 5. Front Speaker A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the front door trim. <Ref. to EI-35, RE- MOVAL, Front Door Trim.> 3) Remove the front speaker mounting screws. ET-00003 4) Disconnect the harness connector and remove front speaker.
Page 303: Antenna
Antenna ENTERTAINMENT 6. Antenna 3) Deposit conductive silver composition (DU- PONT No. 4817) on the broken portion with a draw- A: INSPECTION ing pen. Measure the resistance between antenna terminal and each antenna wire. If an antenna wire is OK, resistance will be less than 1 Ω.
Page 304: Antenna Amplifier
Antenna Amplifier ENTERTAINMENT 7. Antenna Amplifier A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear quarter upper trim. <Ref. to EI- 45, REMOVAL, Rear Quarter Trim.> 3) Disconnect the harness connector and terminal. 4) Remove the mounting screws and detach anten- na amplifier.
Page 305: Front Accessory Power Supply Socket
Front Accessory Power Supply Socket ENTERTAINMENT 8. Front Accessory Power Sup- ply Socket A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the front cover. <Ref. to EI-39, RE- MOVAL, Console Box.> 3) Disconnect the harness connectors and remove the front accessory power supply socket.
Page 306 Front Accessory Power Supply Socket ENTERTAINMENT ET-10...
Page 307 COMMUNICATION SYSTEM Page General Description ..................2 Horn System ....................3 Horn ......................4 Horn Switch....................5...
Page 308: General Description
General Description COMMUNICATION SYSTEM 1. General Description A: CAUTION • Before disassembling or reassembling parts, al- ways disconnect the battery ground cable. When re- placing radio, control module and other parts provided with memory functions, record memory con- tents before disconnecting the battery ground cable. Otherwise, the memory will be erased.
Page 309: Horn System
Horn System COMMUNICATION SYSTEM 2. Horn System A: WIRING DIAGRAM 1. HORN <Ref. to WI-193, WIRING DIAGRAM, Horn Sys- tem.> B: INSPECTION 1. HORN RELAY Measure the horn relay resistance between termi- nals (indicated in table below) when connecting ter- minal No.
Page 310: Horn
Horn COMMUNICATION SYSTEM 3. Horn A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the front fog light assembly (LH). <Ref. to LI-19, REMOVAL, Front Fog Light Assembly.> 3) Remove the horn bracket mounting bolt (A). 4) Disconnect the harness connector and remove the horn assembly (B).
Page 311: Horn Switch
Horn Switch COMMUNICATION SYSTEM 4. Horn Switch A: REMOVAL WARNING: Before servicing, be sure to read the notes in the AB section for proper handling of the driver airbag module. <Ref. to AB-3, CAUTION, Gener- al Description.> 1) Disconnect the ground cable from battery. 2) Remove the driver’s airbag module.
Page 312 Horn Switch COMMUNICATION SYSTEM COM-6...
Page 313 GLASS/WINDOW/MIRROR Page General Description ..................2 Power Window System ................6 Power Window Control Switch ..............7 Remote Control Mirror System..............10 Scalp Cap....................11 Outer Mirror Assembly ................12 Outer Mirror....................14 Remote Control Mirror Switch ..............15 Front Door Glass..................17 Front Regulator and Motor Assembly ............21 Rear Door Glass ..................22 Rear Regulator and Motor Assembly ............24 Windshield Glass ..................25...
Page 314: General Description
General Description GLASS/WINDOW/MIRROR 1. General Description A: COMPONENT 1. FIXED GLASS (10) (11) GW-00326 Windshield glass Locate pin Rear gate glass Dam rubber Fastener (10) Spring Molding Rear quarter glass (11) Cover C pillar Rearview mirror mount Locate pin GW-2...
Page 315: Motor A
General Description GLASS/WINDOW/MIRROR 2. FRONT DOOR GLASS GW-00136 Glass Motor ASSY Tightening torque: N·m (kgf-m, ft-lb) Door sash (Front) Guide rail T1: 7.5 (0.75, 5.4) Door sash (Rear) T2: 14 (1.4, 10.3) Regulator ASSY T3: 6 (0.6, 4.3) GW-3...
Page 316 General Description GLASS/WINDOW/MIRROR 3. REAR DOOR GLASS GW-00003 Door sash (Front) Motor ASSY Tightening torque: N·m (kgf-m, ft-lb) Glass T1: 7.5 (0.75, 5.4) Door sash (Rear) T2: 14 (1.4, 10.3) Regulator ASSY GW-4...
Page 317 General Description GLASS/WINDOW/MIRROR 4. MIRRORS GW-00298 Outer mirror (Large-sized) Scalp cap Spring Outer mirror (Standard) Rearview mirror Mirror Mount B: CAUTION • When the electrical connectors are disconnected, always conduct an operational check after connecting them again. • Avoid impact and damage to glass. C: PREPARATION TOOL TOOL NAME REMARKS...
Page 318: Power Window System
Power Window System GLASS/WINDOW/MIRROR 2. Power Window System A: WIRING DIAGRAM 1. POWER WINDOW <Ref. to WI-240, WIRING DIAGRAM, Power Window System.> B: INSPECTION Symptom Repair order (1) Fuse (SBF-6) (F/B No. 18) (2) Power window circuit breaker All power windows does not operate. (3) Power window relay (4) Wire harness (1) Power window main switch...
Page 319: Power Window Control Switch
Power Window Control Switch GLASS/WINDOW/MIRROR 3. Power Window Control 3) Remove the switch panel. Switch A: REMOVAL 1. MAIN SWITCH 1) Disconnect the ground cable from battery. 2) Using a flat tip screwdriver, remove the screw cov- GW-00008 4) Disconnect the connector. B: INSTALLATION 1.
Page 320: Main Switch
Power Window Control Switch GLASS/WINDOW/MIRROR C: INSPECTION 1. MAIN SWITCH Measure the switch resistance. • LHD model Switch position Terminal No. Standard Less than 1 Ω AUTO UP 13 and 2, 1 and 5 Less than 1 Ω 13 and 2, 1 and 5 1 and 2 Less than 1 Ω...
Page 321 Power Window Control Switch GLASS/WINDOW/MIRROR • RHD model Switch position Terminal No. Standard Less than 1 Ω AUTO UP 12 and 7, 6 and 1 Less than 1 Ω 12 and 7, 6 and 1 1 and 6 Less than 1 Ω Driver’s side 1 and 7 6 and 7...
Page 322: Remote Control Mirror System
Remote Control Mirror System GLASS/WINDOW/MIRROR 4. Remote Control Mirror System A: WIRING DIAGRAM 1. REMOTE CONTROL MIRROR <Ref. to WI-253, WIRING DIAGRAM, Remote Controlled Rearview Mirror System.> B: INSPECTION Symptom Repair order (1) Fuse (F/B No. 4) (F/B No. 13) (F/B No. 17) (F/B No. 18) All function does not operate.
Page 323: Scalp Cap
Scalp Cap GLASS/WINDOW/MIRROR 5. Scalp Cap A: REPLACEMENT 1) Turn the rearview mirror downward. 2) Insert a thin screw driver, push the clip part of scalp cap, and remove the scalp cap. GW-00224 3) Insert the claw at the bottom of scalp cap into door mirror.
Page 324: Outer Mirror Assembly
Outer Mirror Assembly GLASS/WINDOW/MIRROR 6. Outer Mirror Assembly A: REMOVAL 1) Remove the door trim. <Ref. to EI-35, REMOV- AL, Front Door Trim.> 2) Remove the mirror gusset cover. : (1) GW-00061 (1) Hook 3) Disconnect the mirror connector. 4) Remove the grommet, and then loosen the screws to remove mirror assembly.
Page 325 Outer Mirror Assembly GLASS/WINDOW/MIRROR C: INSPECTION Check to ensure that the rearview mirror moves properly when battery voltage is applied to terminals. Heated mirror not-equipped model: Switch position Terminal No. — 1 (+) and 3 (−) DOWN 3 (+) and 1 (−) LEFT 2 (+) and 3 (−) RIGHT...
Page 326: Outer Mirror
Outer Mirror GLASS/WINDOW/MIRROR 7. Outer Mirror A: REPLACEMENT 1) Remove the door mirror assembly. <Ref. to GW- 12, REMOVAL, Outer Mirror Assembly.> 2) Warm the area around the mirror holder (1) with a hair drier until the edges of the mirror holder be- come soft (about 2 or 3 minutes with a 1,000 W dri- er.) 3) Use a flat tip screwdriver without sharp edges to...
Page 327: Remote Control Mirror Switch
Remote Control Mirror Switch GLASS/WINDOW/MIRROR 8. Remote Control Mirror Switch A: REMOVAL Refer to Power Window Control Switch, because the remote control mirror switch is integrated with power window control switch. <Ref. to GW-7, REMOVAL, Power Window Control Switch.> B: INSTALLATION Refer to Power Window Control Switch, because the remote control mirror switch is integrated with power window control switch.
Page 328 Remote Control Mirror Switch GLASS/WINDOW/MIRROR C: INSPECTION Move the rearview mirror switch to each position and check continuity between terminals. GW-00012 Change over switch right position: Switch position Terminal No. Standard — More than 1MΩ 8 and 3, 6 and 7 Less than 1Ω...
Page 329: Front Door Glass
Front Door Glass GLASS/WINDOW/MIRROR 9. Front Door Glass 7) Remove the rear end of door weather strip and weather strip outer. A: REMOVAL 1) Remove the front door trim. <Ref. to EI-35, RE- MOVAL, Front Door Trim.> 2) Remove the front speaker. <Ref. to ET-6, RE- MOVAL, Front Speaker.>...
Page 330 Front Door Glass GLASS/WINDOW/MIRROR B: INSTALLATION 4) For adjustment of clearance between front glass and center pillar cover, loosen the nuts (A), and 1) Install in the reverse order of removal. move the rear sash back and forward until clear- CAUTION: ance becomes the value shown.
Page 331 Front Door Glass GLASS/WINDOW/MIRROR 6) Adjust so that the upper and lower ends of cen- For preventing wind noise, adjust the glass at the ter pillar are the same size. position where tip of gusset is raised up a little. GW-00024 (A) 0 —...
Page 332 Front Door Glass GLASS/WINDOW/MIRROR NOTE: Do not tilt the sash bracket to inner panel during ad- justment. Otherwise smooth regulator operation cannot be achieved. GW-00026 (1) Sash bracket (2) Rear sash (3) Adjust a line parallel (4) Rear sash (5) Inner panel 10) Make adjustment of front sash in the same manner as that of rear sash.
Page 333: Front Regulator And Motor Assembly
Front Regulator and Motor Assembly GLASS/WINDOW/MIRROR 10.Front Regulator and Motor C: INSPECTION 1) Make sure that the power window motor rotates Assembly properly when battery voltage is applied to the ter- A: REMOVAL minals of motor connector. 2) Change polarity of battery connections to termi- 1) Remove the door glass.
Page 334: Rear Door Glass
Rear Door Glass GLASS/WINDOW/MIRROR 11.Rear Door Glass 6) Loosen the two screws to remove the weather strip outer. A: REMOVAL 1) Remove the rear door trim. <Ref. to EI-36, RE- MOVAL, Rear Door Trim.> 2) Remove the front speaker. <Ref. to ET-6, RE- MOVAL, Front Speaker.>...
Page 335 Rear Door Glass GLASS/WINDOW/MIRROR B: INSTALLATION 2) Adjust the crimp of glass using the following di- mensions as a guide line. 1) Install in the reverse order of removal. CAUTION: Make sure that the glass stay is placed securely in sash. 2) Adjust the rear door glass.
Page 336: Rear Regulator And Motor Assembly
Rear Regulator and Motor Assembly GLASS/WINDOW/MIRROR 12.Rear Regulator and Motor As- sembly A: REMOVAL 1) Remove the door glass. <Ref. to GW-22, RE- MOVAL, Rear Door Glass.> 2) Remove the front sash. 3) Disconnect the motor connector. 4) Loosen the four bolts and two nuts to remove regulator assembly.
Page 337: Windshield Glass
Windshield Glass GLASS/WINDOW/MIRROR 13.Windshield Glass A: REMOVAL 1. USING WINDSHIELD KNIFE 1) Remove the cowl panel. <Ref. to EI-32, REMOV- AL, Cowl Panel.> 2) Remove the glass molding. 3) Tape the body side of the circumference of wind- shield glass for protection. GW-00070 4) Apply sufficient amount of soapy water to the ad- hesive layer.
Page 338 Windshield Glass GLASS/WINDOW/MIRROR B: INSTALLATION 4) Apply the dam rubber to back of glass. 1) Clean the external circumference of windshield glass with alcohol or white gasoline. 2) Remove the adhesive layer on the body using cutter knife to obtain smooth face 2 mm (0.08 in) thick.
Page 339 Windshield Glass GLASS/WINDOW/MIRROR 6) Apply primer to the adhesive layer of glass using 9) Apply adhesive to the glass end surface as shown. sponge. Adhesive: Glass primer: Dow Automotive Dow Automotive ESSEX U-400 HV U-401 or U-402 10) Fit the matching pins using suction rubber cup 7) Apply primer to the adhesive layer of body.
Page 340: Inner Rearview Mirror
Inner Rearview Mirror GLASS/WINDOW/MIRROR 14.Inner Rearview Mirror A: REMOVAL NOTE: The spring cannot be reused. Prepare a new spring before removal. 1) Turn the mirror base 90 degrees clockwise or counterclockwise to remove it. GW-00046 2) Remove the spring from mirror base. GW-00047 CAUTION: Be careful not to damage the mirror surface.
Page 341: Rear Gate Glass
Rear Gate Glass GLASS/WINDOW/MIRROR 15.Rear Gate Glass 2) Install the glass in same procedure as for wind- shield glass. A: REMOVAL 1) Remove the rear gate garnish. <Ref. to EB-20, REMOVAL, Rear Gate Garnish Assembly.> 2) Remove the electrical connector from rear de- fogger terminal.
Page 342: Rear Window Defogger System
Rear Window Defogger System GLASS/WINDOW/MIRROR 16.Rear Window Defogger System A: WIRING DIAGRAM 1. REAR WINDOW DEFOGGER <Ref. to WI-251, WIRING DIAGRAM, Rear Window Defogger System.> B: INSPECTION Symptom Repair order (1) Fuse (M/B No. 1) (F/B No. 17) (2) Rear defogger relay (3) Rear defogger timer Rear window defogger does not operate.
Page 343: Rear Window Defogger
Rear Window Defogger GLASS/WINDOW/MIRROR 17.Rear Window Defogger 5) Apply positive lead of voltmeter to positive terminal of heat wire, and then move the negative lead along A: INSPECTION the wire up to negative terminal end. If voltage chang- es from zero to several volts during movement of CAUTION: lead, heat wire is open at the voltage change point.
Page 344: Rear Quarter Glass
Rear Quarter Glass GLASS/WINDOW/MIRROR 18.Rear Quarter Glass A: REMOVAL Remove the glass in the same procedure as for windshield glass. <Ref. to GW-25, REMOVAL, Windshield Glass.> GW-00054 Molding Locating pin Weather strip Adhesive Body Rear door glass Interior trim Cover C pillar B: INSTALLATION 2) Install the glass in the same procedure as for wind- shield glass.
Page 345 Rear Quarter Glass GLASS/WINDOW/MIRROR NOTE: When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy im- pact for at least three days. GW-33...
Page 346: Roof Window Glass
Roof Window Glass GLASS/WINDOW/MIRROR 19.Roof Window Glass A: REMOVAL <Ref. to SR-5, REMOVAL, Sunroof Lid.> B: INSTALLATION <Ref. to SR-5, INSTALLATION, Sunroof Lid.> C: ADJUSTMENT <Ref. to SR-5, ADJUSTMENT, Sunroof Lid.> GW-34...
Page 347 BODY STRUCTURE Page General Description ..................2 Datum Points....................3 Datum Dimensions..................11...
Page 348 General Description BODY STRUCTURE 1. General Description A: PREPARATION TOOL TOOL NAME REMARKS Tram tracking gauge Used for measuring dimen- sion. Tape measure Used for measuring dimen- sion. BS-2...
Page 349 Datum Points BODY STRUCTURE 2. Datum Points A: LOCATION NOTE: • Datum points are specified for body repair. • Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment accuracy. • Both right and left reference points are symmetrical. (38) (39) (35)
Page 350 Datum Points BODY STRUCTURE Radiator panel gauge hole 6 mm (14) Fender attaching hole 10 mm (31) Harness attaching hole 7 mm (0.24 in) dia. (Vehicle center) (0.39 in) dia. (Symmetrical) (0.28 in) dia. (Symmetrical) Radiator attaching hole 12 mm (15) Fender attaching hole 10 mm (32)
Page 351 Datum Points BODY STRUCTURE (27) (29) (18) (28) (44) (31) (18) (44) (45) (19) (46) (47) (48) (24) (42) (41) (45) (43) (46) (43) (47) (48) BS-00002 (18) Front weather strip attaching hole (31) Harness attaching hole 7 mm (45) Combination light attaching hole 5.2 mm (0.20 in) dia.
Page 352 Datum Points BODY STRUCTURE (36) (62) (63) (61) (66) (52) (53) (54) (65) (12) (55) (56) (57) (58) (59) (60) (64) (51) (51) (64) (52) (53) (54) (65) (12) (55) (56) (57) (58) (59) (60) (61) (66) (62) (63) (36) BS-00003 (12) Front strut attaching hole 9.5 mm...
Page 353 Datum Points BODY STRUCTURE BS-00005 BS-00004 BS-00007 BS-00006 (10) (12) (11) BS-00008 BS-00009 (14) (18) (16) (19) (17) (13) (15) BS-00010 BS-00011 BS-7...
Page 354 Datum Points BODY STRUCTURE (23) (21) (24) (20) (22) BS-00015 BS-00014 (27) (25) (26) (28) BS-00016 BS-00017 (29) (34) (31) (30) BS-00019 BS-00018 (37) (32) (35) (36) (33) BS-00020 BS-00021 BS-8...
Page 355 Datum Points BODY STRUCTURE (38) (42) (39) (40) (41) BS-00022 BS-00023 (43) (44) BS-00024 BS-00025 (46) (45) (54) (65) (52) (47) (48) (53) (51) BS-00027 BS-00026 (56) (58) (55) (57) (59) (60) BS-00028 BS-00029 BS-9...
Page 356 Datum Points BODY STRUCTURE (63) (66) (62) (61) BS-00030 BS-00031 (64) BS-00032 BS-10...
Page 357 Datum Dimensions BODY STRUCTURE 3. Datum Dimensions A: MEASUREMENT Refer to LOCATION for details on measurement points. <Ref. to BS-3, LOCATION, Datum Points.> NOTE: • Using a tram tracking gauge, measure all dimen- sions. • When using a tape measure, carefully measure dimensions without letting the tape measure sag or twist.
Page 358 Datum Dimensions BODY STRUCTURE 1. CENTER STRUCTURE (12) (36) (64) (62) (52) (53) (54) (61) (55) (57)(58) (59) 11(0.43) 9(0.35) 20(0.79) 14(0.55) 317(12.48) 485(19.09) 585(23.03) 77(3.03) 474(18.66) 329(12.95) 135(5.31) 620(24.41) 356(14.02) 1070(42.13) 1270(50.00) 694(27.32) 230(9.06) (36) (12) (53) (61) (64) (52) (54) (55)
Page 359 Datum Dimensions BODY STRUCTURE 2. SUSPENSION CROSSMEMBER (62) (54) (65) (66) (63) 75(2.95) 139(5.47) 2547(100.28) 150(5.91) (62) (54) (63) (66) (65) (65) (66) (63) (54) (62) BS-00036 *1: Standard line *2: Side sill Unit: mm (in) BS-13...
Page 360: Front Structure
Datum Dimensions BODY STRUCTURE 3. FRONT STRUCTURE (13) (10) (13) (12) (11) (10) (12) (14) (15) BS-00037 Unit: mm (in) Point to point Dimension Point to point Dimension (1) to (11) 822 (32.36) (7) LH to (15) LH 1,067 (42.01) (2) RH to (11) 842 (33.15) (8) RH to (8) LH...
Page 361 Datum Dimensions BODY STRUCTURE (38) (32) (39) (35) (40) (29) (33) (36) (30) (34) (36) (25) (26) (37) (23) (31) (21) (22) (20) (16) (17) BS-00038 Unit: mm (in) Point to point Dimension Point to point Dimension (16) RH to (20) RH 980 (38.58) (30) LH to (33) LH 796 (31.34)
Page 362 Datum Dimensions BODY STRUCTURE 4. REAR STRUCTURE (27) (18) (29) (19) (28) (18) (44) (24) (31) (19) (44) (24) (41) (42) (46) (45) (47) (46) (48) (45) (47) (48) BS-00039 Unit: mm (in) Point to point Dimension Point to point Dimension (18) RH to (18) LH 1,449 (57.05)
Page 363 INSTRUMENTATION/DRIVER INFO Page General Description ..................2 Combination Meter System .................3 Combination Meter Assembly ..............10 Speedometer.....................13 Tachometer ....................14 Fuel Gauge ....................15 Water Temperature Gauge ...............16 Ambient Sensor..................17...
Page 364: General Description
General Description INSTRUMENTATION/DRIVER INFO 1. General Description A: SPECIFICATION Speedometer Electric pulse type Temperature gauge Cross coil type Fuel gauge Cross coil type Tachometer Electric pulse type Turn signal indicator light 14 V — 2 W Charge indicator light 14 V — 1.4 W Oil pressure indicator light ABS warning light 14 V —...
Page 365: Combination Meter System
Combination Meter System INSTRUMENTATION/DRIVER INFO 2. Combination Meter System A: WIRING DIAGRAM 1. COMBINATION METER <Ref. to WI-106, WIRING DIAGRAM, Combination Meter.> 2. OUTSIDE TEMPERATURE INDICATOR <Ref. to WI-236, WIRING DIAGRAM, Outside Temperature Display System.> IDI-3...
Page 366 Combination Meter System INSTRUMENTATION/DRIVER INFO B: INSPECTION CAUTION: When measuring voltage and resistance of the ECM, TCM, or each sensor, use a tapered pin with a diameter of less than 0.64 mm (0.025 in) in order to avoid poor contact. Do not insert the pin more than 2 mm (0.08 in).
Page 367 Combination Meter System INSTRUMENTATION/DRIVER INFO 2. CHECK POWER SUPPLY AND GROUND CIRCUIT Step Check CHECK POWER SUPPLY FOR COMBINA- Is the voltage more than 10 V? Go to step 2. Check the harness TION METER. for open or short 1) Remove the combination meter. <Ref. to between ignition IDI-10, REMOVAL, Combination Meter switch and combi-...
Page 368 Combination Meter System INSTRUMENTATION/DRIVER INFO Step Check CHECK HARNESS BETWEEN VEHICLE Is the resistance less than 10 Go to step 4. Repair the wiring Ω? SPEED SENSOR AND ENGINE GROUND. harness. 1) Turn the ignition switch to OFF. 2) Measure the resistance between vehicle speed sensor connector and engine ground.
Page 369 Combination Meter System INSTRUMENTATION/DRIVER INFO 5. CHECK ENGINE CONTROL MODULE (ECM) Step Check Is the voltage 0 V ← → 14 V? CHECK ECM SIGNAL. Go to step 2. Check ECM. <Ref. 1) Start the engine. to EN(H4SO)-2, 2) Measure the voltage between ECM con- Basic Diagnostics nector and engine ground.
Page 370 Combination Meter System INSTRUMENTATION/DRIVER INFO Step Check CHECK HARNESS BETWEEN FUEL LEVEL Is the resistance less than 10 Go to step 5. Repair the wiring Ω? SENSOR AND FUEL SUB LEVEL SENSOR. harness. Measure the resistance between fuel level sen- sor harness connector terminal and fuel sub level sensor harness connector terminal.
Page 371 Combination Meter System INSTRUMENTATION/DRIVER INFO Step Check CHECK HARNESS BETWEEN AMBIENT Is the resistance less than 10 Replace the com- Repair the wiring Ω? SENSOR AND COMBINATION METER. bination meter harness. 1) Turn the ignition switch to OFF. printed circuit. 2) Disconnect the connector from combination meter.
Page 372: Combination Meter Assembly
Combination Meter Assembly INSTRUMENTATION/DRIVER INFO 3. Combination Meter Assem- A: REMOVAL 1) Disconnect the ground cable from battery. 2) Set the tilt steering at lowest position. 3) Remove the screws and detach meter visor. IDI00001 4) Remove the screws of combination meter and pull out the meter toward you.
Page 373 Combination Meter Assembly INSTRUMENTATION/DRIVER INFO C: DISASSEMBLY CAUTION: Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces. 1) Disengage the claw (E) to remove case (B) from back cover (A). 2) Disengage the claw (F) to remove meter glass (D) and reflector (C) from inner case. IDI00003 3) Pull up the claw (A) in portion (B) of combination meter printed circuit (C) with combination pliers.
Page 374: Bulb Replacement
Combination Meter Assembly INSTRUMENTATION/DRIVER INFO 1. BULB REPLACEMENT (7) (8) (9) (10) (11) (12) (13) (14) (15) IDI00024 (1) Charge warning (2) Tachometer (3) Speedometer and tachometer (4) Rear fog light indicator light (5) HI-beam indicator (6) Turn signal indicator RH (7) Speedometer (8) Turn signal indicator LH (9) Cruise indicator light or rear differential oil tem-...
Page 375: Speedometer
Speedometer INSTRUMENTATION/DRIVER INFO 4. Speedometer A: REMOVAL Disassemble the combination meter, and then re- move the speedometer. <Ref. to IDI-11, DISAS- SEMBLY, Combination Meter Assembly.> B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Measure the speedometer resistance. IDI00006 (1) COS−...
Page 376: Tachometer
Tachometer INSTRUMENTATION/DRIVER INFO 5. Tachometer A: REMOVAL Disassemble the combination meter, and then re- move the tachometer. <Ref. to IDI-11, DISASSEM- BLY, Combination Meter Assembly.> B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Measure the tachometer resistance. IDI00006 (1) COS−...
Page 377: Fuel Gauge
Fuel Gauge INSTRUMENTATION/DRIVER INFO 6. Fuel Gauge A: REMOVAL Disassemble the combination meter, and then remove the water temperature gauge and fuel gauge assem- bly. <Ref. to IDI-11, DISASSEMBLY, Combination Meter Assembly.> B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Measure the fuel gauge resistance.
Page 378: Water Temperature Gauge
Water Temperature Gauge INSTRUMENTATION/DRIVER INFO 7. Water Temperature Gauge A: REMOVAL Disassemble the combination meter, and then remove the water temperature gauge and fuel gauge assem- bly. <Ref. to IDI-11, DISASSEMBLY, Combination Meter Assembly.> B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Measure the water temperature gauge resistance.
Page 379: Ambient Sensor
Ambient Sensor INSTRUMENTATION/DRIVER INFO 8. Ambient Sensor A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the ambient sensor connector. 3) Remove the ambient sensor (A) from radiator lower panel. IDI00008 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Measure the ambient sensor resistance.
Page 380 Ambient Sensor INSTRUMENTATION/DRIVER INFO IDI-18...
Page 381 SEAT Page General Description ..................2 Front Seat ....................6 Rear Seat ....................13...
Page 382 General Description SEAT 1. General Description A: COMPONENT 1. FRONT SEAT (28) (26) (23) (25) (27) (24) (10) (22) (21) (11) (19) (12) (20) (18) (17) (13) (14) (16) (15) SE-00254 SE-2...
Page 383 General Description SEAT Backrest cover (14) Connecting wire (27) Headrest lock bushing Backrest pad (15) Outer slide rail (28) Backrest frame ASSY Backrest side cover (16) ® TORX bolt Armrest ASSY (17) Bolt cover RH Tightening torque: N·m (kgf-m, ft-lb) Hinge cover cap (18) Reclining lever...
Page 384 General Description SEAT 2. REAR SEAT (12) (13) (14) (16) (15) (10) (17) (11) SE-00253 Webbing guide cap Seat cushion cover (15) Backrest cover LH Webbing guide Seat cushion pad (16) Backrest frame LH Center pillow (10) Hinge CTR (17) Backrest pad LH Headrest free bushing (11)
Page 385 General Description SEAT B: CAUTION When removing the front seat from a side airbag loaded vehicle, follow cautions given in the airbag section. C: PREPARATION TOOL 1. GENERAL TOOL TOOL NAME REMARKS Long nose pliers Used for removing hog ring. Hog ring pliers Used for installing hog ring.
Page 386 Front Seat SEAT 2. Front Seat 8) Remove the two bolts at front side of seat rail. A: REMOVAL 1) Disconnect the ground cable from battery. WARNING: The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate.
Page 387 Front Seat SEAT 3) Loosen the screw, and then remove the hinge 6) Remove the hook at bottom of seat backrest. cover. SE-00051 SE-00042 7) Open the zipper behind backrest. 4) Remove two reclining hinge securing bolts on each side. SE-00262 8) Remove the hog rings (A) at side of inside back- rest from backrest frame.
Page 388 Front Seat SEAT 9) Remove the hog rings (A) which secure the 14) Remove the connecting wire (A), and then backrest cover and backrest pad. loosen the bolts and nuts to remove slide rail. SE-00242 10) Remove the headrest bushes. NOTE: Push the headrest bushes to outside of seat from inside, and then remove them.
Page 389 Front Seat SEAT 17) Remove the hog rings (A), and then remove the 4) Remove two bolts from the reclining hinge on seat cushion cover from seat cushion pad. each side. : (A) SE-00299 18) Open the zipper at bottom of headrest, and then remove the headrest cover from headrest.
Page 390 Front Seat SEAT 7) Open the zipper behind backrest. 10) Remove the headrest bushes. NOTE: Push the headrest bushes to outside of seat from inside, and then remove them. SE-00262 8) Remove the hog rings (A) at side of inside back- rest from backrest frame.
Page 391 Front Seat SEAT 14) Loosen the bolts and nuts to remove the seat 17) Remove the hog rings (A), and then remove the cushion from slide rail. seat cushion cover from seat cushion pad. : (A) SE-00299 18) Open the zipper at bottom of headrest, and then remove the headrest cover from headrest.
Page 392 Front Seat SEAT E: INSPECTION Inspect that there is no tear and fray on backrest cover assembly. NOTE: When there is tear or fray on the door side of back- rest cover assembly, replace the backrest cover assembly with a new one, because there is a pos- sibility that the side airbag will not operate normally.
Page 393 Rear Seat SEAT 3. Rear Seat C: DISASSEMBLY 1) Remove the rear seat. <Ref. to SE-13, REMOV- A: REMOVAL AL, Rear Seat.> 1) Remove the bolts, and then detach the rear seat 2) Remove the hog rings (A) from around the seat cushion.
Page 394 Rear Seat SEAT D: ASSEMBLY Assemble in the reverse order of disassembly. NOTE: • Do not contaminate or damage the cover. • While installing the hog rings, prevent the seat from getting wrinkled. SE-14...
Page 395 SECURITY AND LOCK Page General Description ..................2 Door Lock Control System ................9 Keyless Entry System ................14 Front Inner Remote ...................22 Front Outer Handle ...................23 Front Door Latch Assembly...............24 Front Door Lock Actuator ................25 Rear Inner Remote..................26 Rear Outer Handle ..................27 Rear Door Latch Assembly ...............28 Rear Door Lock Actuator................29 Rear Gate Outer Handle ................30...
Page 396: General Description
General Description SECURITY AND LOCK 1. General Description A: COMPONENT 1. DOOR LOCK ASSEMBLY Without double lock: SL-00288 ⋅ Inner remote ASSY Striker Tightening torque: N m (kgf-m, ft-lb) Inner remote cover Door outer handle T1: 6.4 (0.65, 4.7) Auto-door lock actuator Key cylinder T2: 7.4 (0.75, 5.5) Door latch...
Page 397 General Description SECURITY AND LOCK With double lock: SL-00289 ⋅ Inner remote ASSY Door outer handle Tightening torque: N m (kgf-m, ft-lb) Inner remote cover Key cylinder (switch) T1: 6.4 (0.65, 4.7) Auto-door lock actuator Key cylinder retainer T2: 7.4 (0.75, 5.5) Door latch Key cylinder retainer cover T3: 17.6 (1.8, 13.0)
Page 398 General Description SECURITY AND LOCK 2. REAR GATE LOCK SL-00103 ⋅ Rear gate latch ASSY Striker Tightening torque: N m (kgf-m, ft-lb) Rear gate actuator Rear gate outer handle T1: 7.5 (0.75, 5.4) T2: 25 (2.5, 18.4) SL-4...
Page 399 General Description SECURITY AND LOCK 3. HOOD LOCK AND REMOTE OPENERS SL-00104 ⋅ Hood lock ASSY Pull handle ASSY Tightening torque: N m (kgf-m, ft-lb) Lever ASSY Fuel flap cable ASSY T1: 7.4 (0.75, 5.4) Hood cable ASSY T2: 33 (3.4, 24.6) SL-5...
Page 400 General Description SECURITY AND LOCK 4. IMMOBILIZER SYSTEM IM-00004 Antenna Immobilizer control module (IMM Transponder ECM) Immobilizer indicator light (LED bulb) NOTE: IMM ECM location for RHD model is symmetrically opposite. SL-6...
Page 401 General Description SECURITY AND LOCK 5. KEYLESS ENTRY SYSTEM SL-00055 Double lock module (with double Rear gate latch switch Door switch lock) Keyless entry control module (RHD model) Keyless entry control module (LHD model) B: CAUTION • Be careful not to damage the airbag system wiring harness when servicing the ignition key •...
Page 402 General Description SECURITY AND LOCK C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925580000 PULLER Used for removing trim clip. ST-925580000 2. GENERAL TOOL TOOL NAME REMARKS Circuit tester Used for measuring resistance and voltage. Drill Used for replacing ignition key lock. SL-8...
Page 403: Door Lock Control System
Door Lock Control System SECURITY AND LOCK 2. Door Lock Control System A: WIRING DIAGRAM 1. DOOR LOCK CONTROL <Ref. to WI-198, WIRING DIAGRAM, Door Lock System.> B: INSPECTION 1. SYMPTOM CHART Symptom Repair order Reference The door lock control system does 1.
Page 404 Door Lock Control System SECURITY AND LOCK 2. CHECK FUSE Step Check CHECK FUSE. In the fuse blown out? Replace the fuse Check the power Remove and visually check the fuse No. 2 (in with a new one. supply and ground the main fuse box).
Page 405 Door Lock Control System SECURITY AND LOCK 4. CHECK DOOR LOCK SWITCH AND CIRCUIT Step Check CHECK DOOR LOCK SWITCH CIRCUIT. Is the resistance less than 10 Go to step 2. Go to step 3. Ω? 1) Disconnect the keyless entry control mod- ule or double lock module harness connector.
Page 406 Door Lock Control System SECURITY AND LOCK 5. CHECK DOOR LOCK ACTUATOR AND CIRCUIT Step Check CHECK OUTPUT SIGNAL. Is the voltage more than 10 V? Go to step 2. Replace the key- Measure the voltage between the harness con- less entry control nector terminal of keyless entry control module module or double...
Page 407 Door Lock Control System SECURITY AND LOCK Step Check CHECK KEY CYLINDER LOCK SWITCH. Is the resistance less than 1 Go to step 4. Replace the key Ω? 1) Disconnect the key cylinder lock switch cylinder lock connector. switch. 2) Measure the resistance between key cylin- der lock switch terminals when turning the key cylinder lock switch to lock position.
Page 408: Keyless Entry System
Keyless Entry System SECURITY AND LOCK 3. Keyless Entry System A: WIRING DIAGRAM <Ref. to WI-200, WIRING DIAGRAM, Keyless Entry System.> B: ELECTRICAL SPECIFICATION SL-00036 Content Terminal No. Measuring condition Key warning switch 1 (INPUT) Battery voltage is present when inserting the key into ignition switch. Registration connector 2 (INPUT) 0 V is present when connecting the registration connector.
Page 409 Keyless Entry System SECURITY AND LOCK C: INSPECTION 1. SYMPTOM CHART Symptom Repair order Reference None of the functions of keyless entry 1. Check the transmitter battery. <Ref. to SL-16, CHECK TRANSMIT- system operate. TER BATTERY, INSPECTION, Key- less Entry System.> 2.
Page 410 Keyless Entry System SECURITY AND LOCK Symptom Repair order Reference The room light and ignition switch illu- 1. Check the room light operation. <Ref. to SL-20, CHECK ROOM mination operation does not activate. LIGHT OPERATION, INSPECTION, Keyless Entry System.> 2. Check the ignition switch illumination circuit. <Ref.
Page 411 Keyless Entry System SECURITY AND LOCK 4. CHECK POWER SUPPLY AND GROUND CIRCUIT Step Check CHECK POWER SUPPLY. Is the voltage more than 10 V? Go to step 2. Check the harness 1) Disconnect the keyless entry control mod- for open circuits or ule harness connector.
Page 412 Keyless Entry System SECURITY AND LOCK 6. CHECK DOOR SWITCH Step Check CHECK DOOR SWITCH CIRCUIT. Is the voltage approx. less than Go to step 2. Go to step 3. Measure the voltage between keyless entry 0 V when any one of the doors control module harness connector terminal or rear gate is opened? and chassis ground.
Page 413 Keyless Entry System SECURITY AND LOCK 7. CHECK KEY WARNING SWITCH Step Check CHECK FUSE. Is the fuse blown out? Go to step 2. Replace the fuse Remove and visually check the fuse No. 6 (in with a new one. the main fuse box).
Page 414 Keyless Entry System SECURITY AND LOCK 8. CHECK HAZARD LIGHT OPERATION Step Check CHECK HAZARD LIGHT OPERATION. Does the hazard light blink? Go to step 2. Check the hazard Make sure the hazard light blinks when hazard light circuit. switch is turned ON. CHECK OUTPUT SIGNAL.
Page 415 Keyless Entry System SECURITY AND LOCK 10.CHECK IGNITION SWITCH ILLUMINATION CIRCUIT Step Check CHECK IGNITION SWITCH ILLUMINATION Is the voltage more than 10 V? Go to step 2. Check the harness POWER SUPPLY. for open circuit or 1) Disconnect the ignition switch illumination shorts between harness connector.
Page 416: Front Inner Remote
Front Inner Remote SECURITY AND LOCK 4. Front Inner Remote A: REMOVAL 1) Remove the door trim. <Ref. to EI-35, REMOV- AL, Front Door Trim.> 2) Remove the sealing cover. <Ref. to EB-13, RE- MOVAL, Front Sealing Cover.> 3) Remove a screw and two cables. 4) Remove the front inner remote.
Page 417: Front Outer Handle
Front Outer Handle SECURITY AND LOCK 5. Front Outer Handle A: REMOVAL 1) Remove the door trim. <Ref. to EI-35, REMOV- AL, Front Door Trim.> CAUTION: Do not use excessive force to remove the door panel. This will deform it. 2) Remove the sealing cover.
Page 418: Front Door Latch Assembly
Front Door Latch Assembly SECURITY AND LOCK 6. Front Door Latch Assembly B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. Make sure the lock works properly after installation. 2) Remove the front door trim. <Ref. to EI-35, RE- C: INSPECTION MOVAL, Front Door Trim.>...
Page 419: Front Door Lock Actuator
Front Door Lock Actuator SECURITY AND LOCK 7. Front Door Lock Actuator DOOR ACTUATOR RH: Terminal No. Actuator operation A: REMOVAL Unlocked → Locked No. 1 (+) and No. 4 (–) 1) Remove the front door latch assembly. <Ref. to Locked →...
Page 420: Rear Inner Remote
Rear Inner Remote SECURITY AND LOCK 8. Rear Inner Remote A: REMOVAL 1) Remove the rear door trim. <Ref. to EI-36, RE- MOVAL, Rear Door Trim.> 2) Remove the sealing cover. <Ref. to EB-16, RE- MOVAL, Rear Sealing Cover.> 3) Remove a screw and two cables. 4) Remove the inner remote.
Page 421: Rear Outer Handle
Rear Outer Handle SECURITY AND LOCK 9. Rear Outer Handle A: REMOVAL 1) Remove the rear door trim. <Ref. to EI-36, RE- MOVAL, Rear Door Trim.> CAUTION: Do not use excessive force to remove the door panel. This will deform it. 2) Remove the sealing cover.
Page 422: Rear Door Latch Assembly
Rear Door Latch Assembly SECURITY AND LOCK 10.Rear Door Latch Assembly A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear door trim. <Ref. to EI-36, RE- MOVAL, Rear Door Trim.> 3) Remove the sealing cover. <Ref. to EB-16, RE- MOVAL, Rear Sealing Cover.>...
Page 423: Rear Door Lock Actuator
Rear Door Lock Actuator SECURITY AND LOCK 11.Rear Door Lock Actuator DOOR ACTUATOR RH: Terminal No. Actuator operation A: REMOVAL Unlocked → Locked No. 1 (+) and No. 4 (–) 1) Remove the rear door latch assembly. <Ref. to Locked → Unlocked No.
Page 424: Rear Gate Outer Handle
Rear Gate Outer Handle SECURITY AND LOCK 12.Rear Gate Outer Handle A: REMOVAL 1) Remove the rear gate trim. <Ref. to EI-48, RE- MOVAL, Rear Gate Trim.> 2) Remove the rear wiper motor assembly. <Ref. to WW-17, REMOVAL, Rear Wiper Motor.> 3) Remove the rear finisher.
Page 425: Rear Gate Latch Assembly
Rear Gate Latch Assembly SECURITY AND LOCK 13.Rear Gate Latch Assembly A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear gate trim. <Ref. to EI-48, RE- MOVAL, Rear Gate Trim.> 3) Remove two bolts. SL-00017 4) Remove the rear gate latch assembly, and then disconnect the connector.
Page 426: Rear Gate Latch Lock Actuator
Rear Gate Latch Lock Actuator SECURITY AND LOCK 14.Rear Gate Latch Lock Actua- A: REMOVAL 1) Remove the rear gate latch assembly. <Ref. to SL-31, REMOVAL, Rear Gate Latch Assembly.> 2) Remove three pawls, and then remove the rear gate latch lock actuator from rear gate latch assem- bly.
Page 427: Front Hood Lock Assembly
Front Hood Lock Assembly SECURITY AND LOCK 15.Front Hood Lock Assembly A: REMOVAL 1) Open the hood. 2) Remove the front grille. 3) Remove the bolt. Remove the hood lock assem- bly. 4) Remove the release cable from lock assembly. SL-00019 B: INSTALLATION Install in the reverse order of removal.
Page 428: Remote Openers
Remote Openers SECURITY AND LOCK 16.Remote Openers 6) Rotate the fuel lock inside the quarter panel to left and remove. A: REMOVAL 1. HOOD OPENER 1) Remove the front hood lock assembly. <Ref. to SL-33, REMOVAL, Front Hood Lock Assembly.> 2) Remove the release cable from hood lock.
Page 429: Ignition Key Lock
Ignition Key Lock SECURITY AND LOCK 17.Ignition Key Lock A: REPLACEMENT 1) Remove the ground cable from battery. 2) Remove the steering column. <Ref. to PS-26, REMOVAL, Tilt Steering Column.> 3) Secure the steering column in a vise. Remove the bolt with a drill. SL-00024 4) Remove the ignition key lock.
Page 430: Key Lock Cylinder
Key Lock Cylinder SECURITY AND LOCK 18.Key Lock Cylinder A: REPLACEMENT 1. FRONT DOOR • Without double lock: 1) Remove the door trim. <Ref. to EI-35, REMOVAL, Front Door Trim.> 2) Pull back the sealing cover. <Ref. to EB-13, RE- MOVAL, Front Sealing Cover.>...
Page 431: Immobilizer Control Module
Immobilizer Control Module SECURITY AND LOCK 19.Immobilizer Control Module A: REMOVAL NOTE: The following positions for removal and installation are for LHD models. The positions for RHD models are symmetrically opposite. 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. <Ref. to EI-40, REMOVAL, Instrument Panel Assembly.>...
Page 432: Immobilizer Antenna
Immobilizer Antenna SECURITY AND LOCK 20.Immobilizer Antenna A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. <Ref. to EI-40, REMOVAL, Instrument Panel Assembly.> 3) Remove the screws, separate upper column cover and lower column cover. SL-00062 4) Disconnect the immobilizer antenna connector (A) from immobilizer control module.
Page 433: Keyless Entry Control Module
Keyless Entry Control Module SECURITY AND LOCK 21.Keyless Entry Control Mod- A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box. <Ref. to EI-37, REMOV- AL, Glove Box.> 3) Remove the nut, and then remove the keyless entry control module while disconnecting connec- tor.
Page 434: Double Lock Module
Double Lock Module SECURITY AND LOCK 22.Double Lock Module A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. <Ref. to EI-40, REMOVAL, Instrument Panel Assembly.> 3) Remove the nut, then remove the double lock module while disconnecting the connector.
Page 435: Keyless Transmitter
Keyless Transmitter SECURITY AND LOCK 23.Keyless Transmitter If NG, replace the battery. (Use CR1620 or equiva- lent.) A: REMOVAL D: REPLACEMENT 1. TRANSMITTER BATTERY 1. TRANSMITTER REGISTRATION Remove the battery from transmitter. NOTE: NOTE: • A maximum of three transmitters can be regis- To prevent static electricity damage to transmitter tered for each individual vehicle.
Page 436 Keyless Transmitter SECURITY AND LOCK SL-42...
Page 437 SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) Page General Description ..................2 Sunroof Control System ................4 Sunroof Lid....................5 Sunroof Assembly ..................6 Sunroof Motor .....................8 Sunroof Switch ....................9...
Page 438 General Description SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 1. General Description A: COMPONENT (13) (12) (10) (11) SR-00013 Sunroof lid Harness (13) Shim Rear drain ASSY Sunshade Frame ASSY Garnish Tightening torque: N·m (kgf-m, ft-lb) Motor ASSY (10) Frame bracket T: 7.4 (0.75, 5.4) Drive unit (11) Cover...
Page 439 General Description SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) B: CAUTION • Before disassembling or reassembling parts, always disconnect battery ground cable. When replacing ra- dio, control module and other parts provided with memory functions, record memory contents before dis- connecting the battery ground cable. Otherwise, the memory will be erased.
Page 440 Sunroof Control System SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 2. Sunroof Control System A: WIRING DIAGRAM 1. SUNROOF <Ref. to WI-263, WIRING DIAGRAM, Sunroof System.> B: INSPECTION Symptom Checking order Water leaks. (1) Check roof panel and sunroof lid for improper or poor sealing. (2) Check drain tube for clogging.
Page 441 Sunroof Lid SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 3. Sunroof Lid C: ADJUSTMENT A: REMOVAL 1. ALIGNMENT OF HEIGHT BETWEEN SUNROOF LID AND ROOF PANEL 1) Completely close sunroof lid and open sunshade. 2) Detach the four covers (A) and then remove eight Loosen sunroof lid nuts and then adjust height by add- nuts.
Page 442 Sunroof Assembly SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 4. Sunroof Assembly B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. Be careful not to snag harness. 2) Remove roof trim. <Ref. to EI-47, REMOVAL, Roof Trim.>...
Page 443 Sunroof Assembly SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) E: INSPECTION 1. CHECK FOR MOVEMENT OF SUN- SHADE 1) Attach a spring scale to sunshade edge using a cloth. SR-00008 2) Pull the spring scale to measure force required to move the sunshade. Force required to move sunshade: 25 N (2.5 kgf, 5.5 lb) or less NOTE: Considerable effort is required to start sunshade...
Page 444 Sunroof Motor SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 5. Sunroof Motor C: ADJUSTMENT 1) Reset the sunroof motor. A: REMOVAL (1) Close the sunroof lid completely, and then push the switch to close for more than 1 second. CAUTION: (At this time, the sunroof operates 50 mm (1.97 •...
Page 445 Sunroof Switch SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 6. Sunroof Switch A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove the spot map light. <Ref. to LI-29, RE- MOVAL, Spot Map Light.> 3) Disconnect harness connectors and remove sunroof switch (A). SR-00017 B: INSTALLATION Install in the reverse order of removal.
Page 446 Sunroof Switch SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) SR-10...
Page 447 EXTERIOR/INTERIOR TRIM Page General Description ..................2 Front Grille ....................18 Hood Grille ....................19 Front Under Cover ..................22 Front Bumper ....................23 Rear Bumper.....................30 Mud Guard ....................31 Cowl Panel ....................32 Side Sill Spoiler ..................33 Side Garnish .....................34 Front Door Trim ..................35 Rear Door Trim ..................36 Glove Box....................37 Roof Rail ....................38 Console Box....................39...
Page 448: General Description
General Description EXTERIOR/INTERIOR TRIM 1. General Description A: COMPONENT 1. FRONT GRILLE EI-00230 Front grille Clip Hook Front grille emblem 2. UNDER COVER EI-00002 Under cover Clip Tightening torque: N·m (kgf-m, ft-lb) Service hole cover Bolt T: 18 (1.84, 13.3) EI-2...
Page 449 General Description EXTERIOR/INTERIOR TRIM 3. HOOD GRILLE (10) EI-00003 Hood grille Grille duct Tightening torque: N·m (kgf-m, ft-lb) Black clip Clip T: 4.4 (0.45, 3.25) Black clip Packing C Packing B Packing A Bolt (10) Duct bellows 4. HEAT SHIELD COVER EI-00089 Front heat shield cover Center heat shield cover...
Page 450 General Description EXTERIOR/INTERIOR TRIM 5. FRONT BUMPER (10) EI-00751 Bumper face Upper beam Tightening torque: N·m (kgf-m, ft-lb) E/A form Lower beam T1: 32 (3.3, 24) Fog light Lower beam reinforcement T2: 69 (7.0, 51) Side bracket Clip Main beam (10) Slider side front EI-4...
Page 451 General Description EXTERIOR/INTERIOR TRIM 6. REAR BUMPER EI-00005 Bumper face Rear bumper side bracket ASSY Tightening torque: N·m (kgf-m, ft-lb) Rear bumper upper beam Rear bumper upper beam side T1: 32 (3.3, 24) Rear arch cover T2: 7.4 (0.75, 5.46) Rear bumper front side bracket T3: 4.4 (0.45, 3.26) Center bracket...
Page 452 General Description EXTERIOR/INTERIOR TRIM 7. MUD GUARD EI-00238 Mud guard Screw Air flap Clip Clip (S-shape) EI-6...
Page 453 General Description EXTERIOR/INTERIOR TRIM 8. COWL PANEL EI-00724 Cowl panel Cowl side panel Seal EI-7...
Page 454 General Description EXTERIOR/INTERIOR TRIM 9. SIDE SILL SPOILER EI-00009 Side garnish (Front fender) Side garnish (Rear door) Side garnish (Side sill) Side garnish (Front door) Side garnish (Rear quarter) EI-8...
Page 455 General Description EXTERIOR/INTERIOR TRIM 10.ROOF RAIL EI-00010 Roof rail Tightening torque: N·m (kgf-m, ft-lb) T: 7.5 (0.76, 5.53) 11.DOOR TRIM EI-00233 Front door trim Rear door trim Gusset cover Clip Ash tray Bracket Trim panel Weather strip upper Power window switch cover EI-9...
Page 456 General Description EXTERIOR/INTERIOR TRIM 12.REAR GATE TRIM EI-00012 EI-10...
Page 457 General Description EXTERIOR/INTERIOR TRIM 13.CONSOLE BOX EI-00225 Rear cup holder Console front cover Accessory socket Console lid Console box Console cover Console pocket EI-11...
Page 458 General Description EXTERIOR/INTERIOR TRIM 14.INSTRUMENT PANEL • LHD MODEL (12) (14) (15) (16) (13) (10) (11) EI-00793 Pad & frame Center panel (13) Grille cover Center compartment Air vent grille (14) Air vent grille (Defroster) Grille cover Cup holder (15) Switch panel Lower cover (10)
Page 459 General Description EXTERIOR/INTERIOR TRIM • RHD MODEL (12) (14) (15) (4) (16) (13) (10) (11) EI-00226 Pad & frame Center panel (13) Grille cover Center compartment Air vent grille (14) Air vent grille (Defroster) Grille cover Cup holder (15) Switch panel Lower cover (10) Glove box panel...
Page 460 General Description EXTERIOR/INTERIOR TRIM 15.INNER TRIM (14) (16) (15) (13) (10) (12) (11) EI-00015 Front pillar upper trim Rear skirt trim (15) Center pillar inner rib Center pillar upper trim Side sill rear cover (16) Bracket Rear pillar upper trim (10) Center pillar lower trim Rear rail trim...
Page 461 General Description EXTERIOR/INTERIOR TRIM 16.ROOF TRIM EI-00016 17.FLOOR MAT EI-00111 Vehicle front Floor mat EI-15...
Page 462 General Description EXTERIOR/INTERIOR TRIM 18.LUGGAGE FLOOR MAT EI-00220 Front floor mat Side floor mat RH Side floor mat LH Floor box Center floor mat EI-16...
Page 463 General Description EXTERIOR/INTERIOR TRIM 19.INNER ACCESSORIES EI-00229 Hook Assist grip (Retractable) Tightening torque: N·m (kgf-m, ft-lb) Sun visor T: 2 (0.20, 1.46) B: PREPARATION TOOL TOOL NAME REMARKS Clip remover Used for removal of trim. Clip clamp pliers Used for removal of various clips and clamps. EI-17...
Page 464: Front Grille
Front Grille EXTERIOR/INTERIOR TRIM 2. Front Grille B: INSTALLATION 1) Remove the three hooks remained on body dur- A: REMOVAL ing removal, then install them to front grille. 1) Open the front hood. 2) Remove the two upper clips of front grille side. Slide the front grille side to vehicle outside, then re- move the four lower hooks (A) to remove front grille side.
Page 465: Hood Grille
Hood Grille EXTERIOR/INTERIOR TRIM 3. Hood Grille A: REMOVAL 1) Remove the five screws and clip (A) to remove hood duct. EI-00022 2) Remove the five nuts. EI-00023 3) Remove the three black clips to remove hood grille. EI-00024 EI-19...
Page 466 Hood Grille EXTERIOR/INTERIOR TRIM B: INSTALLATION EI-00025 Black clip Black clip Bolt 1) Replace the black clip (1), (2) with a new one. In- 4) Install the five nuts. stall the clip with arrow mark facing the front side of Tightening torque: grille (A).
Page 467 Hood Grille EXTERIOR/INTERIOR TRIM 6) Install the hood duct with clip (A) and five screws. EI-00022 C: INSPECTION Make sure that the clip is firmly engaged. Make sure that there is no abnormal gap at whole periphery of hood grille. Make sure that there is no damage on hood grille.
Page 468: Front Under Cover
Front Under Cover EXTERIOR/INTERIOR TRIM 4. Front Under Cover A: REMOVAL 1) Lift-up the vehicle. 2) Loosen the bolts, remove the clips, and then re- move the under cover. EI-00030 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 18 N·m (1.84 kgf-m, 13.3 ft-lb) EI-22...
Page 469: Front Bumper
Front Bumper EXTERIOR/INTERIOR TRIM 5. Front Bumper 5) Remove the front grille and front grille side. <Ref. to EI-18, REMOVAL, Front Grille.> A: REMOVAL 6) Remove the eight clips, and pull out the bumper 1) Disconnect the ground cable from battery. slightly.
Page 470 Front Bumper EXTERIOR/INTERIOR TRIM B: INSTALLATION Install in the reverse order of removal. Tightening torque: Refer to COMPONENT in General Descrip- tion. <Ref. to EI-4, FRONT BUMPER, COMPO- NENT, General Description.> EI-24...
Page 471 Front Bumper EXTERIOR/INTERIOR TRIM C: REPAIR 1. COATING METHOD FOR PP BUMPER Pro- cess Process name Job contents Set the bumper on paint worktable if required. Bumper mounting Use paint worktable conforming to inner shape of bumper when possible. EI-00038 (1) Bumper (2) Set bumper section Mask specified part (black base) with masking tape.
Page 472 Front Bumper EXTERIOR/INTERIOR TRIM 2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER NOTE: All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be re- stored to its former condition. Damage limited to shallow scratches that cause only a change in the lustre of the base material or coating, can be almost fully restored.
Page 473 Front Bumper EXTERIOR/INTERIOR TRIM 3) Deep damage such as a break or hole that requires filling Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not really worth the expense. (The surface, however, will become almost flush with adjacent areas.) Recommended repair kit: PP Part Repair Kit (NRM) Pro- cess...
Page 474 Front Bumper EXTERIOR/INTERIOR TRIM Pro- cess Process name Job contents Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam- aged area. Welding EI-00237 (1) Melt hatched area (2) Welding rod (3) Section NOTE: •...
Page 475 Front Bumper EXTERIOR/INTERIOR TRIM Pro- cess Process name Job contents Solid color Metallic color Use a “block” coating method. Use a “block” coating method. • Recommended paint: • Recommended paint: Suncryl (SC) Suncryl (SC) No. 307 Flex Hardener No. 307 Flex Hardener SC Reducer (thinner) SC Reducer (thinner) Top coat (I)
Page 476: Rear Bumper
Rear Bumper EXTERIOR/INTERIOR TRIM 6. Rear Bumper 7) Remove the rear skirt trim. 8) Remove the bolt to remove bracket from A: REMOVAL bumper. 1) Disconnect the ground cable from battery. 2) Remove the bolts and clips. EI-00047 9) Loosen the four nuts to remove rear bumper. EI-00046 10) Disengage the clips to remove bumper upper EI-00043...
Page 477: Mud Guard
Mud Guard EXTERIOR/INTERIOR TRIM 7. Mud Guard A: REMOVAL 1) Jack-up the vehicle. 2) Remove the clip to remove air flap. 3) Remove the screws and clips to remove mud guard. EI-00049 B: INSTALLATION Install in the reverse order of removal. EI-31...
Page 478: Cowl Panel
Cowl Panel EXTERIOR/INTERIOR TRIM 8. Cowl Panel A: REMOVAL 1) Open the front hood. 2) Remove the wiper arm. <Ref. to WW-12, RE- MOVAL, Front Wiper Arm.> 3) Remove the clips to remove cowl side panels. EI-00050 4) Loosen the clips to remove cowl panel. : (A) EI-0725 (A) Clip...
Page 479: Side Sill Spoiler
Side Sill Spoiler EXTERIOR/INTERIOR TRIM 9. Side Sill Spoiler A: REMOVAL Remove the clips (one on front fender arch, six on bottom of side sill spoiler, one on top of side sill spoiler), then remove the side sill spoiler. EI-00053 B: INSTALLATION Install in the reverse order of removal.
Page 480: Side Garnish
Side Garnish EXTERIOR/INTERIOR TRIM 10.Side Garnish B: INSTALLATION 1) Apply the PRIMER (SUMITOMO 3M K-500 or A: REMOVAL equivalent) widely to the slightly larger area where 1) Incise the edge of garnish using cutter, and then double-sided tape was adhered, and then adhere remove the garnish with pulling towards you by the double-sided tape (SUMITOMO 3M 5305 or hands.
Page 481: Front Door Trim
Front Door Trim EXTERIOR/INTERIOR TRIM 11.Front Door Trim A: REMOVAL CAUTION: Do not apply excessive force to the clip. Other- wise the clip may be broken. 1) Disconnect the ground cable from battery. 2) Remove the gusset cover. 3) Pull up the inner remote cover toward you to re- move upper hook.
Page 482: Rear Door Trim
Rear Door Trim EXTERIOR/INTERIOR TRIM 12.Rear Door Trim A: REMOVAL CAUTION: Do not apply excessive force to the clip. Other- wise the clip may be broken. 1) Disconnect the ground cable from battery. 2) Pull up the inner remote cover toward you to re- move upper hook.
Page 483: Glove Box
Glove Box EXTERIOR/INTERIOR TRIM 13.Glove Box A: REMOVAL 1) Open the glove box. 2) Loosen the screws to remove glove box. EI-00057 (A) Hook (B) Clip B: INSTALLATION Install in the reverse order of removal. EI-37...
Page 484: Roof Rail
Roof Rail EXTERIOR/INTERIOR TRIM 14.Roof Rail A: REMOVAL 1) Remove the roof trim. <Ref. to EI-47, REMOVAL, Roof Trim.> 2) Remove the five mounting nuts. 3) Detach the clip at front edge sideways carefully to remove the roof rail upwards. EI-00058 NOTE: Remove the clip at “C”...
Page 485: Console Box
Console Box EXTERIOR/INTERIOR TRIM 15.Console Box 5) Loosen the screws. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console front cover. EI-00726 (A) Hook pawl 3) Remove the shift knob (MT model). 4) Loosen the screws to remove console cover. EI-00061 6) Remove the hook pawl of console side panel to remove console box.
Page 486: Instrument Panel Assembly
Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 16.Instrument Panel Assembly 6) Loosen the screws. A: REMOVAL CAUTION: • All airbag system wiring harness and connec- tors are colored yellow. Do not use electrical test equipment on these circuits. • Be careful not to damage the airbag system harness when servicing the instrument panel.
Page 487 Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 9) Loosen the screws and clips, and then remove NOTE: the side console panel. Remove the front pillar upper trim if necessary. <Ref. to EI-43, REMOVAL, Upper Inner Trim.> 19) Disconnect the combination meter harness con- nector.
Page 488 Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 6) Loosen the four instrument panel installation bolts. B: INSTALLATION Install in the reverse order of removal. CAUTION: • Be careful not to snag the harness. • Make sure to connect the harness connector. NOTE: When setting the instrument panel into position, push the hook into grommet (A) on the body panel.
Page 489: Upper Inner Trim
Upper Inner Trim EXTERIOR/INTERIOR TRIM 17.Upper Inner Trim A: REMOVAL 1) Remove the lower inner trim. <Ref. to EI-44, RE- MOVAL, Lower Inner Trim.> 2) Remove the front molding (A). 3) Remove the front pillar upper trim (B). 4) Detach the front seat belt shoulder anchor, then remove the center pillar upper trim (C).
Page 490: Lower Inner Trim
Lower Inner Trim EXTERIOR/INTERIOR TRIM 18.Lower Inner Trim A: REMOVAL 1) Remove the side sill front cover (A). 2) Remove the rear seat cushion <Ref. to SE-13, REMOVAL, Rear Seat.>, then remove side sill rear cover (B). 3) Remove the center pillar lower trim (C). : (D) EI-00072 (D) Clip...
Page 491: Rear Quarter Trim
Rear Quarter Trim EXTERIOR/INTERIOR TRIM 19.Rear Quarter Trim B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Remove the rear seat. <Ref. to SE-13, REMOV- Be sure to securely hook pawls of inner trim AL, Rear Seat.> panel to body flange.
Page 492: Sun Visor
Sun Visor EXTERIOR/INTERIOR TRIM 20.Sun Visor A: REMOVAL Remove the mounting screws then detach sun vi- sor (A) and hook (B). EI-00074 B: INSTALLATION Install in the reverse order of removal. EI-46...
Page 493: Roof Trim
Roof Trim EXTERIOR/INTERIOR TRIM 21.Roof Trim 8) Remove the clips, and then remove the roof trim. A: REMOVAL CAUTION: When removing the clip, use great care not to damage the roof trim. 1) Disconnect the ground cable from battery. 2) Remove the over head console. (Sunroof model) <Ref.
Page 494: Rear Gate Trim
Rear Gate Trim EXTERIOR/INTERIOR TRIM 22.Rear Gate Trim A: REMOVAL CAUTION: Be careful not to damage the clips or their holes. Remove the rear gate inner handle (A) from rear gate and then detach trim panel. EI-00078 B: INSTALLATION Install in the reverse order of removal. EI-48...
Page 495: Floor Mat
Floor Mat EXTERIOR/INTERIOR TRIM 23.Floor Mat A: REMOVAL 1) Remove the front seats. <Ref. to SE-6, REMOV- AL, Front Seat.> 2) Remove the rear seat cushion. <Ref. to SE-13, REMOVAL, Rear Seat.> 3) Remove the console box. <Ref. to EI-39, Con- sole Box.>...
Page 496: Luggage Floor Mat
Luggage Floor Mat EXTERIOR/INTERIOR TRIM 24.Luggage Floor Mat A: REMOVAL 1) Remove the back mat of rear seat backrest. 2) Remove the clips, then detach the rear floor mats and boxes. EI-00080 B: INSTALLATION Install in the reverse order of removal. EI-50...
Page 497: Instrument Panel Center Compartment
Instrument Panel Center Compartment EXTERIOR/INTERIOR TRIM 25.Instrument Panel Center Compartment A: REMOVAL 1) Disconnect the ground cable from battery. 2) Insert a flat tip screwdriver, and then pry up to re- move the clips. EI-00081 (A) Clip 3) Remove the instrument panel center compartment from instrument panel.
Page 498: Heat Shield Cover
Heat Shield Cover EXTERIOR/INTERIOR TRIM 26.Heat Shield Cover A: REMOVAL 1. FRONT HEAT SHIELD COVER Loosen the four bolts to remove front heat shield cover. DI-00211 (A) Transmission mount 2. CENTER HEAT SHIELD COVER Loosen the four bolts to remove center heat shield cover.
Page 499 EXTERIOR BODY PANEL Page General Description ..................2 Front Hood Panel ..................9 Front Fender Panel ...................10 Front Door Panel..................11 Front Sealing Cover ..................13 Rear Door Panel ..................14 Rear Sealing Cover...................16 Rear Gate Panel ..................17 Rear Gate Garnish Assembly ..............20...
Page 500: General Description
General Description EXTERIOR BODY PANEL 1. General Description A: SPECIFICATION (E),(F) EB-00001 Front hood panel Rear door panel Side sill Front fender panel Rear quarter panel Front door panel Door panel Section Part Specification Front hood panel to Front fender panel 3.5±1.0 mm (0.14±0.04 in) Front fender panel to Front door panel 4.7±1.0 mm (0.19±0.04 in)
Page 501 General Description EXTERIOR BODY PANEL B: COMPONENT 1. FRONT HOOD EB-00038 Front hood Seal Tightening torque: N·m (kgf-m, ft-lb) Hinge T1: 24.5 (2.5, 18.1) EB-3...
Page 502 General Description EXTERIOR BODY PANEL 2. FRONT FENDER PANEL EB-00003 Front fender panel Tightening torque: N·m (kgf-m, ft-lb) T: 7.4 (0.75, 5.5) EB-4...
Page 503 General Description EXTERIOR BODY PANEL 3. FRONT DOOR PANEL (10) (13) (12) (11) EB-00183 Gusset Upper hinge Tightening torque: N·m (kgf-m, ft-lb) Weather strip (10) Key cylinder (Driver’s side only) T1: 7.5 (0.76, 5.5) Stabilizer (Outer) (11) Front sash T2: 14 (1.4, 10.3) Stabilizer (Inner) (12) Rear sash...
Page 504 General Description EXTERIOR BODY PANEL 4. REAR DOOR PANEL (10) EB-00174 Weather strip Rear sash Tightening torque: N·m (kgf-m, ft-lb) Stabilizer (Outer) Lower hinge T1: 7.5 (0.76, 5.5) Stabilizer (Inner) (10) Upper hinge T2: 25 (2.5, 18) Door panel T3: 30 (3.1, 18) Checker T4: 33 (3.4, 24) Sealing cover...
Page 505 General Description EXTERIOR BODY PANEL 5. REAR GATE PANEL EB-00037 Damper stay Rear gate Tightening torque: N·m (kgf-m, ft-lb) Hinge Rear gate garnish T1: 7.5 (0.76, 5.5) T2: 14 (1.4, 10.1) T3: 25 (2.5, 18.1) EB-7...
Page 506 General Description EXTERIOR BODY PANEL C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925610000 WRENCH Used for removing and installing door hinge. ST-925610000 2. GENERAL TOOL TOOL NAME REMARKS Support jack Used for supporting door panel. EB-8...
Page 507: Front Hood Panel
Front Hood Panel EXTERIOR BODY PANEL 2. Front Hood Panel 3) Rotate the hood buffer to adjust lateral height. A: REMOVAL 1) Open the front hood to remove washer nozzles. 2) Release the clips to remove front hood insulator. EB-00010 EB-00008 3) Remove the bolts to remove front hood from hinges.
Page 508: Front Fender Panel
Front Fender Panel EXTERIOR BODY PANEL 3. Front Fender Panel A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the front bumper face. <Ref. to EI-23, REMOVAL, Front Bumper.> 3) Remove the mud guard. <Ref. to EI-31, RE- MOVAL, Mud Guard.>...
Page 509: Front Door Panel
Front Door Panel EXTERIOR BODY PANEL 4. Front Door Panel 11) Remove the checker bolts. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the front door trim. <Ref. to EI-35, RE- MOVAL, Front Door Trim.> 3) Remove the outer mirror assembly. <Ref. to GW-12, REMOVAL, Outer Mirror Assembly.>...
Page 510 Front Door Panel EXTERIOR BODY PANEL C: ADJUSTMENT 1) Using the ST, loosen the body-side bolts of upper and lower hinges to align the position of front door panel longitudinally and vertically. ST 925610000 WRENCH EB-00016 2) Loosen the door-side bolts of upper and lower hinges to align the position of front door panel ver- tically and laterally at the front end.
Page 511: Front Sealing Cover
Front Sealing Cover EXTERIOR BODY PANEL 5. Front Sealing Cover C: INSPECTION If the sealing cover is damaged, replace it with a A: REMOVAL new one. 1) Disconnect the ground cable from battery. 2) Remove the front door trim. <Ref. to EI-35, REMOVAL, Front Door Trim.>...
Page 512: Rear Door Panel
Rear Door Panel EXTERIOR BODY PANEL 6. Rear Door Panel 11) Remove the checker bolts. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear door trim. <Ref. to EI-36, RE- MOVAL, Rear Door Trim.> 3) Remove the rear sealing cover. <Ref. to EB-16, REMOVAL, Rear Sealing Cover.>...
Page 513 Rear Door Panel EXTERIOR BODY PANEL 2) Loosen the door-side bolts of upper and lower hing- es to align the position of rear door panel vertically and laterally at front-end. EB-00015 3) Loosen the screw (A) and lightly tap striker (B) using plastic hammer to adjust striker to align the position of rear door panel vertically and laterally at the rear end.
Page 514: Rear Sealing Cover
Rear Sealing Cover EXTERIOR BODY PANEL 7. Rear Sealing Cover A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear door trim. <Ref. to EI-36, RE- MOVAL, Rear Door Trim.> 3) Remove the door trim bracket. EB-00034 4) Remove the sealing cover.
Page 515: Rear Gate Panel
Rear Gate Panel EXTERIOR BODY PANEL 8. Rear Gate Panel 11) Using a support, support the rear gate and then remove damper stay mounting bolts. A: REMOVAL 1. REAR GATE PANEL 1) Disconnect the ground cable from battery. 2) Open the rear gate. 3) Remove the rear gate trim.
Page 516 Rear Gate Panel EXTERIOR BODY PANEL 2. REAR GATE DAMPER STAY B: INSTALLATION 1) Open the rear gate. Use a support to support the 1. REAR GATE PANEL rear gate. 1) Install in the reverse order of removal. 2) Install the rear gate panel with uniform clearance to the body.
Page 517 Rear Gate Panel EXTERIOR BODY PANEL C: DISPOSAL 1. REAR GATE DAMPER STAY CAUTION: Gas is colorless, odorless and harmless. How- ever, gas pressure may spray cutting powder or oil. Be sure to wear dust-resistant goggles. 1) Cover with a vinyl case as shown in the figure. EB-00031 (1) Rear gate damper stay (2) Vinyl sack...
Page 518: Rear Gate Garnish Assembly
Rear Gate Garnish Assembly EXTERIOR BODY PANEL 9. Rear Gate Garnish Assembly A: REMOVAL 1) Remove the rear gate panel trim. <Ref. to EI-48, REMOVAL, Rear Gate Trim.> 2) Remove the rear wiper motor. <Ref. to WW-17, REMOVAL, Rear Wiper Motor.> 3) Remove the seven frange nuts from inside of rear gate panel.
Page 519 CRUISE CONTROL SYSTEM Page General Description ..................2 Actuator.......................5 Cruise Control Module ................7 Cruise Control Main Switch.................8 Cruise Control Command Switch ..............9 Stop and Brake Switch................10 Clutch Switch ....................11 Inhibitor Switch (AT model) ...............12 Neutral Position Switch (MT model)............13...
Page 520: General Description
General Description CRUISE CONTROL SYSTEM 1. General Description A: COMPONENT 1. EXCEPT 2.5 L TURBO MODEL CC-00001 Actuator Cruise control main switch Cruise control module Inhibitor switch (AT model) Clutch switch (MT model) Cruise control command switch Stop and brake switch NOTE: Electrical component location are for LHD vehicles.
Page 521 General Description CRUISE CONTROL SYSTEM 2. 2.5 L TURBO MODEL CC-00262 Inhibitor switch (AT model) Clutch switch (MT model) Neutral position switch (MT model) Cruise control command switch Stop and brake switch Cruise control main switch Engine control module CC-3...
Page 522 General Description CRUISE CONTROL SYSTEM B: CAUTION • Before disassembling or reassembling parts, al- ways disconnect the battery ground cable. When re- pairing the radio, control module and other parts with memory functions, make note of the memory before disconnecting the battery ground cable. All memory will be erased.
Page 523: Actuator
Actuator CRUISE CONTROL SYSTEM 2. Actuator • RHD model A: REMOVAL CAUTION: • Be careful not to apply excessive load to the wire cable when adjusting and/or installing; oth- erwise, the actuator may be deformed or dam- aged. • Do not bend the cable sharply with a radius less than 100 mm (3.94 in);...
Page 524 Actuator CRUISE CONTROL SYSTEM C: INSPECTION Measure the cruise control actuator resistance. CC-00012 Terminal No. Standard Approx. 5 Ω 4 and 1 Approx. 5 Ω 4 and 2 Approx. 5 Ω 4 and 5 Approx. 39 Ω 3 and 6 If NG, replace the cruise control actuator.
Page 525: Cruise Control Module
Cruise Control Module CRUISE CONTROL SYSTEM 3. Cruise Control Module A: NOTE Engine Control Module (ECM) controls cruise con- trol system (Turbo model). B: REMOVAL 1. NON-TURBO MODEL 1) Disconnect the ground cable from battery. 2) Remove the glove box. <Ref. to EI-37, REMOV- AL, Glove Box.>...
Page 526: Cruise Control Main Switch
Cruise Control Main Switch CRUISE CONTROL SYSTEM 4. Cruise Control Main Switch B: INSTALLATION Install in the reverse order of removal. A: REMOVAL C: INSPECTION 1) Disconnect the ground cable from battery. Measure the cruise control main switch resistance. 2) Remove the screws and clip from instrument panel lower cover.
Page 527: Cruise Control Command Switch
Cruise Control Command Switch CRUISE CONTROL SYSTEM 5. Cruise Control Command 7) Disconnect the horn and cruise control com- mand switch connector, then remove the cruise Switch control command switch. A: REMOVAL WARNING: Before servicing, be sure to read the notes in the AB section for proper handling of the driv- er’s airbag module.
Page 528: Stop And Brake Switch
Stop and Brake Switch CRUISE CONTROL SYSTEM 6. Stop and Brake Switch A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector from stop and brake switch, and then remove the switch. <Ref. to BR- 54, REMOVAL, Stop Light Switch.> B: INSTALLATION Install in the reverse order of removal.
Page 529: Clutch Switch
Clutch Switch CRUISE CONTROL SYSTEM 7. Clutch Switch A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector from clutch switch, and then remove the switch. <Ref. to CL-34, RE- MOVAL, Clutch Pedal.> B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Measure the clutch switch resistance.
Page 530: Inhibitor Switch (At Model)
Inhibitor Switch (AT model) CRUISE CONTROL SYSTEM 8. Inhibitor Switch (AT model) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector from inhibitor switch, and then remove the switch. <Ref. to 4AT-52, RE- MOVAL, Inhibitor Switch.> B: INSTALLATION Install in the reverse order of removal.
Page 531: Neutral Position Switch (Mt Model)
Neutral Position Switch (MT model) CRUISE CONTROL SYSTEM 9. Neutral Position Switch (MT model) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector from neutral position switch, and then remove the switch. <Ref. to 5MT- 43, BACK-UP LIGHT AND NEUTRAL POSITION SWITCH, REMOVAL, Switches and Harness.>...
Page 532 Neutral Position Switch (MT model) CRUISE CONTROL SYSTEM CC-14...
Page 533: Cc(H4So)-7
CC(H4SO) Page Basic Diagnostic Procedure ................2 General Description ..................4 Electrical Components Location..............6 Cruise Control Module I/O Signal..............7 Subaru Select Monitor.................9 Diagnostic Procedure with Symptom ............11 List of Diagnostic Trouble Code (DTC) .............27 Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....29...
Page 534: Basic Diagnostic Procedure
Go to “List of Diag- Go to step 4. DIAGNOSIS. nostic Trouble Perform the cruise cancel conditions diagno- Code (DTC)”. sis. <Ref. to CC(H4SO)-9, Subaru Select Mon- <Ref. to itor.> CC(H4SO)-27, List of Diagnostic Trou- ble Code (DTC).> CHECK CRUISE CONTROL SET OPERA- Can the cruise control be set Go to step 5.
Page 535 Basic Diagnostic Procedure CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK CRUISE CONTROL RELEASE OP- Is the cruise control released Go to step 10. Go to symptom 7. ERATION. after brake pedal has been <Ref. to Check the cruise control release operation. depressed? CC(H4SO)-11, SYMPTOM...
Page 536: General Description
TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical systems. (Newly adopted tool) ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical systems. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish:...
Page 537 General Description CRUISE CONTROL SYSTEM (DIAGNOSTIC) C: INSPECTION 5. CABLE FREE PLAY 1. BATTERY Measure the battery voltage and specific gravity of electrolyte. Standard voltage: 12 V, or more Specific gravity: Above 1.260 2. CRUISE CONTROL CABLE CC-00037 1) Check that the throttle cam-to-lever clearance (A) or cable (B) deflection amount (D) is within specifications.
Page 538: Electrical Components Location
Electrical Components Location CRUISE CONTROL SYSTEM (DIAGNOSTIC) 3. Electrical Components Location A: LOCATION CC-00001 Actuator Cruise control main switch Cruise control module Inhibitor switch (AT model) Clutch switch (MT model) Cruise control command switch Stop and brake switch CC(H4SO)-6...
Page 539 Cruise Control Module I/O Signal CRUISE CONTROL SYSTEM (DIAGNOSTIC) 4. Cruise Control Module I/O Signal A: ELECTRICAL SPECIFICATION 20 19 18 17 16 15 14 13 12 11 CC-00027 Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling) Cruise indicator light •...
Page 540 Cruise Control Module I/O Signal CRUISE CONTROL SYSTEM (DIAGNOSTIC) Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling) Brake switch/Clutch switch Leave clutch pedal released (MT model), while cruise control main switch is (MT model) turned ON.
Page 541: Subaru Select Monitor
(Code No.) which occurred dur- <Ref. to CC(H4SO)-4, SPECIAL TOOL, PREPA- ing driving. When there are plural cancel condi- RATION TOOL, General Description.> tions (Code No.), they are shown on the Subaru Select Monitor. CAUTION: • The cruise control memory stores not only the cruise “cancel”...
Page 542 Subaru Select Monitor CRUISE CONTROL SYSTEM (DIAGNOSTIC) 6) Turn the Subaru Select Monitor switch to ON. 3. REAL-TIME DIAGNOSIS 1) Connect the select monitor. 2) Turn the ignition switch and cruise control main switch to ON. 3) Turn the Subaru Select Monitor switch to ON.
Page 543: Diagnostic Procedure With Symptom
Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) 6. Diagnostic Procedure with Symptom A: SYMPTOM CHART Symptom Repair area Reference Cruise control main switch is (1) Check the power supply. <Ref. to CC(H4SO)-13, CHECK POWER SUPPLY, Diag- not turned ON. nostic Procedure with Symptom.>...
Page 544 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) Symptom Repair area Reference Cruise control is not released (1) Check the CANCEL <Ref. to CC(H4SO)-19, CHECK CRUISE CONTROL after CANCEL switch has switch. COMMAND SWITCH, Diagnostic Procedure with Symp- been pressed. tom.>...
Page 545 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) B: CHECK POWER SUPPLY TROUBLE SYMPTOM: Cruise control can be set normally, but indicator does not come on. (When main switch is pressed.) WIRING DIAGRAM: IGNITION BATTERY SWITCH F/B No.18 SBF-4 F/B No.14 COMBINATION CRUISE CONTROL METER...
Page 546 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK POWER SUPPLY. Is the voltage more than 10 V? Go to step 2. • Check the fuse 1) Turn the ignition switch to OFF. No. 18 (in fuse & 2) Disconnect the cruise control module har- relay box).
Page 547 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) C: CHECK CRUISE CONTROL MAIN SWITCH TROUBLE SYMPTOM: Cruise control main switch is not turned ON and cruise control cannot be set. NOTE: When the main relay (built-in cruise control module) operates, the main switch circuit is in normal condition. The main relay operation can be checked by hearing the operation sound.
Page 548 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK CRUISE CONTROL MAIN SWITCH Is the voltage more than 10 V? Go to step 2. • Check the fuse CIRCUIT. No. 18 (in fuse & 1) Turn the ignition switch to OFF. relay box).
Page 549 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) D: CHECK CRUISE INDICATOR LIGHT TROUBLE SYMPTOM: Cruise control can be set normally, but indicator light does not come on. (When main switch is pressed.) WIRING DIAGRAM: IGNITION BATTERY SWITCH F/B No.18 SBF-4 F/B No.14 COMBINATION...
Page 550 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK CRUISE INDICATOR LIGHT CIR- Is the voltage more than 10 V? Go to step 2. • Check the fuse CUIT. No. 13 (in fuse & 1) Turn the ignition switch to OFF. relay box).
Page 551 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) E: CHECK CRUISE CONTROL COMMAND SWITCH TROUBLE SYMPTOM: Cruise control cannot be set. (Cancelled immediately.) WIRING DIAGRAM: BATTERY M/B No.6 HORN SWITCH RESUME/ SET/ CANCEL CRUISE CONTROL ACCEL COAST SWITCH COMMAND SWITCH SWITCH SWITCH HORN RELAY...
Page 552 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK SET/COAST SWITCH CIRCUIT. Is the voltage 0 V when the Go to step 2. Go to step 4. 1) Turn the ignition switch to OFF. SET/COAST switch is not 2) Disconnect the cruise control module har- pressed? Is the voltage more ness connector.
Page 553 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) F: CHECK STOP LIGHT SWITCH AND BRAKE SWITCH TROUBLE SYMPTOM: Cruise control cannot be set. WIRING DIAGRAM: BATTERY F/B No.16 SBF-1 SBF-2 STOP LIGHT SWITCH AND BRAKE SWITCH STOP LIGHT CLUTCH SWITCH SWITCH (MT MODEL) BRAKE SWITCH...
Page 554 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 V? Go to step 2. • Check the fuse SWITCH CIRCUIT. No. 16 (in fuse & 1) Turn the ignition switch to OFF. relay box).
Page 555 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) G: CHECK CLUTCH SWITCH (MT MODEL) TROUBLE SYMPTOM: Cruise control cannot be set. WIRING DIAGRAM: BATTERY F/B No.16 SBF-1 SBF-2 STOP LIGHT SWITCH AND BRAKE SWITCH STOP LIGHT CLUTCH SWITCH SWITCH (MT MODEL) BRAKE SWITCH B107...
Page 556 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK CLUTCH SWITCH CIRCUIT. Is the voltage more than 10 V? Go to step 2. Check the harness 1) Turn the ignition switch to OFF. for open or short 2) Disconnect the clutch switch harness con- between clutch nector.
Page 557 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) H: CHECK INHIBITOR SWITCH (AT MODEL) TROUBLE SYMPTOM: Cruise control cannot be set. WIRING DIAGRAM: BATTERY M/B No.2 SBF-1 CRUISE CONTROL MODULE SECURITY RELAY B323 TO SECURITY SYSTEM :WITH SECURITY SYSTEM :WITHOUT SECURITY SYSTEM STARTER MOTOR INHIBITOR...
Page 558 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK INHIBITOR SWITCH CIRCUIT. Is the voltage more than 10 V? Go to step 2. Check the harness 1) Turn the ignition switch to OFF. for open or short 2) Disconnect the inhibitor switch harness between inhibitor connector.
Page 559: List Of Diagnostic Trouble Code (Dtc)
List of Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) 7. List of Diagnostic Trouble Code (DTC) A: LIST Item Contents of diagnosis Reference Inner relay is seized. Cruise control module inner relay is seized when main <Ref. to CC(H4SO)-29, switch is OFF.
Page 560 List of Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Item Contents of diagnosis Reference Motor drive shaft does not Motor drive gear engagement is not properly adjusted. <Ref. to CC(H4SO)-38, engage properly. DTC 38 MOTOR DRIVE SHAFT DOES NOT ENGAGE PROPERLY., Diagnostic Procedure with Diagnostic Trouble Code...
Page 561: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)
Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) 8. Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC 21, 24, 25 AND 2A CRUISE CONTROL MODULE BUILT-IN RE- LAY, CPU RAM DIAGNOSIS: • Poor welding of built-in relay of cruise control mod- ule.
Page 562 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) B: DTC 22 VEHICLE SPEED SENSOR DIAGNOSIS: Disconnection or short circuit of vehicle speed sensor system. TROUBLE SYMPTOM: Cruise control cannot be set. (Cancelled immediately.) WIRING DIAGRAM: IGNITION BATTERY RELAY M/B No.5 VEHICLE SPEED...
Page 563 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK TRANSMISSION TYPE. Is the target MT model? Go to step 2. Go to step 6. CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V? Go to step 3. Check the harness AND VEHICLE SPEED SENSOR.
Page 564 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check Is the voltage less than 0 V ← CHECK TCM. Replace the cruise Replace the TCM. → more than 5 V? 1) Connect the harness connector to TCM. control module.
Page 565 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) C: DTC 28 WIRING HARNESS OPENED. Step Check CHECK BATTERY. Is the battery specific gravity Go to step 2. Charge or replace Measure the battery specific gravity of electro- more than 1.260? the battery.
Page 566 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) D: DTC 35 AND 36 ACTUATOR MOTOR DIAGNOSIS: Open or poor contact of cruise control actuator motor. TROUBLE SYMPTOM: Cruise control cannot be set. (Cancelled immediately.) WIRING DIAGRAM: CRUISE CONTROL MODULE CRUISE CONTROL ACTUATOR...
Page 567 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK POWER SUPPLY. Is the voltage more than 10 V? Go to step 2. Check the harness 1) Turn the ignition switch to OFF. for open or short 2) Disconnect the harness connector from between cruise cruise control actuator.
Page 568 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) E: DTC 37 ACTUATOR MOTOR CLUTCH DIAGNOSIS: Open or poor contact of cruise control actuator motor clutch. TROUBLE SYMPTOM: Cruise control cannot be set. (Cancelled immediately.) WIRING DIAGRAM: CRUISE CONTROL MODULE CRUISE CONTROL ACTUATOR...
Page 569 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK POWER SUPPLY. Is the voltage more than 10 V? Go to step 2. Check the harness 1) Turn the ignition switch to OFF. for open or short 2) Disconnect the harness connector from between cruise cruise control actuator.
Page 570 CHECK THE OPERATING CURRENT TO AC- Is the voltage more than 10 A? Replace the cruise Check the power TUATOR MOTOR. control module. supply circuit. 1) Connect the Subaru Select Monitor to data <Ref. to CC-7, <Ref. to link connector. Cruise Control CC(H4SO)-13, 2) Try to drive the vehicle while operating the Module.>...
Page 571 CRUISE CONTROL SYSTEM (DIAGNOSTIC) CC(H4DOTC) Page General Description ..................2...
Page 572 General Description CRUISE CONTROL SYSTEM (DIAGNOSTIC) 1. General Description A: SPECIFICATION Specifications for 2.0 L turbo model are included in CC(H4SO) section. <Ref. to CC(H4SO)-2, Basic Di- agnostic Procedure.> CC(H4DOTC)-2...
Page 573 Basic Diagnostic Procedure ................2 General Description ..................4 Electrical Components Location..............5 Engine Control Module (ECM) I/O Signal ...........6 Subaru Select Monitor.................8 Diagnostic Procedure with Symptom ............10 List of Diagnostic Trouble Code (DTC) .............13 Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....16...
Page 574: Basic Diagnostic Procedure
Basic Diagnostic Procedure CRUISE CONTROL SYSTEM (DIAGNOSTIC) 1. Basic Diagnostic Procedure A: PROCEDURE Step Check CHECK MALFUNCTION INDICATOR LIGHT. Does the malfunction indicator Go to step 5. Go to step 2. Check the malfunction indicator light illumi- light illuminate? nates. CHECK CRUISE INDICATOR LIGHT.
Page 575 Basic Diagnostic Procedure CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK CRUISE CONTROL RELEASE OP- Is the cruise control released Go to step 11. Go to symptom 7. ERATION. after brake pedal has been <Ref. to Check the cruise control release operation. depressed? CC(H4DOTC 2.5)- 10, SYMPTOM...
Page 576: General Description
TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical systems. (Newly adopted tool) ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical systems. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish:...
Page 577: Electrical Components Location
Electrical Components Location CRUISE CONTROL SYSTEM (DIAGNOSTIC) 3. Electrical Components Location A: LOCATION CC-00262 Inhibitor switch (AT model) Clutch switch (MT model) Neutral switch (MT model) Cruise control command switch Stop light and brake switch Cruise control main switch Engine control module (ECM) CC(H4DOTC 2.5)-5...
Page 578: Engine Control Module (Ecm) I/O Signal
Engine Control Module (ECM) I/O Signal CRUISE CONTROL SYSTEM (DIAGNOSTIC) 4. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION To A: B134 To B: B135 To C: B136 To D: B137 17 16 12 11 17 16 12 11 12 11 17 16 12 11...
Page 579 Engine Control Module (ECM) I/O Signal CRUISE CONTROL SYSTEM (DIAGNOSTIC) B: WIRING DIAGRAM <Ref. to WI-110, WIRING DIAGRAM, Cruise Control System.> CC(H4DOTC 2.5)-7...
Page 580: Subaru Select Monitor
CC-00029 though cruise cancel condition is not entered). 4) Connect the Subaru Select Monitor to data link (2) Cruise control memory of ECM stores the connector. cancel condition (Code No.) which occurred dur- (1) Data link connector is located in the lower ing driving.
Page 581 1) Connect the select monitor. 2) Turn the ignition switch and cruise control main switch to ON. 3) Turn the Subaru Select Monitor switch to ON. 4) On the «Main Menu» display screen, select the {2. Each System Check} and press [YES] key.
Page 582: Diagnostic Procedure With Symptom
Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) 6. Diagnostic Procedure with Symptom A: SYMPTOM CHART Symptom Repair area Reference (1) Check the cruise indicator <Ref. to CC(H4DOTC 2.5)-11, CHECK CRUISE INDICA- Cruise control main switch is light. TOR LIGHT, Diagnostic Procedure with Symptom.> not turned to ON.
Page 583 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) B: CHECK CRUISE INDICATOR LIGHT TROUBLE SYMPTOM: Cruise control can be set, but cruise indicator light does not illuminate. WIRING DIAGRAM: IGNITION BATTERY SWITCH F/B No.18 SBF-4 F/B No.14 CRUISE CONTROL MAIN SWITCH COMBINATION METER ILLUMINATION CUSTOM...
Page 584 Diagnostic Procedure with Symptom CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK CRUISE INDICATOR LIGHT CIR- Is the voltage more than 10 V? Go to step 2. • Check the fuse CUIT. No. 14 (in fuse & 1) Turn the ignition switch to OFF. relay box).
Page 585: List Of Diagnostic Trouble Code (Dtc)
List of Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) 7. List of Diagnostic Trouble Code (DTC) A: LIST Item Contents of diagnosis Reference Main switch Cruise control is released after the main switch of cruise This DTC is indicated control command switch is turned to OFF.
Page 586 List of Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Item Contents of diagnosis Reference Cruise control switch is Each switch of cruise control command switch has This DTC is indicated abnormal when the igni- already been ON when the ignition switch is turned to without operating the main tion switch is turned to ON.
Page 587 List of Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Item Contents of diagnosis Reference Prohibition when accelera- Vehicle is driven at the higher speed than set vehicle This DTC is indicated tor pedal position is contin- speed for an extremely long time (approx. 10 minutes) when running for a long ued to be large.
Page 588 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) 8. Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC 11, 15, 21 AND 24 CRUISE CONTROL COMMAND SWITCH TROUBLE SYMPTOM: • Cruise control cannot be set. (Cancelled immediately.) •...
Page 589: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)
Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK CRUISE CONTROL MAIN SWITCH Is the voltage 0 V when the Go to step 2. • Check the fuse CIRCUIT. main switch is not pressed? Is No.
Page 590 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) B: DTC 12 AND 25 STOP LIGHT SWITCH AND BRAKE SWITCH TROUBLE SYMPTOM: • Cruise control cannot be set. • Cruise control cannot be released. WIRING DIAGRAM: BATTERY F/B No.16 SBF-1 SBF-2 IGNITION...
Page 591 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 V? Go to step 2. • Check the fuse SWITCH CIRCUIT. No. 16 (in fuse & 1) Turn the ignition switch to OFF.
Page 592 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) C: DTC 13 CLUTCH SWITCH TROUBLE SYMPTOM: • Cruise control cannot be set. • Cruise control cannot be released. WIRING DIAGRAM: BATTERY F/B No.16 SBF-1 SBF-2 IGNITION SWITCH F/B No.11 SBF-4 STOP LIGHT SWITCH AND BRAKE SWITCH...
Page 593 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK CLUTCH SWITCH CIRCUIT. Is the voltage more than 10 V? Go to step 2. • Check the fuse 1) Turn the ignition switch to OFF. No. 11 (fuse & 2) Disconnect the clutch switch harness con- relay box).
Page 594 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) D: DTC 14 NEUTRAL POSITION SWITCH TROUBLE SYMPTOM: Cruise control cannot be set. WIRING DIAGRAM: B137 B128 NEUTRAL POSITION SWITCH B128 :MT MODEL :AT MODEL STARTER MOTOR INHIBITOR SWITCH (AT MODEL) GE-2 B128...
Page 595 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK TRANSMISSION TYPE. Is the target MT model? Go to step 2. Go to step 5. CHECK NEUTRAL POSITION SWITCH CIR- Is the voltage more than 10 V? Go to step 3. Check the harness CUIT.
Page 596 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) E: DTC 16 IGNITION SWITCH TROUBLE SYMPTOM: Cruise control cannot be set. WIRING DIAGRAM: IGNITION BATTERY SWITCH F/B No.11 SBF-4 SBF-1 B137 B137 CC-00259 CC(H4DOTC 2.5)-24...
Page 597 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK IGNITION SWITCH CIRCUIT. Is the voltage more than 10 V? Check the poor • Check the fuse 1) Turn the ignition switch to OFF. contact of ECM No.
Page 598 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) F: DTC 22 AND 32 VEHICLE SPEED SENSOR DIAGNOSIS: Disconnection or short circuit of vehicle speed sensor system. TROUBLE SYMPTOM: Cruise control cannot be set. (Cancelled immediately.) WIRING DIAGRAM: F/B No.5 IGNITION BATTERY...
Page 599 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check CHECK TRANSMISSION TYPE. Is the target MT model? Go to step 2. Go to step 6. CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V? Go to step 3. Check the harness AND VEHICLE SPEED SENSOR.
Page 600 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTIC) Step Check Is the voltage 1 V ← → 5 V? CHECK TCM Check the poor Check the poor 1) Connect the harness connector to TCM. contact of ECM contact of TCM 2) Lift-up the vehicle and support with rigid harness connec-...
Page 601 Basic Diagnostic Procedure ................2 General Description ..................3 Electrical Components Location..............5 Immobilizer Control Module I/O Signal............6 Subaru Select Monitor.................7 Read Diagnostic Trouble Code (DTC) ............8 Clear Memory Mode..................9 Diagnostics Chart for Immobilizer Warning Light ........10 List of Diagnostic Trouble Code (DTC) .............14...
Page 602: Basic Diagnostic Procedure
Repair the related 1) Turn the ignition switch to OFF. play? parts. 2) Connect the Subaru Select Monitor to data link connector. <Ref. to IM-7, Subaru Select Monitor.> 3) Turn the ignition switch and Subaru Select Monitors witch to ON.
Page 603: General Description
General Description IMMOBILIZER (DIAGNOSTIC) 2. General Description • When repeatedly turning the ignition switch to ON or OFF while diagnostic items are being A: CAUTION checked, it should be switched in cycles of “ON” for at least 5 seconds → “OFF” for at least CAUTION: 8 seconds.
Page 604 General Description IMMOBILIZER (DIAGNOSTIC) B: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOLNUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical systems. (Newly adopted tool) ST24082AA230 22771AA030 SUBARUSELECT Troubleshooting for electrical systems. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) •...
Page 605: Electrical Components Location
Electrical Components Location IMMOBILIZER (DIAGNOSTIC) 3. Electrical Components Location A: LOCATION IM-00004 Antenna Immobilizer control module (IMM Transponder ECM) Immobilizer warning light (LED) NOTE: IMM ECM location for RHD model is symmetrically opposite. IM-5...
Page 606: Immobilizer Control Module I/O Signal
Immobilizer Control Module I/O Signal IMMOBILIZER (DIAGNOSTIC) 4. Immobilizer Control Module I/O Signal A: WIRING DIAGRAM 1. IMMOBILIZER <Ref. to WI-194, WIRING DIAGRAM, Immobilizer System.> IM-6...
Page 607: Subaru Select Monitor
1. HOW TO USE SUBARU SELECT MONI- 1) Prepare the Subaru Select Monitor kit. CC-00045 (1) Power switch 6) Using the Subaru Select Monitor, call up any DTCs and various data, and then record them. CC-00028 2. READ DIAGNOSTIC TROUBLE CODE 2) Connect the diagnosis cable to Subaru Select (DTC) FOR ENGINE.
Page 608: Read Diagnostic Trouble Code (Dtc)
{History Diagnostic Code(s)}, and then press the [YES] key. NOTE: • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MAN- UAL. • For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC).
Page 609: Clear Memory Mode
{Clear Memory}, and then press the [YES] key. 5) When the `Done’ is shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF. NOTE: • After the memory has been cleared, the ISC must be initialized.To do this, turn the ignition switch to ON po-...
Page 610 Diagnostics Chart for Immobilizer Warning Light IMMOBILIZER (DIAGNOSTIC) 8. Diagnostics Chart for Immobilizer Warning Light A: INSPECTION 1. CHECK IMMOBILIZER WARNING CIRCUIT WIRING DIAGRAM: BATTERY SBF-1 M/B No.2 IGNITION SWITCH SBF-5 SBF-4 F/B No.11 COMBINATION METER IMMOBILIZER WARNING LIGHT B100 LHD : LHD MODEL : RHD MODEL : LHD TURBO MODEL...
Page 611: Diagnostics Chart For Immobilizer Warning Light
Diagnostics Chart for Immobilizer Warning Light IMMOBILIZER (DIAGNOSTIC) Step Check CHECK IMMOBILIZER WARNING LIGHT. Does the immobilizer warning Go to step 2. Go to step 5. 1) Turn the ignition switch to OFF. light illuminate? 2) Disconnect the harness connector from IMM ECM.
Page 612 Diagnostics Chart for Immobilizer Warning Light IMMOBILIZER (DIAGNOSTIC) 2. CHECK KEY WARNING SWITCH CIRCUIT WIRING DIAGRAM: BATTERY M/B No.6 LHD : LHD MODEL : RHD MODEL KEY WARNING SWITCH B141 IMM ECM B141 8 9 10 11 12 5 6 7 8 IM-00006 IM-12...
Page 613 Diagnostics Chart for Immobilizer Warning Light IMMOBILIZER (DIAGNOSTIC) Step Check CHECK POWER SUPPLY CIRCUIT. Is the voltage more than 10 V? Go to step 2. Check the harness 1) Disconnect the harness connector from key for open or short warning switch. between key warn- 2) Measure the voltage between key warning ing switch and...
Page 614: List Of Diagnostic Trouble Code (Dtc)
List of Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) 9. List of Diagnostic Trouble Code (DTC) A: LIST Item Contents of diagnosis Index No. <Ref. to IM-15, DTC P1571 REFERENCE CODE Reference Code Incompati- Reference code incompatibility P1571 INCOMPATIBILITY, Diagnostics Procedure with bility between IMM ECM and ECM Diagnostic Trouble Code (DTC).>...
Page 615: Diagnostics Procedure With Diagnostic Trouble Code (Dtc)
Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) 10.Diagnostics Procedure with Diagnostic Trouble Code (DTC) A: DTC P1571 REFERENCE CODE INCOMPATIBILITY DIAGNOSIS: Reference code incompatibility between IMM ECM and ECM Step Check PERFORM TEACHING OPERATION ON IG- Is teaching operation for all Replace the ECM NITION KEY.
Page 616 Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) B: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT) DIAGNOSIS: Communication failure between IMM ECM and ECM WIRING DIAGRAM: IGNITION BATTERY SWITCH SBF-1 SBF-4 F/B No.11 SBF-5 : TURBO MODEL : NON-TURBO MODEL LHD : LHD MODEL RHD : RHD MODEL : LHD TURBO MODEL...
Page 617 Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) Step Check CHECK POWER SUPPLY CIRCUIT OF IMM Is the voltage more than 10 V? Go to step 2. Check the harness ECM. for open or short 1) Turn the ignition switch to OFF. between IMM 2) Disconnect the harness connector from ECM and fuse.
Page 618 Module (ECM).> 3) Perform communication line check. <Ref. to all ignition keys <Ref. to IM-7, COMMUNICATION LINE CHECK, (including the tran- FU(H4DOTC)-50, OPERATION, Subaru Select Monitor.> sponder). Then Engine Control perform teaching Module (ECM).> operation. Refer to <Ref. to the teaching oper- FU(H4DOTC 2.5)-...
Page 619 Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) C: DTC P1574 KEY COMMUNICATION FAILURE DIAGNOSIS: Failure of IMM ECM to verify key (transponder) ID code Step Check Is the voltage −30 to 30 V? CHECK IMM ECM FUNCTION. Go to step 2. Replace the IMM Insert the key to ignition switch (LOCK posi- (Approx.
Page 620 Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) D: DTC P0513 INCORRECT IMMOBILIZER KEY DIAGNOSIS: Use of unregistered key in IMM ECM Step Check PERFORM TEACHING OPERATION ON IG- Is teaching operation for all Replace all ignition NITION KEY. keys completed? keys (including the Perform teaching operation on all keys of the...
Page 621 Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) G: DTC P1570 ANTENNA DIAGNOSIS: Faulty antenna WIRING DIAGRAM: B142 B142 IM-00008 IM-21...
Page 622 Diagnostics Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTIC) Step Check CHECK ANTENNA CIRCUIT. Is the resistance less than 10 Go to step 2. Replace the Ω? 1) Turn the ignition switch to OFF. antenna. <Ref. to 2) Disconnect the harness antenna connector SL-38, Immobi- from IMM ECM.

Subaru FORESTER 2004 Service Manual

Hvac System (Heater, Ventilator and A/C) AC

Hvac System (Auto A/C)(Diagnostic) AC

Airbag System Ab

Airbag System (Diagnostic) Ab

Seat Belt System Sb

Lighting System Li

Wiper and Washer System Ww

Entertainment Et

Communication System Com

Glass/Window/Mirror Gw

Instrumentation/Driver Info IDI

Security and Lock Sl

Exterior/Interior Trim Ei

Exterior Body Panel Eb

Cruise Control System CC

Cruise Control System (Diagnostic) CC(H4So)

Cruise Control Module I\/O Signal 4. Cruise Control Module I\/O Signal

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