Page 1 2002 Model Year PDF Service Manual Supplement For STi Model GENERAL INFORMATION SECTION (Pub.No.G1841GE1) ENGINE 2 SECTION (Pub.No.G1841GE3) TRANSMISSION SECTION (Pub.No.G1841GE4) CHASSIS SECTION (Pub.No.G1841GE5) BODY SECTION (Pub.No.G1841GE6) WIRING SYSTEM SECTION (Pub.No.G1841GE7)
Page 3 GENERAL INFORMATION SECTION SPECIFICATIONS IDENTIFICATION This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reas-...
Page 5: Specifications
SPECIFICATIONS Page Impreza .......................2...
Page 6 IMPREZA SPECIFICATIONS 1. Impreza A: DIMENSIONS Model Sedan Wagon OUTBACK Overall length mm (in) 4,405 (173.4) Overall width mm (in) 1,730 (68.1) 1,695 (66.7) 1,710 (67.3) 1,730 (68.1) Overall height (at C.W.) mm (in) 1,465 (57.7), 1,475 (58.1), 1,440 (56.7) 1,440 (56.7) 1,485 (58.5)#4 1,495 (58.9)#4...
Page 7 IMPREZA SPECIFICATIONS C: ELECTRICAL Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L Ignition timing at BTDC/rpm MT: 10°±10°/700 5°±10°/700 10°±10°/700 12°±10°/750 12°±10°/700 idling speed AT: 15°±10°/700 Spark Type and Without NGK: BKR6E NGK: BKR6E NGK: BKR6E (with- plug manufacturer (without catalyst)
Page 8 IMPREZA SPECIFICATIONS D: TRANSMISSION Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L Transmission type Clutch type DSPD DSPD DSPD DSPD DSPD Gear ratio 3.454, 3.454 2.785 3.454 2.785 2.785 3.454 2.785 3.636 3.166#1 1.947, 2.062 1.545 2.062 1.545 1.545 2.062...
Page 9 IMPREZA SPECIFICATIONS G: BRAKE Model 1.6 L Non-turbo 2.0 L, 2.5 L Turbo 2.0 L, STi Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Drum brake Disc brake Ventilated disc brake Parking brake Mechanical on rear brakes H: TIRE Rim size...
Page 10 IMPREZA SPECIFICATIONS J: WEIGHT 1. LHD VEHICLE Sedan Option code#1 Model 1.6 L Curb weight (C.W.) Front kgf (lb) (1,609) (1,654) (1,654) (1,698) (1,654) (1,698) (1,631) (1,676) Rear kgf (lb) (1,146) (1,146) (1,146) (1,146) (1,146) (1,146) (1,179) (1,179) Total kgf (lb) 1,250 1,270 1,270...
Page 11 IMPREZA SPECIFICATIONS Option code#1 Model 2.5 L 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) 760 (1,676) 785 (1,731) 815 (1,797) 875 (1,929) Rear kgf (lb) 535 (1,179) 530 (1,168) 550 (1,213) 575 (1,268) Total kgf (lb) 1,295 (2,855) 1,315 (2,899) 1,365 (3,009) 1,450 (3,197)
Page 12 IMPREZA SPECIFICATIONS Wagon Option code#1 Model 1.6 L Curb weight (C.W.) Front kgf (lb) (1,620) (1,653) (1,664) (1,698) (1,664) (1,698) (1,642) (1,676) Rear kgf (lb) (1,202) (1,202) (1,202) (1,202) (1,202) (1,202) (1,235) (1,235) Total kgf (lb) 1,280 1,295 1,300 1,315 1,300 1,315 1,305...
Page 13 IMPREZA SPECIFICATIONS Option code#1 Model 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) 805 (1,775) 825 (1,819) Rear kgf (lb) 585 (1,290) 585 (1,290) Total kgf (lb) 1,390 (3,065) 1,410 (3,109) Maximum permissible Front kgf (lb) 970 (2,138) 970 (2,138) axle weight (M.P.A.W.) Rear kgf (lb)
Page 14 IMPREZA SPECIFICATIONS 2. RHD VEHICLE Sedan Option code#1 Model 1.6 L Curb weight (C.W.) Front kgf (lb) 735 (1,621) 755 (1,665) 750 (1,654) 770 (1,698) Rear kgf (lb) 520 (1,146) 520 (1,146) 520 (1,146) 520 (1,146) Total kgf (lb) 1,255 (2,767) 1,275 (2,811) 1,270 (2,800) 1,290 (2,844)
Page 15 IMPREZA SPECIFICATIONS Option code#1 Model 2.0 L 2.0 L 2.0 L Turbo 2.5 L Turbo Unladen mass (U.M.) Front kgf (lb) (1,654) (1,709) (1,830) (1,885) (1,720) (1,775) (1,973) Rear kgf (lb) (1,179) (1,168) (1,235) (1,224) (1,191) (1,179) (1,268) Total kgf (lb) 1,285 1,305 1,390...
Page 16 IMPREZA SPECIFICATIONS Wagon Option code#1 Model 1.6 L Curb weight (C.W.) Front kgf (lb) 740 (1,631) 755 (1,664) 755 (1,664) 770 (1,698) Rear kgf (lb) 545 (1,202) 545 (1,202) 545 (1,202) 545 (1,202) Total kgf (lb) 1,285 (2,833) 1,300 (2,866) 1,300 (2,866) 1,315 (2,900) Maximum permissible...
Page 17 IMPREZA SPECIFICATIONS Option code#1 Model 2.0 L 2.0 L Turbo OUTBACK Unladen mass (U.M.) Front kgf (lb) 760 (1,676) 775 (1,709) 750 (1,653) 765 (1,687) 825 (1,819) 850 (1,874) Rear kgf (lb) 570 (1,257) 565 (1,246) 570 (1,257) 570 (1,257) 585 (1,290) 585 (1,290) Total...
Page 18 IMPREZA SPECIFICATIONS SPC-14...
Page 19 IDENTIFICATION Page Identification ....................2...
Page 20 IDENTIFICATION IDENTIFICATION 1. Identification A: IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the VIN is as follows: • Europe, Australia and General (Except GCC) ]JF1GD5LJ32G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passenger car, FHI made...
Page 21 IDENTIFICATION IDENTIFICATION 3. MODEL NUMBER PLATE The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts. GD9BL7R Digits Code...
Page 22 IDENTIFICATION IDENTIFICATION • Transmission TY856WN2AA Digits Code Meaning Details Transmission T: Transmission Transmission type Y: Full-time AWD MT center differential V: Full-time AWD AT center differential Z: Full-time AWD AT MPT 3 and 4 Classification 75: 5MT 85: 6MT 1B: AT Series 4: 5MT 6: 6MT...
Page 23 IDENTIFICATION IDENTIFICATION • Option code ECPS Digits Code Meaning Details 1 to 2 Destination EC: EC KO: KO K4: K4 KS: KS EK: EK KA: KA K1: K1 3 to 4 Main option of vehicle — ID-5...
Page 24 IDENTIFICATION IDENTIFICATION ID-6...
Page 25 (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(TURBO) MECHANICAL ME(STi) This service manual has been prepared to provide SUBARU service personnel ENGINE (DIAGNOSTICS) EN(TURBO) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures...
Page 27 FUEL INJECTION (FUEL SYSTEMS) FU(TURBO) Page General Description Throttle Body Intake Manifold Engine Coolant Temperature Sensor Crankshaft Position Sensor Camshaft Position Sensor Knock Sensor Throttle Position Sensor Mass Air Flow and Intake Air Temperature Sensor Pressure Sensor Idle Air Control Solenoid Valve Fuel Injector Tumble Generator Valve Assembly ............2 Tumble Generator Valve Actuator...............3...
Page 28 TUMBLE GENERATOR VALVE ASSEMBLY FUEL INJECTION (FUEL SYSTEMS) 13.Tumble Generator Valve As- sembly A: REMOVAL 2. STI MODEL NOTE: Tumble generator valve actuator and sensor are not applied to STi model. B: INSTALLATION 2. STI MODEL NOTE: Tumble generator valve actuator and sensor are not applied to STi model.
Page 29 TUMBLE GENERATOR VALVE ACTUATOR FUEL INJECTION (FUEL SYSTEMS) 14.Tumble Generator Valve Ac- tuator A: REMOVAL 3. STI MODEL NOTE: Tumble generator valve actuator is not applied to STi model. B: INSTALLATION 3. STI MODEL NOTE: Tumble generator valve actuator is not applied to STi model.
Page 30: Exhaust Temperature Sensor
EXHAUST TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 18.Exhaust Temperature Sensor A: REMOVAL 2. STI MODEL NOTE: Exhaust temperature sensor is not applied to STi model. B: INSTALLATION 2. STI MODEL NOTE: Exhaust temperature sensor is not applied to STi model. FU(TURBO)-4...
Page 31 VARIABLE VALVE TIMING CAMSHAFT POSITON SENSOR FUEL INJECTION (FUEL SYSTEMS) 34.Variable Valve Timing Cam- shaft Positon Sensor A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the intercooler. <Ref. to IN(TURBO)- 10, REMOVAL, Intercooler.> 3) Remove the intake manifold. <Ref. to FU(TUR- BO)-15, REMOVAL, Intake Manifold.>...
Page 32 VARIABLE VALVE TIMING SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 35.Variable Valve Timing Sole- noid Valve A: REMOVAL Refer to following procedure for removal. <Ref. to ME(STi)-59, REMOVAL, Camshaft.> B: INSTALLATION Install in the reverse order of removal. FU(TURBO)-6...
Page 33: Emission Control
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(TURBO) Page General Description Front Catalytic Converter Rear Catalytic Converter Precatalytic Converter.................2 Canister Purge Control Solenoid Valve Two-way Valve...
Page 34 PRECATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. Precatalytic Converter A: REMOVAL 2. STI MODEL NOTE: Precatalytic converter is not applied to STi model. B: INSTALLATION 2. STI MODEL NOTE: Precatalytic converter is not applied to STi model. EC(TURBO)-2...
Page 35 INTAKE (INDUCTION) IN(TURBO) Page General Description ..................2 Air Cleaner Air Intake Duct Intake Duct Intercooler Turbocharger Air By-pass Valve Resonator Chamber Intercooler Water Tank................3...
Page 36: General Description
GENERAL DESCRIPTION INTAKE (INDUCTION) 1. General Description A: COMPONENT 5. INTERCOOLER WATER TANK EN1545 Water tank assembly Water tank cap Tightening torque: N·m (kgf-m, ft-lb) T: 6.0 (0.61, 4.4) IN(TURBO)-2...
Page 37 INTERCOOLER WATER TANK INTAKE (INDUCTION) 9. Intercooler Water Tank A: REMOVAL 1) Disconnect the ground cable from battery. G6M0095 2) Remove the trunk trim. <Ref. to EI-52, REMOV- AL, Trunk Trim.> 3) Disconnect the water tank connector. EN1541 4) Remove the two water tank installation bolts. EN1542 5) Remove the hose between body and water tank, then remove the water tank.
Page 38 INTERCOOLER WATER TANK INTAKE (INDUCTION) IN(TURBO)-4...
Page 39: Table Of Contents
MECHANICAL ME(STi) Page General Description ..................2 Compression .....................22 Idle Speed ....................23 Ignition Timing...................24 Intake Manifold Vacuum................25 Engine Oil Pressure ..................26 Fuel Pressure....................27 Valve Clearance..................28 Engine Assembly ..................32 Engine Mounting ..................41 Preparation for Overhaul................42 V-belt......................43 Crankshaft Pulley ..................45 Belt Cover ....................46 Timing Belt Assembly................47 Camshaft Sprocket..................56 Crankshaft Sprocket..................58...
Page 40 GENERAL DESCRIPTION MECHANICAL 1. General Description A: SPECIFICATIONS Horizontally opposed, liquid cooled, 4-cylinder, Type 4-stroke gasoline engine Valve arrangement Belt driven, double overhead camshaft, 4-valve/cylinder Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95) Piston displacement 1,994 (121.67) (cu in) Compression ratio Compression pressure...
Page 41 GENERAL DESCRIPTION MECHANICAL Belt ten- sion Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in) adjuster Spacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in) Tensioner bush I.D. 18.0 — 18.08 mm (0.7087 — 0.7118 in) 0.025 —...
Page 42 GENERAL DESCRIPTION MECHANICAL Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in) Surface grinding limit 0.1 mm (0.004 in) 92.005 — 92.015 mm (3.6222 — 3.6226 in) Cylinder bore 91.995 — 92.005 mm (3.6218 — 3.6222 in) 0.015 mm (0.0006 in) Taper Cylinder Limit...
Page 43 GENERAL DESCRIPTION MECHANICAL Bend limit 0.035 mm (0.0014 in) Out-of-roundness 0.020 mm (0.0008 in) or less Crank pin and crank jour- Grinding limit 0.25 mm (0.0098 in) 51.984 — 52.000 mm (2.0466 — 2.0472 in) 0.03 mm (0.0012 51.954 — 51.970 mm (2.0454 — 2.0461 in) in) US 0.05 mm Crank pin outer diameter...
Page 44: Timing Belt
GENERAL DESCRIPTION MECHANICAL B: COMPONENT 1. TIMING BELT (12) (14) (10) (14) (11) (17) (13) (15) (16) (18) EN1192 Right-hand belt cover No. 2 Right-hand intake camshaft (17) Right-hand belt cover sprocket Timing belt guide (18) Crankshaft pulley Crankshaft sprocket (10) Left-hand intake camshaft sprocket...
Page 45 GENERAL DESCRIPTION MECHANICAL ME(STi)-7...
Page 46 GENERAL DESCRIPTION MECHANICAL 2. CYLINDER HEAD AND CAMSHAFT (10) (12) (13) (11) (13) (28) (14) (24) (25) (26) (10) (18) (17) (11) (27) (22) (21) (28) (20) (15) (16) (19) (23) EN1193 ME(STi)-8...
Page 47 GENERAL DESCRIPTION MECHANICAL Rocker cover (RH) (13) Cylinder head gasket (25) Gasket Rocker cover gasket (RH) (14) Cylinder head (LH) (26) Oil filler duct Variable valve timing solenoid (15) Intake camshaft (LH) (27) O-ring valve assembly (RH) (16) Exhaust camshaft (LH) (28) Stud bolt Intake camshaft cap (RH)
Page 48 GENERAL DESCRIPTION MECHANICAL 3. CYLINDER HEAD AND VALVE ASSEMBLY (11) (11) (12) (10) (12) (10) EN1194 Exhaust valve Intake valve oil seal Valve lifter Intake valve Valve spring (10) Exhaust valve oil seal Cylinder head Retainer (11) Intake valve guide Valve spring seat Retainer key (12)
Page 49: Cylinder Block
GENERAL DESCRIPTION MECHANICAL 4. CYLINDER BLOCK EN0144 Oil pressure switch (15) Oil cooler Tightening torque: N·m (kgf-m, ft-lb) Cylinder block (RH) (16) Waster by-pass pipe T1: 5 (0.5, 3.6) Service hole plug (17) Connector T2: 6.4 (0.65, 4.7) Gasket (18) Oil strainer T3: 10 (1.0, 7) Oil separator cover...
Page 50 GENERAL DESCRIPTION MECHANICAL 5. CRANKSHAFT AND PISTON (10) (11) (13) (11) (12) (12) (11) (11) (14) (10) (17) (16) (15) (16) (15) EN1519 Flywheel Circlip (15) Crankshaft bearing #1, #3 Ball bearing Connecting rod bolt (16) Crankshaft bearing #2, #4 Top ring (10) Connecting rod...
Page 51 GENERAL DESCRIPTION MECHANICAL 6. ENGINE MOUNTING S2M1783A Heat shield cover Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-lb) Front cushion rubber T1: 35 (3.6, 25.8) T2: 42 (4.3, 30.9) T3: 85 (8.7, 62.7) ME(STi)-13...
Page 52 GENERAL DESCRIPTION MECHANICAL C: CAUTION • Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to • Wear working clothing, including a cap, protec- assembly. tive goggles, and protective shoes during opera- •...
Page 53 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498457100 ENGINE STAND Used with ENGINE STAND (499817000). ADAPTER LH B2M3852 498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos- STOPPER ening and tightening crankshaft pulley bolt, etc. B2M3853 398744300 PISTON GUIDE Used for installing piston in cylinder.
Page 54 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499017100 PISTON PIN Used for installing piston pin, piston and connect- GUIDE ing rod. B2M3856 499037100 CONNECTING Used for removing and installing connecting rod ROD BUSHING bushing. REMOVER & INSTALLER B2M3857 499097700 PISTON PIN Used for removing piston pin.
Page 55 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977500 CAMSHAFT Used for removing and installing intake camshaft. (Newly adopted SPROCKET tool) WRENCH EN1195 499587700 CAMSHAFT OIL Used for installing camshaft oil seal. SEAL INSTALLER B2M3860 499587200 CRANKSHAFT • Used for installing crankshaft oil seal. OIL SEAL •...
Page 56 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499718000 VALVE SPRING Used for removing and installing valve spring. REMOVER B2M3864 498267700 VALVE GUIDE Used for installing intake and exhaust valve ADJUSTER guides. B2M3865 499767200 VALVE GUIDE Used for removing valve guides. REMOVER B2M3867 499767400...
Page 57 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499817000 ENGINE STAND • Stand used for engine disassembly and assem- bly. • Used with ENGINE STAND ADAPTER RH (498457000) & LH (498457100). B2M3869 499977300 CRANK PULLEY Used for stopping rotation of crankshaft pulley WRENCH when loosening and tightening crankshaft pulley bolts.
Page 58 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587100 OIL SEAL Used for installing oil pump oil seal. INSTALLER B2M3875 499587600 OIL SEAL GUIDE Used for installing camshaft oil seal. S1H0136 499597200 OIL SEAL GUIDE Used for installing camshaft oil seal. Used with OIL SEAL GUIDE (499587600).
Page 59 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA190 CARTRIDGE Troubleshooting for electrical systems. B2M3876 22771AA030 SELECT MONI- Troubleshooting for electrical systems. TOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) B2M3877 2.
Page 60 COMPRESSION MECHANICAL 2. Compression A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measure- ment. 1) After warming-up the engine, turn the ignition switch to OFF. 2) Make sure that the battery is fully charged. 3) Release fuel pressure.
Page 61: Idle Speed
TOR. 5) Connect SUBARU SELECT MONITOR to the data link connector. 6) Turn the ignition switch to ON, and SUBARU SELECT MONITOR switch to ON. 7) Select {2. Each System Check} in Main Menu. 8) Select {Engine Control System} in Selection Menu.
Page 62: Ignition Timing
TOR. 5) Connect SUBARU SELECT MONITOR to the data link connector. 6) Turn the ignition switch to ON, and SUBARU SELECT MONITOR switch to ON. 7) Select {2. Each System Check} in Main Menu. 8) Select {Engine Control System} in Selection Menu.
Page 63: Intake Manifold Vacuum
INTAKE MANIFOLD VACUUM MECHANICAL 5. Intake Manifold Vacuum 3) Keep the engine at the idle speed and read the vacuum gauge indication. A: INSPECTION By observing the gauge needle movement, the in- 1) Warm-up the engine. ternal condition of the engine can be diagnosed as described below.
Page 64: Engine Oil Pressure
ENGINE OIL PRESSURE MECHANICAL 6. Engine Oil Pressure A: INSPECTION 1) Remove the oil pressure switch from engine cyl- inder block. <Ref. to LU-21, REMOVAL, Oil Pres- sure Switch.> 2) Connect the oil pressure gauge hose to cylinder block. 3) Connect the battery ground cable. G6M0095 4) Start the engine, and measure the oil pressure.
Page 65: Fuel Pressure
FUEL PRESSURE MECHANICAL 7. Fuel Pressure 6) Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake mani- A: INSPECTION fold. WARNING: Fuel pressure: Before removing the fuel pressure gauge, re- Standard; 284 — 314 kPa (2.9 — 3.2 kg/cm lease fuel pressure.
Page 66: Valve Clearance
VALVE CLEARANCE MECHANICAL 8. Valve Clearance 10) When inspecting #2 and #4 cylinders: (1) Disconnect the battery cables, and then re- A: INSPECTION move the battery and battery carrier. CAUTION: Inspection and adjustment of valve clearance should be performed while engine is cold. 1) Set the vehicle on a lift.
Page 67 VALVE CLEARANCE MECHANICAL (5) Move the washer tank upward. NOTE: If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on. H6M0431 (6) Disconnect the spark plug cords from spark plugs (#2 and #4 cylinders).
Page 68 VALVE CLEARANCE MECHANICAL (3) Set the arrow mark on camshaft sprocket to B: ADJUSTMENT position shown in the figure, and measure #1 CAUTION: cylinder exhaust valve and #4 cylinder intake Adjustment of valve clearance should be per- valve clearances. formed while engine is cold. 1) Measure all valve clearances.
Page 69 VALVE CLEARANCE MECHANICAL Part No. Thickness mm (in) Part No. Thickness mm (in) 13228 AA100 4.68 (0.1843) 13228 AA610 5.19 (0.2043) 13228 AA110 4.69 (0.1846) 13228 AA620 5.20 (0.2047) 13228 AA120 4.70 (0.1850) 13228 AA630 5.21 (0.2051) 13228 AA130 4.71 (0.1854) 13228 AA640 5.22 (0.2055) 13228 AA140...
Page 70: Engine Assembly
ENGINE ASSEMBLY MECHANICAL 9. Engine Assembly (3) Disconnect the A/C pressure hoses from A/C compressor. A: REMOVAL 1) Set the vehicle on lift arms. 2) Open the front hood fully and support with stay. 3) Raise the rear seat, and turn floor mat up. 4) Release the fuel pressure.
Page 71 ENGINE ASSEMBLY MECHANICAL (4) Generator connector, terminal and A/C (2) Heater inlet outlet hose compressor connectors EN0205 B2M1291I 13) Remove the power steering pump from brack- (A) A/C compressor connector (1) Loosen the lock bolt and slider bolt, and re- (B) Generator connector and terminal move the front side V-belt.
Page 72 ENGINE ASSEMBLY MECHANICAL (4) Remove the power steering pump from en- 16) Remove the nuts which install front cushion gine. rubber onto front crossmember. H2M1954 S2M1927 17) Separate the clutch release fork from release (5) Remove the power steering tank from the bracket by pulling it upward.
Page 73 ENGINE ASSEMBLY MECHANICAL (3) Screw 6 mm dia. bolt into release fork shaft, 19) Disconnect the fuel delivery hose, return hose and remove it. and evaporation hose. CAUTION: • Catch fuel from hose into container. • Disconnect the hose with its end wrapped with cloth to prevent fuel from splashing.
Page 74 ENGINE ASSEMBLY MECHANICAL 22) Support the transmission with a garage jack. B: INSTALLATION 1) Install the clutch release fork and bearing onto CAUTION: transmission. Before moving the engine away from transmis- (1) Remove the release bearing from clutch sion, check to be sure no work has been over- cover with flat type screw driver.
Page 75 ENGINE ASSEMBLY MECHANICAL (4) Apply grease to the specified points. (6) Tighten the plug. • Spline FX2200 Tightening torque: • Shaft SUNLIGHT 2 44 N·m (4.5 kgf-m, 32.5 ft-lb) S2M1846 2) Install the front cushion rubbers to engine. Tightening torque: 34 N·m (3.5 kgf-m, 25.3 ft-lb) 3) Install the engine onto transmission.
Page 76 ENGINE ASSEMBLY MECHANICAL 6) Remove the garage jack. 11) Install the power steering pump on bracket. (1) Install the power steering tank on bracket. G2M0297 EN0361 7) Install the pitching stopper. (2) Install the power steering pump on bracket, Tightening torque: and tighten bolts.
Page 77 ENGINE ASSEMBLY MECHANICAL (5) Install the front side V-belt, and adjust it. 17) Connect the following cables. <Ref. to ME-44, FRONT SIDE BELT, INSTAL- (1) Accelerator cable LATION, V-belt.> (2) Clutch release spring 12) Tighten the nuts which hold lower side of trans- CAUTION: mission to engine.
Page 78 ENGINE ASSEMBLY MECHANICAL 25) Charge the A/C system with refrigerant. <Ref. to AC-22, OPERATION, Refrigerant Charging Pro- cedure.> 26) Remove the front hood stay, and close the front hood. 27) Take off the vehicle from lift arms. ME(STi)-40...
Page 79: Engine Mounting
ENGINE MOUNTING MECHANICAL 10.Engine Mounting A: REMOVAL 1) Remove the engine assembly. <Ref. to ME(STi)- 32, REMOVAL, Engine Assembly.> 2) Remove the engine mounting from engine as- sembly. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Engine mounting; 35 N·m (3.6 kgf-m, 25.8 ft-lb) C: INSPECTION Make sure there are no cracks or other damage.
Page 80: Preparation For Overhaul
PREPARATION FOR OVERHAUL MECHANICAL 11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from the body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER ST2 498457100 ENGINE STAND ADAPTER ST3 499817000 ENGINE STAND S2M1876A 2) In this section the procedures described under each index are all connected and stated in order.
Page 81 V-BELT MECHANICAL 12.V-belt 4) Remove the rear side belt tensioner. A: REMOVAL 1. FRONT SIDE BELT NOTE: Perform the following procedures 1) to 4) with the engine installed to the body. 1) Remove the V-belt cover. S2M0113 B: INSTALLATION 1. FRONT SIDE BELT CAUTION: Wipe off any oil or water on the belt and pulley.
Page 82 V-BELT MECHANICAL 2. REAR SIDE BELT 1) Install the rear side belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. <Ref. to ME(STi)-44, INSPECTION, V-belt.> 2) Tighten the lock nut (A). Tightening torque: Lock nut (A); 22.6 N·m (2.3 kgf-m, 16.6 ft-lb) EN0226 C: INSPECTION...
Page 83: Crankshaft Pulley
CRANKSHAFT PULLEY MECHANICAL 13.Crankshaft Pulley 3) Confirm that the tightening angle of the crank- shaft pulley bolt is 45° or more. If not, conduct the A: REMOVAL following procedures (1) through (4). 1) Remove the V-belt. <Ref. to ME(STi)-43, RE- •...
Page 84: Belt Cover
BELT COVER MECHANICAL 14.Belt Cover A: REMOVAL 1) Remove the V-belt. <Ref. to ME(STi)-43, RE- MOVAL, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME(STi)- 45, REMOVAL, Crankshaft Pulley.> 3) Remove the left-hand belt cover (A). 4) Remove the right-hand belt cover (B). 5) Remove the front belt cover (C).
Page 85: Timing Belt Assembly
TIMING BELT ASSEMBLY MECHANICAL 15.Timing Belt Assembly A: REMOVAL 1. TIMING BELT 1) Remove the V-belt. <Ref. to ME(STi)-43, RE- MOVAL, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME(STi)- 45, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME(STi)-46, EN0259 REMOVAL, Belt Cover.>...
Page 86 TIMING BELT ASSEMBLY MECHANICAL (2) Using a white paint, put alignment and/or ar- 7) Remove the timing belt. row marks on timing belts in relation to the CAUTION: sprockets. After the timing belt has been removed, never rotate intake and exhaust, camshaft sprocket. If the camshaft sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent.
Page 87 TIMING BELT ASSEMBLY MECHANICAL B: INSTALLATION 2) Install the automatic belt tension adjuster as- sembly. 1. AUTOMATIC BELT TENSION ADJUST- Tightening torque: ER ASSEMBLY AND BELT IDLER 25 N·m (2.5 kgf-m, 18.1 ft-lb) 1) Preparation for installation of automatic belt ten- sion adjuster assembly: CAUTION: •...
Page 88 TIMING BELT ASSEMBLY MECHANICAL 2. TIMING BELT (4) Align single line mark (A) on the left-hand exhaust camshaft sprocket with notch (B) on 1) Preparation for installation of automatic belt ten- belt cover by turning sprocket counterclockwise sion adjuster assembly. <Ref. to ME(STi)-49, AU- (as viewed from front of engine).
Page 89 TIMING BELT ASSEMBLY MECHANICAL (6) Ensure the camshaft and crankshaft sprock- • Do not allow the camshafts to rotate in the di- ets are positioned properly. rection shown in the figure as this causes both intake and exhaust valves to lift simultaneous- CAUTION: ly, resulting in interference with their heads.
Page 90 TIMING BELT ASSEMBLY MECHANICAL 3) Installation of timing belt: S2M0418 Align alignment mark on the timing belt with marks on sprockets in the alphabetical order shown in the figure. While aligning marks, position the timing belt properly. CAUTION: • Disengagement of more than three timing belt teeth may result in interference between the valve and piston.
Page 91 TIMING BELT ASSEMBLY MECHANICAL 4) Install the belt idlers. Tightening torque: 39 N·m (4.0 kgf-m, 28.9 ft-lb) CAUTION: Make sure that the marks on timing belt and sprockets are aligned. EN0255 H2M2398 5) After ensuring that the marks on the timing belt and sprockets are aligned, remove the stopper pin from tensioner adjuster.
Page 92 TIMING BELT ASSEMBLY MECHANICAL 2. AUTOMATIC BELT TENSION ADJUST- 1) Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, re- place the automatic belt tension adjuster assembly. CAUTION: Slight traces of oil at rod's oil seal does not in- dicate a problem.
Page 93 TIMING BELT ASSEMBLY MECHANICAL 3. BELT TENSION PULLEY 1) Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the belt tension pulley if faulty. 2) Check the belt tension pulley for smooth rota- tion.
Page 94: Camshaft Sprocket
CAMSHAFT SPROCKET MECHANICAL 16.Camshaft Sprocket B: INSTALLATION 1) Install the camshaft sprocket No. 1. and No. 2. A: REMOVAL To lock the camshaft, use ST. 1) Remove the V-belt. <Ref. to ME(STi)-43, RE- ST 499207400 CAMSHAFT SPROCKET MOVAL, V-belt.> WRENCH 2) Remove the crankshaft pulley.
Page 95 CAMSHAFT SPROCKET MECHANICAL C: INSPECTION 1) Check the sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between the sprocket and key. 3) Check the crankshaft sprocket notch for sensor for damage and contamination of foreign matter. ME(STi)-57...
Page 96: Crankshaft Sprocket
CRANKSHAFT SPROCKET MECHANICAL 17.Crankshaft Sprocket C: INSPECTION 1) Check the sprocket teeth for abnormal wear and A: REMOVAL scratches. 1) Remove the V-belt. <Ref. to ME(STi)-43, RE- 2) Make sure there is no free play between the MOVAL, V-belt.> sprocket and key. 2) Remove the crankshaft pulley.
Page 97 CAMSHAFT MECHANICAL 18.Camshaft 10) Remove the right-hand belt cover No.2. A: REMOVAL 1) Remove the V-belt. <Ref. to ME(STi)-43, IN- STALLATION, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME(STi)- 45, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME(STi)-46, REMOVAL, Belt Cover.>...
Page 98 CAMSHAFT MECHANICAL 17) Loosen the exhaust camshaft cap bolts equal- B: INSTALLATION ly, a little at a time in alphabetical sequence shown 1) Camshaft installation: in the figure. Apply engine oil to cylinder head at camshaft bear- ing location before installing the camshaft. Install the camshaft so that each valve is close to or in contact with “base circle”...
Page 99 CAMSHAFT MECHANICAL 2) Camshaft cap and variable valve timing solenoid (4) Similarly, tighten cap on the exhaust side. valve assembly installation: After tightening cap, ensure the camshaft ro- (1) Apply fluid packing sparingly to cap mating tates only slightly while holding it at “base” circle. surface.
Page 100 CAMSHAFT MECHANICAL (3) Install the rocker cover on cylinder head. 10) Install the right-hand belt cover No. 2. Ensure the gasket is properly positioned during Tightening torque: installation. 5 N·m (0.5 kgf-m, 3.6 ft-lb) 5) Install the oil pipe. Tightening torque: 30 N·m (3.1 kgf-m, 22.1 ft-lb) B2M0738 11) Install the left-hand belt cover No.
Page 101 CAMSHAFT MECHANICAL C: INSPECTION (5) Remove the bearing caps. (6) Measure the widest point of the plastigauge 1) Measure the bend, and repair or replace if nec- on each journal. essary. If the oil clearance exceeds the limit, replace the Limit: camshaft.
Page 102 CAMSHAFT MECHANICAL 6) Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the limit, re- place caps and cylinder head as a set. If necessary replace the camshaft. Standard: 0.015 — 0.070 mm (0.0006 — 0.0028 in) Limit: 0.1 mm (0.004 in) B2M1217...
Page 103: Cylinder Head Assembly
CYLINDER HEAD ASSEMBLY MECHANICAL 19.Cylinder Head Assembly 12) Similarly, remove the right side cylinder head. B: INSTALLATION A: REMOVAL 1) Install the cylinder head and gaskets on cylinder 1) Remove the V-belt. <Ref. to ME(STi)-43, RE- block. MOVAL, V-belt.> CAUTION: 2) Remove the crankshaft pulley.
Page 104 CYLINDER HEAD ASSEMBLY MECHANICAL 9) Install the crankshaft pulley. <Ref. to ME(STi)- 45, INSTALLATION, Crankshaft Pulley.> 10) Install the V-belt. <Ref. to ME(STi)-43, IN- STALLATION, V-belt.> C: DISASSEMBLY 1) Remove the valve lifters. 2) Compress the valve spring and remove the valve spring retainer key.
Page 105 CYLINDER HEAD ASSEMBLY MECHANICAL D: ASSEMBLY (11) (11) (12) (10) (12) (10) EN1194 Exhaust valve Intake valve oil seal Valve lifter Intake valve Valve spring (10) Exhaust valve oil seal Cylinder head Retainer (11) Intake valve guide Valve spring seat Retainer key (12) Exhaust valve guide...
Page 106 CYLINDER HEAD ASSEMBLY MECHANICAL 1) Installation of valve spring and valve: CAUTION: (1) Coat the stem of each valve with engine oil Uneven torque for the cylinder head nuts can and insert the valve into valve guide. cause warping. When reassembling, pay spe- cial attention to the torque so as to tighten CAUTION: evenly.
Page 107 CYLINDER HEAD ASSEMBLY MECHANICAL 3. VALVE GUIDE (3) Turn the cylinder head upside down and place ST as shown in the figure. 1) Check the clearance between valve guide and ST 498267700 VALVE GUIDE ADJUSTER stem. The clearance can be checked by measuring the outside diameter of valve stem and the inside diameter of valve guide with outside and inside mi- crometers respectively.
Page 108 CYLINDER HEAD ASSEMBLY MECHANICAL (8) Recheck the contact condition between 5. VALVE SPRINGS valve and valve seat after replacing the valve 1) Check valve springs for damage, free length, guide. and tension. Replace the valve spring if it is not within the specifications presented in the table.
Page 109 CYLINDER HEAD ASSEMBLY MECHANICAL 6. INTAKE AND EXHAUST VALVE OIL 3) Measure the inner diameter of valve lifter mating part on cylinder head. SEAL Inner diameter: Replace the oil seal with new one, if lip is damaged 34.994 — 35.016 mm (1.3777 — 1.3786 in) or spring out of place, or when the surfaces of in- take valve and valve seat are reconditioned or in- take valve guide is replaced.
Page 110 CYLINDER HEAD ASSEMBLY MECHANICAL (4) Once the reaction is completed (about 4 — 5 hours have elapsed), carefully remove the valve using large pincers so that the reaction liq- uid does not contact your skin, and dispose of it with other parts that are being disposed of. (5) The reaction liquid is a strong alkaline solu- tion, so it must be disposed of in accordance with local regulations.
Page 111 CYLINDER BLOCK MECHANICAL 20.Cylinder Block (3) Insert a oil pan cutter blade between cylin- der block-to-oil pan clearance and remove the A: REMOVAL oil pan. NOTE: CAUTION: Before conducting this procedure, drain the engine Do not use a screwdriver or similar tool in place oil completely if applicable.
Page 112 CYLINDER BLOCK MECHANICAL EN0294 Service hole plug Circlip Service hole cover Gasket Piston pin O-ring 21) Remove the service hole cover and service 22) Rotate the crankshaft to bring #1 and #2 pis- hole plugs using hexagon wrench [14 mm (0.55 tons to bottom dead center position, then remove in)].
Page 113 CYLINDER BLOCK MECHANICAL 23) Draw out the piston pin from #1 and #2 pistons 24) Similarly remove the piston pins from #3 and #4 using ST. pistons. ST 499097700 PISTON PIN REMOVER 25) Remove the bolts which connect cylinder block ASSY on the side of #2 and #4 cylinders.
Page 114 CYLINDER BLOCK MECHANICAL 32) Draw out each piston from the cylinder block using wooden bar or hammer handle. CAUTION: Do not confuse the combination of piston and cylinder. B: INSTALLATION B2M2407A Crankshaft bearing Rear oil seal Tightening torque: N·m (kgf-m, ft-lb) Crankshaft T1: 25 (2.5, 18.1) Cylinder block...
Page 115 CYLINDER BLOCK MECHANICAL 3) Temporarily tighten the 10 mm cylinder block 6) Install the rear oil seal using ST1 and ST2. connecting bolts in alphabetical sequence shown in ST1 499597100 CRANKSHAFT OIL SEAL the figure. GUIDE ST2 499587200 CRANKSHAFT OIL SEAL IN- STALLER B2M0088D 4) Tighten the 10 mm cylinder block connecting...
Page 116 CYLINDER BLOCK MECHANICAL 11) Position the lower rail gap at (E) or (F) in the fig- CAUTION: ure. Use new circlips. CAUTION: • Ensure the ring gaps do not face the same di- rection. • Ensure the ring gaps are not within the piston skirt area.
Page 117 CYLINDER BLOCK MECHANICAL 13) Installing piston: (3) Install the circlip using ST. (1) Turn the cylinder block so that #1 and #2 cyl- NOTE: inders face upward. Use new circlips. (2) Using the ST1, turn the crankshaft so that ST 499897200 PISTON CIRCLIP PLIER #1 and #2 connecting rods are set at bottom dead center.
Page 118 CYLINDER BLOCK MECHANICAL B2M1323K Piston Service hole plug Tightening torque: N·m (kgf-m, ft-lb) Piston pin Service hole cover T1: 6.4 (0.65, 4.7) Circlip O-ring T2: 69 (7.0, 50.6) Gasket (6) Turn the cylinder block so that #3 and #4 cyl- 19) Apply fluid packing to matching surfaces and inders face upward.
Page 119 CYLINDER BLOCK MECHANICAL 20) Apply fluid packing to matching surfaces and (2) Apply fluid packing to matching surface of install the oil separator cover. the oil pump. Fluid packing: Fluid packing: THREE BOND 1215 or equivalent THREE BOND 1215 or equivalent B2M0390B S2M1834A 21) Install the flywheel.
Page 120 CYLINDER BLOCK MECHANICAL 24) Install the water pump and gasket. 28) Install the water by-pass pipe between oil cool- er and water pump. Tightening torque: Tightening torque: First; 12 N·m (1.2 kgf-m, 8.7 ft-lb) 6.4 N·m (0.65 kgf-m, 4.72 ft-lb) Second;...
Page 121 CYLINDER BLOCK MECHANICAL C: DISASSEMBLY EN1522 Connecting rod cap Top ring Oil ring Connecting rod bearing Second ring Circlip 1) Remove the connecting rod cap. 2) Remove the connecting rod bearing. CAUTION: Arrange removed connecting rod, connecting rod cap and bearing in order to prevent confu- sion.
Page 122 CYLINDER BLOCK MECHANICAL D: ASSEMBLY EN1523 Connecting rod bearing Second ring Tightening torque: N·m (kgf-m, ft-lb) Connecting rod Top ring T: 52 (5.3, 38.4) Connecting rod cap Circlip Oil ring 1) Install the connecting rod bearings on connect- E: INSPECTION ing rods and connecting rod caps.
Page 123 CYLINDER BLOCK MECHANICAL 2. CYLINDER AND PISTON 2) How to measure the inner diameter of each cyl- inder: 1) The cylinder bore size is stamped on the cylinder Measure the inner diameter of each cylinder in both block's front upper surface. the thrust and piston pin directions at the heights CAUTION: shown in the figure, using a cylinder bore gauge.
Page 124 CYLINDER BLOCK MECHANICAL 4) How to measure the outer diameter of each pis- 6) Boring and honing: ton: (1) If the value of taper, out-of-roundness, or Measure the outer diameter of each piston at the cylinder-to-piston clearance measured exceeds height shown in the figure. (Thrust direction) the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize pis- CAUTION:...
Page 125 CYLINDER BLOCK MECHANICAL 3) Make sure that the piston pin can be inserted 4. PISTON RING into the piston pin hole with a thumb at 20°C (68°F). 1) If the piston ring is broken, damaged, or worn, or Replace if defective. if its tension is insufficient, or when the piston is re- Standard clearance between piston pin and placed, replace the piston ring with a new one of...
Page 126 CYLINDER BLOCK MECHANICAL 2) Squarely place the piston ring and oil ring in cyl- 5. CONNECTING ROD inder, and measure the piston ring gap with a thick- 1) Replace the connecting rod, if the large or small ness gauge. end thrust surface is damaged. 2) Check for bend or twist using a connecting rod Unit: mm (in) aligner.
Page 127 CYLINDER BLOCK MECHANICAL 4) Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc. 5) Measure the oil clearance on individual connect- ing rod bearings by means of plastigauge. If any oil clearance is not within specification, replace the defective bearing with a new one of standard size or undersize as necessary.
Page 128 CYLINDER BLOCK MECHANICAL 6. CRANKSHAFT AND CRANKSHAFT BEARING 1) Clean the crankshaft completely and check for cracks by means of red lead check etc., and re- place if defective. 2) Measure the crankshaft bend, and correct or re- place if it exceeds the limit. CAUTION: If a suitable V-block is not available, install #1 and #5 crankshaft bearing on the cylinder...
Page 129 CYLINDER BLOCK MECHANICAL Unit: mm (in) Crank journal diameter Crank pin diameter #1, #3, #5 #2, #4 59.992 — 60.008 59.992 — 60.008 51.984 — 52.000 Journal O.D. (2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472) Standard Bearing size 1.998 —...
Page 130: Engine Trouble In General
ENGINE TROUBLE IN GENERAL MECHANICAL 21.Engine Trouble in General A: INSPECTION A — Very often NOTE: B — Sometimes “RANK” shown in the chart refer to the possibility of C — Rarely reason for the trouble in order (“Very often” to “Rarely”) Trouble Problem Parts, etc.
Page 131 ENGINE TROUBLE IN GENERAL MECHANICAL Trouble Problem Parts, etc. Possible Cause Rank 4) Engine stalls after initial • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> combustion. • Intake system • Loosened or cracked intake duct • Loosened or cracked PCV hose •...
Page 132 ENGINE TROUBLE IN GENERAL MECHANICAL Trouble Problem Parts, etc. Possible Cause Rank 3. Low output, hesitation and • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> poor acceleration • Intake system • Loosened or cracked intake duct • Loosened or cracked PCV hose •...
Page 133 ENGINE TROUBLE IN GENERAL MECHANICAL Trouble Problem Parts, etc. Possible Cause Rank 5. Engine does not return to • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> idle. • Intake system • Loosened or cracked vacuum hose • Others •...
Page 134 ENGINE TROUBLE IN GENERAL MECHANICAL Trouble Problem Parts, etc. Possible Cause Rank 10. Excessive fuel consump- • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> tion • Intake system • Dirty air cleaner element • Belt • Defective timing •...
Page 135: Engine Noise
ENGINE NOISE MECHANICAL 22.Engine Noise A: INSPECTION Type of sound Condition Possible cause • Valve mechanism is defective. • Incorrect valve clearance Sound increases as engine Regular clicking sound • Worn valve rocker speed increases. • Worn camshaft • Broken valve spring •...
Page 136 ENGINE NOISE MECHANICAL ME(STi)-98...
Page 137 Engine Control Module (ECM) I/O Signal ..........14 Engine Condition Data Transmission Control Module (TCM) I/O Signal Data Link Connector OBD-II General Scan Tool Subaru Select Monitor Read Diagnostic Trouble Code Inspection Mode Clear Memory Mode Compulsory Valve Operation Check Mode...
Page 138: Electrical Components Location
ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) 4. Electrical Components Location A: LOCATION 1. ENGINE • Module LHD model EN1423 RHD model EN1424 Engine control module (ECM) Test mode connector CHECK ENGINE malfunction indi- Data link connector cator lamp (MIL) EN(TURBO)-2...
Page 139 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN0718 B3M1575A EN0716 EN1425 EN(TURBO)-3...
Page 140 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • Sensor (8) (9) EN1524 Pressure sensor Knock sensor Tumble generator valve position sensor (Except STi model) Engine coolant temperature sen- Camshaft position sensor Crankshaft position sensor Variable valve timing camshaft position sensor (STi model) Throttle position sensor Mass air flow and intake air tem- perature sensor...
Page 141 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN1009 EN1008 EN1010 EN1011 EN1012 EN1013 EN1014 EN1015 EN1525 EN(TURBO)-5...
Page 142 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN0948 Front oxygen (A/F) sensor Exhaust temperature sensor Front catalytic converter (Except STi model) Precatalytic converter (Except STi Rear oxygen sensor model) Rear catalytic converter EN(TURBO)-6...
Page 143 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN1016 EN1017 EN0949 EN1018 EN0950 EN(TURBO)-7...
Page 144 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) LHD model EN1019 RHD model EN1020 Fuel level sensor Fuel sub level sensor EN1036 EN1037 EN(TURBO)-8...
Page 145 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN(TURBO)-9...
Page 146 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) • Solenoid Valve, Actuator, Emission Control System Parts and Ignition System Parts EN1526 Wastegate control solenoid valve Ignition coil Variable valve timing solenoid valve (STi model) Idle air control solenoid valve Tumble generator valve actuator (Except STi model) Purge control solenoid valve EN(TURBO)-10...
Page 147 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN1021 EN1022 EN1023 EN1024 EN0952 EN1527 EN(TURBO)-11...
Page 148 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) LHD model EN1025 RHD model EN1026 Fuel pump Fuel pump controller Radiator sub fan relay 1 Main relay Radiator main fan relay 1 Radiator sub fan relay 2 Fuel pump relay Radiator main fan relay 2 Starter EN(TURBO)-12...
Page 149 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) LHD model EN0953 EN1027 RHD model EN1028 EN1029 EN0954 EN1030 EN(TURBO)-13...
Page 150 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) 5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION B134 B135 B136 B137 EN0955 Signal (V) Con- Termi- Content nector Note Ignition SW ON nal No. Engine ON (Idling) (Engine OFF) −7 —...
Page 151 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Con- Termi- Content nector Note Ignition SW ON nal No. Engine ON (Idling) (Engine OFF) Signal — 0.3 — 4.5 — Mass air flow sen- Shield — — Intake air temperature B135 —...
Page 152 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Con- Termi- Content nector Note Ignition SW ON nal No. Engine ON (Idling) (Engine OFF) Sensor power supply B135 — Line end check 1 B134 — B136 13 — 14 Waveform B136 13 —...
Page 153 ENGINE CONTROL MODULE (ECM) I/O SIGNAL ENGINE (DIAGNOSTICS) Signal (V) Con- Termi- Content nector Note Ignition SW ON nal No. Engine ON (Idling) (Engine OFF) Less than 1 ←→ More Less than 1 ←→ More AT diagnosis input sig- B135 Waveform nal *2 than 4...
Page 154 LIST OF DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) 17.List of Diagnostic Trouble Code (DTC) A: LIST 2. STI MODEL Following DTCs are only for STi model. Refer to normal turbo model for DTCs except following. Item Index P0011 Variable valve timing system 1 (RH). <Ref.
Page 155 Subaru Select • Engine oil sage. Monitor and OBD-II general scan tool. (amount, con- Replace the...
Page 156 Subaru Select • Engine oil sage. Monitor and OBD-II general scan tool. (amount, con- Replace the...
Page 157 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(TURBO)-21...
Page 158 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) DK:DTC P0365 — VARIABLE VALVE TIMING CAMSHAFT POSITION SENSOR B CIRCUIT MALFUNCTION 1 (RH) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 159 2)Measure the ignition timing advance using according to engine output tor. Subaru Select Monitor or OBD-II general scan change? NOTE: Idling: −2 — +2 degree tool, while running the vehicle at approx. 30 In this case, repair Vehicle running: −2 —...
Page 160 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK VARIABLE VALVE TIMING CAM- Is the resistance between 1 Check oil pres- Replace the vari- SHAFT POSITION SENSOR. and 4 kΩ? sure passage and able valve timing 1)Remove the variable valve timing camshaft stuck of variable camshaft position position sensor.
Page 161 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(TURBO)-25...
Page 162 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) DL:DTC P0390 — VARIABLE VALVE TIMING CAMSHAFT POSITION SENSOR B CIRCUIT MALFUNCTION 2 (LH) — • DTC DETECTING CONDITION: • Immediately at fault recognition • TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 163 2)Measure the ignition timing advance using according to engine output tor. Subaru Select Monitor or OBD-II general scan change? NOTE: Idling: −2 — +2 degree tool, while running the vehicle at approx. 30 In this case, repair Vehicle running: −2 —...
Page 164 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK VARIABLE VALVE TIMING CAM- Is the resistance between 1 Check oil pres- Replace the vari- SHAFT POSITION SENSOR. and 4 kΩ? sure passage and able valve timing 1)Remove the variable valve timing camshaft stuck of oil vari- camshaft position position sensor.
Page 165 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(TURBO)-29...
Page 166 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) DM:DTC P1306 — VARIABLE VALVE TIMING SOLENOID VALVE 1 CIRCUIT LOW INPUT (RH) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 167 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair the open Ω? VARIABLE VALVE TIMING SOLENOID circuit in harness VALVE. between ECM and 1)Turn the ignition switch to OFF.
Page 168 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) DN:DTC P1307 — VARIABLE VALVE TIMING SOLENOID VALVE 1 CIRCUIT HIGH INPUT (RH) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 169 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair the open Ω? VARIABLE VALVE TIMING SOLENOID circuit in harness VALVE. between ECM and 1)Turn the ignition switch to OFF.
Page 170 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) DO:DTC P1308 — VARIABLE VALVE TIMING SOLENOID VALVE 2 CIRCUIT LOW INPUT (LH) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 171 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair the open Ω? VARIABLE VALVE TIMING SOLENOID circuit in harness VALVE. between ECM and 1)Turn the ignition switch to OFF.
Page 172 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) DP:DTC P1309 — VARIABLE VALVE TIMING SOLENOID VALVE 2 CIRCUIT HIGH INPUT (LH) — • DTC DETECTING CONDITION: • Two consecutive driving cycles with fault • TROUBLE SYMPTOM: • Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref.
Page 173 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair the open Ω? VARIABLE VALVE TIMING SOLENOID circuit in harness VALVE. between ECM and 1)Turn the ignition switch to OFF.
Page 174 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(TURBO)-38...
Page 175 MANUAL TRANSMISSION AND MT (6MT) DIFFERENTIAL CLUTCH SYSTEM This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reas-...
Page 177: Control Systems
CONTROL SYSTEMS Page General Description ..................2 Select Lever Select Cable MT Gear Shift Lever MT Drive Select Lever Drive Select Cable General Diagnostic..................4 6MT Gear Shift Lever..................5 Reverse Check Cable ................13...
Page 178 GENERAL DESCRIPTION CONTROL SYSTEMS 1. General Description B: COMPONENT 4. 6MT GEAR SHIFT LEVER (29) (28) (10) (11) (30) (10) (11) (33) (10) (10) (11) (10) (10) (12) (13) (14) (15) (16) (17) (19) (32) (31) (26) (23) (21) (24) (27) (18) (25)
Page 179 GENERAL DESCRIPTION CONTROL SYSTEMS Gear shift knob (15) Lever bush (29) Spring pin Console box front (16) Spring pin (30) Shift rod Boot plate (17) Bush (31) Reverse check lever Slider (18) Boot (32) Band clip Spring pin (19) Inner boot (33) Boss Spring...
Page 180: General Diagnostic
GENERAL DIAGNOSTIC CONTROL SYSTEMS 7. General Diagnostic A: INSPECTION Symptom Possible cause Remedy 1. Select lever (1) Starter does not run. Adjust the select cable and inhibitor switch, or inspect circuit. (2) Back-up light does not light up. Adjust the select cable and inhibitor switch, or inspect circuit.
Page 181 6MT GEAR SHIFT LEVER CONTROL SYSTEMS 8. 6MT Gear Shift Lever 11) Move the transmission to right side, and then remove the joint COMPL, stay bolt and reverse A: REMOVAL check cable. 1) Set the vehicle on a lift. NOTE: 2) Disconnect the ground cable from battery.
Page 182 6MT GEAR SHIFT LEVER CONTROL SYSTEMS B: INSTALLATION 5) Install the reverse check cable end, washer and snap pin to reverse check lever. 1) Insert the gear shift lever from room side. NOTE: NOTE: • Take care to install the snap pin in proper direc- After inserting the rod and stay, temporarily put tion.
Page 183 6MT GEAR SHIFT LEVER CONTROL SYSTEMS C: DISASSEMBLY 4) Remove the reverse check cable from cable plate. 1) Remove the spring pin from slider. TR0961 TR0958 (A) Cable plate (A) Slider (B) Reverse check cable (B) Spring pin 5) Remove the reverse check cable from gear shift 2) Remove the slider and spring.
Page 184 6MT GEAR SHIFT LEVER CONTROL SYSTEMS 7) Disassemble the lock wire. 11) Remove the snap ring from stay. NOTE: Do not reuse the lock wire. TR0966 (A) Snap ring TR0964 12) Separate the gear shift lever and stay. (A) Lock wire 8) Remove the boss from rod.
Page 185 6MT GEAR SHIFT LEVER CONTROL SYSTEMS 14) Remove the spring pin, and then remove the 1) Mount the bush and cushion rubber on the stay. bush, washer and snap ring. TR0970 TR0969 (A) Bush (A) Bush (B) Stay (B) Washer (C) Cushion rubber (C) Snap ring 2) Install the bush and spacer to boss.
Page 186 6MT GEAR SHIFT LEVER CONTROL SYSTEMS 4) Apply grease to the bush and boot, and then in- 8) Install the rod. stall to the gear shift lever. Tightening torque: 11.8 N·m (1.2 kgf-m, 8.7 ft-lb) TR0968 TR0965 (A) Boot (B) Bush (A) Rod 5) Apply sufficient grease into the boss, and then (B) Lever...
Page 187 6MT GEAR SHIFT LEVER CONTROL SYSTEMS 13) Insert the reverse check cable into gear shift NOTE: assembly, and fix with band clip. • Install the lock wire to stay groove. • Bend the extra wire to same direction of lock wire NOTE: winding.
Page 188 6MT GEAR SHIFT LEVER CONTROL SYSTEMS 16) Fix the slider and reverse check cable end with E: INSPECTION spring pin. 1) Check each part (bushing, cushion rubber, spac- er, boot, stay and rod, etc.) for deformation, dam- NOTE: age and wear. Repair or replace any defective part. Apply grease to the sliding part of slider.
Page 189 REVERSE CHECK CABLE CONTROL SYSTEMS 9. Reverse Check Cable 6) Cut the band clip, and then separate the reverse check cable from gear shift lever. A: REMOVAL 1) Set the vehicle on a lift. 2) Remove the gear shift knob. 3) Remove the console box front.
Page 190 REVERSE CHECK CABLE CONTROL SYSTEMS 12) Move the transmission to right side, and then 15) Loosen the lock nut, then remove the reverse remove the stay bolt and reverse check cable. check cable from cable plate. NOTE: If the transmission is not moved, stay bolt will con- tact body and damage may occur.
Page 191 REVERSE CHECK CABLE CONTROL SYSTEMS 4) Lower the vehicle. 8) Install the reverse check cable end, washer and snap pin to reverse check lever. 5) Insert the reverse check cable to the gear shift lever assembly, then fix with the band clip. NOTE: NOTE: Take care to install the snap pin in proper direction.
Page 192 REVERSE CHECK CABLE CONTROL SYSTEMS C: INSPECTION 6) Move the transmission to right side, and then re- move the stay bolt and reverse check cable. 1) Verify whether the slider moves smoothly. If not, adjust the reverse check cable or check damage of NOTE: slider.
Page 193 REVERSE CHECK CABLE CONTROL SYSTEMS 9) Install the crossmember. <Ref. to 6MT-35, IN- STALLATION, Transmission Mounting System.> 10) Install the rear exhaust pipe and muffer. <Ref. to EX(TURBO)-13, INSTALLATION, Rear Exhaust Pipe.>, <Ref. to EX(TURBO)-14, INSTALLATION, Muffer.> 11) Install the reverse check cable end, washer and snap pin to reverse check lever.
Page 194 REVERSE CHECK CABLE CONTROL SYSTEMS CS-18...
Page 195: Table Of Contents
MANUAL TRANSMISSION AND DIFFERENTIAL Page General Description ..................2 Transmission Gear Oil ................32 Oil Seal......................33 Vehicle Speed Sensor................34 Transmission Mounting System ..............35 Manual Transmission Assembly ...............37 Preparation for Overhaul................42 Air Breather Hose..................43 Oil Pipe......................44 Back-up Light Switch.................45 Neutral Position Switch ................47 Extension Case ..................49 Reverse Checking System................55 Transfer Drive Gear ..................58...
Page 196: Transmission Gear Oil
GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 1. General Description A: SPECIFICATION 1. MANUAL TRANSMISSION AND FRONT DIFFERENTIAL Item Type 6-forward speeds and 1-reverse 3.636 2.375 1.761 Transmission gear ratio 1.346 0.971 [1.062] 0.756 [0.842] Reverse 3.545 Type of gear Hypoid Front reduc- Final tion gear...
Page 197: Clutch Housing
GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL B: COMPONENT 1. CLUTCH HOUSING (10) (12) (13) (11) TR0595 Oil level gauge Speedometer driven gear Tightening torque: N·m (kgf-m, ft-lb) Oil seal (10) Snap ring T1: 6.4 (0.65, 4.7) Snap ring (11) Gasket T2: 41 (4.2, 30.2) Washer (12)
Page 198 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 2. ADAPTER PLATE (10) (12) (13) (11) TR0596 Breather hose Gasket Tightening torque: N·m (kgf-m, ft-lb) Transmission harness stay Spring T1: 6.4 (0.65, 4.7) Plug (10) Ball T2: 37 (3.8, 27.3) Gasket (11) Lubrication pipe T3: 50 (5.1, 36.9) Spring (12)
Page 199: Transmission Case
GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 3. TRANSMISSION CASE (10) (11) (12) (13) (14) (16) (15) (16) (16) TR0597 Pilot bolt Return spring Tightening torque: N·m (kgf-m, ft-lb) Neutral switch (10) Pressure relief valve T1: 13 (1.3, 9.6) Back-up light switch (11) Return spring T2: 16 (1.6, 11.8)
Page 200 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 4. OIL PAN AND OIL PUMP (11) (12) (13) (10) TR0598 Main case Oil pan Tightening torque: N·m (kgf-m, ft-lb) Oil pump cover Plate T1: 6.4 (0.65, 4.7) Oil guide (10) Gasket T2: 10 (1.0, 7.4) Oil pump driven gear ASSY (11) Oil guide...
Page 201 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 5. EXTENSION CASE AND CENTER DIFFERENTIAL (19) (17) (18) (16) (20) (23) (24) (12) (25) (26) (21) (15) (22) (11) (10) (14) (13) (33) (27) (29) (28) (30) (31) (32) TR0599 Taper roller bearing (15) Extension guide (29)
Page 202 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 6. SHIFTER FORK AND FORK ROD (10) (15) (18) (14) (22) (17) (13) (16) (12) (20) (21) (11) (19) (23) (24) TR0600 Spring pin Support (17) 5th-6th shifter arm Interlock arm (10) Snap ring (18) 5th-6th fork COMPL Interlock block...
Page 203 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 7. MAIN SHAFT ASSY (13) (12) (11) (10) (22) (20) (29) (28) (27) (21) (26) (25) (19) (24) (15) (18) (23) (14) (17) (16) TR0601 Main shaft (12) 4th bush (23) 6th bush Needle bearing (13) Needle bearing (24)
Page 204 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 8. DRIVE PINION AND DRIVEN SHAFT ASSY (15) (14) (13) (24) (23) (12) (11) (22) (10) (21) (20) (27) (26) (19) (25) (18) (17) (16) TR0602 Drive pinion shaft (13) 1st-2nd sleeve (25) Lock nut Taper roller bearing (14) Shifting insert...
Page 205 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 9. REVERSE IDLER GEAR ASSY (17) (16) (15) (14) (13) (12) (20) (11) (18) (10) (19) TR0603 Base COMPL Reverse coupling sleeve (17) Reverse idler holder Washer (10) Reverse idler gear (18) Spring pin Reverse idler gear No.2 (11) Spring...
Page 206 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 10.FRONT DIFFERENTIAL WITHOUT LSD (16) (12) (15) (11) (13) (12) (10) (13) (11) (14) (15) (10) (14) TR0604 Drive pinion shaft Roller bearing (15) Circlip Hypoid driven gear Differential case (16) Speedometer drive gear Pinion shaft (10) Oil seal...
Page 207 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 11.FRONT DIFFERENTIAL WITH LSD (11) (10) (10) TR0605 Drive pinion shaft Differential side retainer (11) Speedometer drive gear Hypoid driven gear O-ring Roller bearing Axle drive shaft Tightening torque: N·m (kgf-m, ft-lb) Differential case ASSY Retainer lock plate T1: 25 (2.5, 18.1) Oil seal...
Page 208 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 12.TRANSMISSION MOUNTING (11) (10) (12) TR0606 Pitching stopper Center crossmember (Except Tightening torque: N·m (kgf-m, ft-lb) EUROPE model) Spacer T1: 7.5 (0.76, 5.5) Cushion C Rear plate T2: 35 (3.6, 25.8) Front plate (10) Front crossmember T3: 50 (5.1, 36.9) Rear cushion rubber...
Page 209 • Avoid damaging the mating surface of the case. • Use SUBARU genuine gear oil, grease etc. or • Before applying sealant, completely remove the the equivalent. Do not mix gear oil, grease etc. with old seal.
Page 210 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498515700 REMOVER Used for removing roller bearing of drive pinion shaft. B3M1942 498147000 DEPTH GAUGE Used for adjusting main shaft axial end play. B3M1944 498247001 MAGNET BASE • Used for measuring backlash between side gear and pinion, and hypoid gear.
Page 211 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498077000 REMOVER Used for removing differential taper roller bear- ing. B3M1998 899858600 REMOVER Used for removing roller bearing. B3M2125 399513600 INSTALLER Used for installing oil seal. B3M2129 499757002 INSTALLER Used for installing bearing cone of transfer driven gear (extension core side).
Page 212 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499787000 WRENCH ASSY Used for removing and installing differential side retainer (right side). B3M1953 499827000 PRESS Used for installing speedometer oil seal when installing speedometer cable to transmission. B3M1954 499877000 RACE 4-5 Used for disassembling driven shaft and transfer...
Page 213 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899904100 REMOVER Used for removing and installing straight pin. B3M1965 899824100 PRESS Used for installing speedometer shaft oil seal. B3M1969 498057300 INSTALLER Used for installing extension oil seal. B3M1972 498255400 PLATE Used for measuring backlash.
Page 214 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 41099AA010 ENGINE SUPPORT Used for supporting engine. BRACKET B3M1975 41099AA020 ENGINE SUPPORT Used for supporting engine. B3M1976 398527700 PULLER ASSY Used for removing extension case oil seal and clutch housing oil seal. B3M1977 398643600 GAUGE...
Page 215 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398177700 INSTALLER Used for assembling main shaft. B3M1905 398663600 PLIERS • Used for removing and installing neutral set spring. • Used with claw (18756AA000). B3M2123 499247300 INSTALLER • Used for removing axle shaft. •...
Page 216 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499247400 INSTALLER Used for installing transfer drive gear ball bear- ing. B3M1999 499797000 OIL SEAL Used for installing differential side retainer oil INSTALLER seal. B3M2197 498077610 REMOVER Used for removing speedometer drive gear. B3M2015 398497701 SEAT...
Page 217 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398437700 INSTALLER Used for installing front differential side bearing. TR0939 498745600 INSTALLER Used for installing oil pump drive gear. B4M2498 18632AA000 STAND ASSY Used for disassembling and assembling trans- (Newly adopted tool) mission.
Page 218 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18657AA010 INSTALLER • Used for installing oil seal to reverse check. (Newly adopted tool) • Used with OIL SEAL GUIDE (18671AA000). TR0610 18657AA000 INSTALLER Used for installing oil seal to shift rod. (Newly adopted tool) TR0610 18758AA000...
Page 219 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18631AA000 HANDLE Used for measuring front differential backlash. (Newly adopted tool) TR0613 18756AA000 CLAW • Used for installing and removing neutral set (Newly adopted tool) spring. • Used with INSTALLER (399893600). TR0614 18754AA000 REMOVER...
Page 220 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18665AA000 HOLDER • Used for installing and removing main shaft (Newly adopted tool) lock nut. • Used with BASE (18664AA000). TR0940 18666AA000 HOLDER • Used for installing and removing driven shaft (Newly adopted tool) lock nut.
Page 221 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18722AA000 REMOVER Used for disassembling main shaft. (Newly adopted tool) TR0621 18651AA000 INSTALLER Used for assembling main shaft. (Newly adopted tool) TR0622 18852AA000 TORQUE WRENCH • Used for tightening main shaft lock nut. (Newly adopted tool) •...
Page 222 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18669AA000 PUNCH Used for caulking driven shaft lock nut. (Newly adopted tool) TR0624 18670AA000 PUNCH Used for caulking drive pinion shaft lock nut. (Newly adopted tool) TR0624 18620AA000 ADAPTER Used for installing and removing driven gear (Newly adopted tool) WRENCH...
Page 223 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18723AA000 REMOVER Used for disassembling the driven shaft. (Newly adopted tool) TR0626 18630AA000 WRENCH ASSY Used for removing and installing differential side (Newly adopted tool) retainer (left side). TR0627 18672AA000 GUIDE CLIP Used for installing reverse idler gear snap ring.
Page 224 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18654AA000 INSTALLER Used for assembling driven shaft. (Newly adopted tool) TR0630 18663AA000 SOCKET Used for installing and removing oil pump cover. (Newly adopted tool) TR0631 18853AA000 HEIGHT GAUGE Used for selecting shift rod. (Newly adopted tool) TR0632 18760AA000...
Page 225 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 2. GENERAL PURPOSE TOOLS TOOL NAME REMARKS Circuit Tester Used for measuring resistance, voltage and ampere. 6MT-31...
Page 226 TRANSMISSION GEAR OIL MANUAL TRANSMISSION AND DIFFERENTIAL 2. Transmission Gear Oil B: REPLACEMENT 1) Pull out the oil level gauge. A: INSPECTION 2) Lift-up the vehicle. 1) Park the vehicle on a level surface. 3) Remove the transmission under cover. 2) Turn the ignition switch to OFF, and wait until the 4) Drain the transmission gear oil completely.
Page 227: Oil Seal
OIL SEAL MANUAL TRANSMISSION AND DIFFERENTIAL 3. Oil Seal 6) Using the ST, install the oil seal. ST 498057300 INSTALLER A: INSPECTION Inspect for oil leakage from the oil seal. Replace the oil seal if the lips is deformed, hardened, dam- aged, worn or defective if any.
Page 228: Vehicle Speed Sensor
VEHICLE SPEED SENSOR MANUAL TRANSMISSION AND DIFFERENTIAL 4. Vehicle Speed Sensor C: INSPECTION Inspect that the speedometer is normally operated, A: REMOVAL because vehicle speed sensor cannot be inspected 1) Disconnect the ground cable from battery. as single part. If it is not normally operated, inspect 2) Remove the intercooler.
Page 229 TRANSMISSION MOUNTING SYSTEM MANUAL TRANSMISSION AND DIFFERENTIAL 5. Transmission Mounting Sys- B: INSTALLATION 1. PITCHING STOPPER A: REMOVAL 1) Install the pitching stopper. Tightening torque: 1. PITCHING STOPPER T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb) 1) Disconnect the ground cable from battery. T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb) 2) Remove the intercooler.
Page 230 TRANSMISSION MOUNTING SYSTEM MANUAL TRANSMISSION AND DIFFERENTIAL C: INSPECTION Repair or replace parts if the results of the inspec- tion below are not satisfactory. 1. PITCHING STOPPER Make sure that the pitching stopper is not bent or damaged. Make sure that the rubber is not stiff, cracked, or otherwise damaged.
Page 231: Manual Transmission Assembly
MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 6. Manual Transmission As- 9) Remove the starter assembly. <Ref. to SC-5, REMOVAL, Starter.> sembly 10) Remove the clutch operating cylinder. A: REMOVAL NOTE: 1) Set the vehicle on a lift, then open the front hood Hang the removed operating cylinder with wire.
Page 232 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 16) Remove the front stabilizer bolt. 20) Set the transmission jack under the transmis- sion, then remove the front crossmember and rear crossmember. TR0090 17) Remove the ball joint of transverse link from TR0643 housing.
Page 233 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 22) Remove the fixing bolt of engine and transmis- 3) Move the transmission to the right side, then in- sion, then remove the transmission from vehicle. stall the joint COMPL bolt, stay bolt and reverse check cable.
Page 234 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 6) Make sure the release bearing is installed com- 9) Install the starter assembly. pletely. Tightening torque: NOTE: 50 N·m (5.1 kgf-m, 36.9 ft-lb) • Push the release fork to operating cylinder side 10) Install the transmission and body ground cable.
Page 235 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 13) Using the ST, install the spring pin of front drive 17) Install the center exhaust pipe. <Ref. to shaft. EX(TURBO)-9, INSTALLATION, Center Exhaust ST 398791700 REMOVER Pipe.> 18) Install the rear exhaust pipe and muffler. <Ref. NOTE: to EX(TURBO)-13, INSTALLATION, Rear Exhaust Align each chamfered part of front drive shaft and...
Page 236 PREPARATION FOR OVERHAUL MANUAL TRANSMISSION AND DIFFERENTIAL 7. Preparation for Overhaul A: PROCEDURE 1) Clean oil, grease, dirt and dust from transmis- sion. 2) Remove the drain plug to drain oil. After drain- ing, retighten it as before. NOTE: Replace the gasket with a new one. Tightening torque: Oil pan side 44 N·m (4.5 kgf-m, 32.5 ft-lb)
Page 237: Air Breather Hose
AIR BREATHER HOSE MANUAL TRANSMISSION AND DIFFERENTIAL 8. Air Breather Hose A: REMOVAL Disconnect the air breather hose. TR0650 B: INSTALLATION Install the air breather hose. TR0650 C: INSPECTION Make sure the hose is not cracked or clogged. 6MT-43...
Page 238: Oil Pipe
OIL PIPE MANUAL TRANSMISSION AND DIFFERENTIAL 9. Oil Pipe A: REMOVAL Remove the oil pipe. NOTE: Do not reuse the gasket. TR0651 B: INSTALLATION Install in the reverse order of removal. NOTE: Always use a new gasket. Tightening torque: 32 N·m (3.3 kgf-m, 23.6 ft-lb) TR0651 C: INSPECTION 1) Make sure there is no damage on pipe.
Page 239 BACK-UP LIGHT SWITCH MANUAL TRANSMISSION AND DIFFERENTIAL 10.Back-up Light Switch B: INSTALLATION 1) Install the back-up light switch. A: REMOVAL Tightening torque: 1) Remove the manual transmission assembly 32 N·m (3.3 kgf-m, 23.6 ft-lb) from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Transmission Assembly.>...
Page 240 BACK-UP LIGHT SWITCH MANUAL TRANSMISSION AND DIFFERENTIAL C: INSPECTION 1) Disconnect the ground cable from battery. 2) Remove the intercooler. <Ref. to IN(TURBO)- 10, REMOVAL, Intercooler.> 3) Disconnect the transmission harness and chas- sis harness. TR0654 (A) Transmission connector 4) Measure the resistance between back-up light switch terminals.
Page 241 NEUTRAL POSITION SWITCH MANUAL TRANSMISSION AND DIFFERENTIAL 11.Neutral Position Switch B: INSTALLATION 1) Install the neutral position switch. A: REMOVAL Tightening torque: 1) Remove the manual transmission assembly 32 N·m (3.3 kgf-m, 23.6 ft-lb) from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Transmission Assembly.>...
Page 242 NEUTRAL POSITION SWITCH MANUAL TRANSMISSION AND DIFFERENTIAL C: INSPECTION 1) Disconnect the ground cable from battery. 2) Remove the intercooler. <Ref. to IN(TURBO)- 10, REMOVAL, Intercooler.> 3) Disconnect the transmission harness and chas- sis harness. TR0654 (A) Transmission connector 4) Measure the resistance between neutral posi- tion switch terminals.
Page 243: Extension Case
EXTENSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 12.Extension Case 5) Install the extension case. Tightening torque: A: REMOVAL 48 N·m (4.9 kgf-m, 35.4 ft-lb) 1) Remove the manual transmission assembly from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-42, Preparation for Overhaul.>...
Page 244 EXTENSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 4) Using the ST, remove the bearing cone. D: ASSEMBLY ST 18758AA000 PULLER 1) Install the reverse checking system. <Ref. to 6MT-56, INSTALLATION, Reverse Checking Sys- tem.> 2) Install the extension case oil seal. <Ref. to 6MT- 33, REPLACEMENT, Oil Seal.>...
Page 245 EXTENSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 8) Install the extension guide, and then install the 3) Measure the depth “Z” between end of extension transfer driven gear. <Ref. to 6MT-58, INSTALLA- case and contact point of bearing cone. TION, Transfer Drive Gear.> ST 398643600 GAUGE E: INSPECTION...
Page 246 EXTENSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 7) Using the ST, remove the neutral set spring and 11) Set the ST. support. ST 18831AA000 GAUGE ST1 18756AA000 CLAW ST2 398663600 PLIERS TR0669 12) Rotate the transfer driven gear approx. ten TR0666 times to get the bearing accustomed.
Page 247 EXTENSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 15) Select the nearest thrust washer from the fol- 19) Using the ST, install the neutral set spring and lowing table, according to the calculated value “t”. support. ST1 18756AA000 CLAW Standard clearance between thrust washer and ST2 398663600 PLIERS taper roller bearing:...
Page 248 EXTENSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 2. SELECTING THE TRANSFER DRIVE 4) Select the nearest thrust washer from the follow- ing table, according to the calculated value “t”. GEAR THRUST WASHER Standard clearance between thrust washer and 1) Measure the height “Z” between end of transmis- transfer drive gear: sion case and end of ST.
Page 249 REVERSE CHECKING SYSTEM MANUAL TRANSMISSION AND DIFFERENTIAL 13.Reverse Checking System 6) Remove the spring pin, then remove the reverse check lever and oil seal from reverse check shaft. A: REMOVAL NOTE: 1) Remove the manual transmission assembly Do not reuse the oil seal. from vehicle.
Page 250 REVERSE CHECKING SYSTEM MANUAL TRANSMISSION AND DIFFERENTIAL B: INSTALLATION 3) Install the spring and reverse check shaft to ex- tension case. 1) Insert the reverse lock plunger. 2) Install in the order of reverse check plug, spring, NOTE: gasket and plug. Be sure the spring end aligns with the hole of re- verse check shaft and cutout portion of extension Tightening torque:...
Page 251 REVERSE CHECKING SYSTEM MANUAL TRANSMISSION AND DIFFERENTIAL 5) Set the ST1 to reverse check shaft. Install a new 9) Install the extension case. <Ref. to 6MT-49, IN- oil seal, then press with ST2. STALLATION, Extension Case.> ST1 18671AA000 OIL SEAL GUIDE 10) Install the manual transmission assembly to ve- hicle.
Page 252: Transfer Drive Gear
TRANSFER DRIVE GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 14.Transfer Drive Gear C: DISASSEMBLY 1) Remove the snap ring. A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-42, Preparation for Overhaul.>...
Page 253 TRANSFER DRIVE GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 2) Install the snap ring. TR0687 3) Inspect the clearance between snap ring and ball bearing. <Ref. to 6MT-59, INSPECTION, Transfer Drive Gear.> E: INSPECTION 1) Bearings Replace the bearings in the following cases: •...
Page 254: Transfer Driven Gear
TRANSFER DRIVEN GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 15.Transfer Driven Gear C: DISASSEMBLY 1) Using the ST, remove the roller bearing of exten- A: REMOVAL sion case side. 1) Remove the manual transmission assembly ST 498515700 REMOVER from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Transmission Assembly.>...
Page 255 TRANSFER DRIVEN GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 2) Using the ST, install the roller bearing of trans- mission case side. ST 499757002 INSTALLER CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). B3M2139A (A) Roller bearing E: INSPECTION...
Page 256: Center Differential
CENTER DIFFERENTIAL MANUAL TRANSMISSION AND DIFFERENTIAL 16.Center Differential 2) Install the thrust washer and center differential. A: REMOVAL 1) Remove the manual transmission case assem- bly from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-42, Preparation for Overhaul.>...
Page 257 CENTER DIFFERENTIAL MANUAL TRANSMISSION AND DIFFERENTIAL 2) Using the ST, remove the oil pump drive gear. ST 498077610 REMOVER TR0697 D: ASSEMBLY 1) Using the ST, install the oil pump drive gear. ST 498745600 INSTALLER CAUTION: Do not apply pressure in excess of 20 kN (2.0 ton, 2.2 US ton, 2.0 lmp ton).
Page 258: Oil Pump
OIL PUMP MANUAL TRANSMISSION AND DIFFERENTIAL 17.Oil Pump 8) Using the ST, remove the neutral set spring and support. A: REMOVAL ST1 18756AA000 CLAW 1) Remove the manual transmission assembly ST2 398663600 PLIERS from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Transmission Assembly.>...
Page 259 OIL PUMP MANUAL TRANSMISSION AND DIFFERENTIAL 11) Remove the oil pump shaft assembly and plate. B: INSTALLATION 1) Apply oil to the outer periphery of outer rotor, NOTE: then install to transmission case. Remove the bolts using ST, because tool may break if general tool is used.
Page 260 OIL PUMP MANUAL TRANSMISSION AND DIFFERENTIAL 5) If replacing the oil pump cover assembly, select 11) Install the oil guide. the transfer driven gear and thrust washer, then in- stall them to the extension case. <Ref. to 6MT-51, ADJUSTMENT, Extension Case.> 6) Install the selector arm No.2 and shifter arm.
Page 261 OIL PUMP MANUAL TRANSMISSION AND DIFFERENTIAL 3) Side clearance Measure to the transmission case and rotor. Re- place the inner rotor and outer rotor as a set if clear- ance exceeds specification. Specification of clearance at tip: 0.03 — 0.10 mm (0.0012 — 0.0039 in) TR0704 6MT-67...
Page 262 TRANSMISSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 18.Transmission Case 10) Remove the pilot bolt. A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-42, Preparation for Overhaul.> 3) Remove the oil pipe, neutral position switch, back-up light switch and harness.
Page 263 TRANSMISSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL B: INSTALLATION 4) Make sure the interlock block and reverse inter- lock block are aligned in neutral position by inspect- 1) Make sure that each shifter fork and interlock ing through the pilot bolt installation hole. If not block is shifted to neutral position.
Page 264 TRANSMISSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 9) Install the snap ring, washer and collar of driven C: DISASSEMBLY gear assembly. 1) Remove the oil pipe and oil guide. TR0714 (A) Oil pipe (B) Oil guide 2) Remove the bolt, then remove the O-ring, relief spring and relief valve.
Page 265 TRANSMISSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 4) Remove the harness bracket. D: ASSEMBLY 1) Install the oil strainer and magnet. Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb) TR0717 5) Remove the oil pan. TR0719 (A) Oil pan magnet (B) Oil strainer 2) Apply liquid gasket to the oil pan.
Page 266 TRANSMISSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 5) Install the ball, valve spring and new O-ring. Tightening torque: T1: 13 N·m (1.3 kgf-m, 9.6 ft-lb) T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb) TR0721 (A) O-ring (B) Relief valve spring (C) Relief valve (D) Valve spring (E) Ball (F) Harness bracket...
Page 267 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 19.Main Shaft Assembly 12) Remove all checking plug, gasket, checking spring, plunger and checking ball from adapter A: REMOVAL plate. 1) Remove the manual transmission assembly NOTE: from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Do not reuse the gasket.
Page 268 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL B: INSTALLATION 4) Install the main shaft assembly to 3rd-4th shifter fork, and then assemble to driven gear assembly. 1) Adjust the 3rd-4th, and 5th-6th shifter fork rod. <Ref. to 6MT-123, ADJUSTMENT, Shifter Fork (A ) ( B ) and Rod.>...
Page 269 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 6) Install the reverse shifter fork assembly to re- 10) Install the plunger, checking spring, new gasket verse idler gear assembly. and checking plug. Tightening torque: 37 N·m (3.8 kgf-m, 27.3 ft-lb) TR0933 (A) Reverse idler gear assembly (B) Reverse shifter fork (C) Reverse sleeve...
Page 270 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 11) Install the checking ball, checking spring, new 14) Install the reverse idler holder gasket and checking plug. Tightening torque: 37 N·m (3.8 kgf-m, 27.3 ft-lb) TR0723 (A) Reverse idler holder 15) Install the striking rod. 16) Install the transmission case.
Page 271 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 3) Set the main shaft assembly on ST, then remove 6) Remove the 5th-6th sleeve, 6th needle bearing the lock nut and washer. and 6th baulk ring. ST1 18665AA000 HOLDER ST2 18664AA000 BASE NOTE: Use a 38 mm (1.50 in) socket wrench.
Page 272 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL D: ASSEMBLY NOTE: Install the 3rd synchro cone, by aligning protrusion NOTE: portions of the 3rd synchro cone with 3rd drive gear Replace the following parts as a set. hole portion. • Sleeve and hub •...
Page 273 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL (2) Set to the main shaft, taking care not to (3) Using the ST, press in the 3rd-4th hub and overlap the main shaft oil hole and 4th bush oil 4th bush at once. hole.
Page 274 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 6) Install the 3rd-4th shifting insert key in proper 8) Install the 4th baulk ring. place of 3rd-4th sleeve. NOTE: Angle of each shifting insert key is 120° apart. TR0740 9) Sufficiently apply gear oil to the main shaft, 4th needle bearing and inner periphery of 4th drive gear.
Page 275 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 11) Install the 5th bush. 14) Install the 5th needle bearing and 5th drive gear. (1) Set to the main shaft, taking care not to overlap the main shaft oil hole and 5th bush oil hole.
Page 276 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL (2) Using the ST, press in the 5th-6th hub. 18) Install the 5th-6th shifting insert key in proper place of 5th-6th sleeve. ST1 18651AA000 INSTALLER ST2 398177700 INSTALLER NOTE: Angle of each shifting insert key is 120° apart. CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
Page 277 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 20) Install the 6th baulk ring. 24) Set the 6th bush to main shaft, taking care not to overlap the 6th bush oil hole and main shaft oil hole. TR0748 21) Sufficiently apply gear oil to the main shaft, 6th TR0737 needle bearing and inner periphery of 6th drive gear.
Page 278 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 28) Using the ST, install the retainer and outer 31) Set the main shaft assembly to ST, then tighten bearing inner race. the lock nut. ST1 18651AA000 INSTALLER ST1 18665AA000 HOLDER ST2 398177700 INSTALLER ST2 18664AA000 BASE CAUTION:...
Page 279 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL E: INSPECTION F: ADJUSTMENT Disassembled parts should be washed clean first 1. SELECTION OF MAIN SHAFT SNAP and then inspected carefully. RING AND WASHER 1) Bearing Replace the bearings in the following cases: NOTE: •...
Page 280 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 3) Measure the height to edge surface of ball bear- 4) According to measurement value, select the ing (height A1). snap ring and washer from the following table. Snap ring Thickness: mm A1: mm (in) Part No.
Page 281 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 20.Driven Gear Assembly B: INSTALLATION 1) Adjust the main shaft snap ring. <Ref. to 6MT- A: REMOVAL 85, ADJUSTMENT, Main Shaft Assembly.> 1) Remove the manual transmission assembly 2) Adjust the 1st-2nd shifter rod. <Ref. to 6MT-123, from vehicle.
Page 282 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL C: DISASSEMBLY 5) Remove the driven gear key. NOTE: Each sleeve and hub engage at a specified point. Mark an engagement point on the sleeve and hub before disassembly. 1) Secure the ST on workbench. ST 18664AA000 BASE 2) Lift the caulking of lock nut.
Page 283 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 8) Remove the outer baulk ring, 2nd synchro cone D: ASSEMBLY and inner baulk ring. NOTE: Replace the following parts as a set: • Sleeve and hub • Outer baulk ring, 1st synchro cone, inner baulk ring •...
Page 284 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 5) Align protrusion portions of the 1st synchro cone • Make sure to install the 1st-2nd hub in proper di- to the holes of 1st drive gear to install. rection. TR0771 6) Install the outer baulk ring. TR0950 TR0772 (A) 1st-2nd hub...
Page 285 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 10) Install the shifting insert key in proper place of 11) Install the 1st-2nd sleeve to 1st-2nd hub. 1st-2nd sleeve. NOTE: NOTE: Make sure to install the 1st-2nd sleeve in proper di- Angle of each shifting insert key is 120° apart. rection.
Page 286 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 14) Install the inner baulk ring. 18) Using the ST, install the 3rd-4th driven gear. ST 18654AA000 INSTALLER CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 lmp ton). NOTE: •...
Page 287 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 21) Using the ST, install the 5th-6th driven gear. 25) Install the ST3 to lock nut, then install the ST to driven gear assembly and tighten lock nut. ST 18654AA000 INSTALLER ST1 18666AA000 HOLDER CAUTION: ST2 18664AA000 BASE Do not apply pressure in excess of 40 kN (4.0...
Page 288 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 26) Using the ST, caulk four portions on the lock E: INSPECTION nut to obtain dimension A 44 ± 0.5 mm (1.73 ± 0.02 Disassembled parts should be washed clean first in). and then inspected carefully. ST1 18669AA000 PUNCH DRIVEN SHAFT 1) Bearing Replace the bearings in the following cases:...
Page 289 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL F: ADJUSTMENT 1) Measure length “H”, which is from transmission case and oil pump cover mating surface to ball bearing edge. TR0988 (A) Transmission case (B) Ball bearing (C) Driven gear assembly 2) Using the following equation, calculate the washer thickness of driven gear assembly.
Page 290 REVERSE IDLER GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 21.Reverse Idler Gear Assembly 1) Remove the spring pin. A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-42, Preparation for Overhaul.>...
Page 291 REVERSE IDLER GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 5) Remove the collar. 9) Remove the washer and needle bearing. 6) Remove the reverse sleeve. TR0795 TR0792 (A) Needle bearing 7) Remove the outer baulk ring, reverse synchro (B) Washer cone and inner baulk ring from reverse sleeve. 10) Remove the knock pin.
Page 292 REVERSE IDLER GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 12) Remove the sub gear and spring. 2) Install the friction plate and snap ring. NOTE: Make sure to install the friction plate in proper di- rection. TR0797 (A) Sub gear (B) Spring TR0798 (C) Punch mark (mark A) (A) Friction plate...
Page 293 REVERSE IDLER GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 6) Install the reverse idler gear No.2. 8) Install the reverse sleeve to reverse idler gear No.2. NOTE: Make sure to install the reverse sleeve in proper di- rection. TR0936 7) Install the shifting insert key in proper place of reverse sleeve.
Page 294 REVERSE IDLER GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 12) Align the protrusion portion of reverse synchro 3) Gears cone with reverse idler gear hole, then install the Replace the gears in the following cases: reverse idler gear. • The gear teeth surfaces are broken or excessive- ly worn.
Page 295 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 22.Drive Pinion Shaft Assembly 3) Install each gear assembly. <Ref. to 6MT-74, IN- STALLATION, Main Shaft Assembly.> A: REMOVAL 4) Install the transmission case. <Ref. to 6MT-69, 1) Remove the manual transmission assembly INSTALLATION, Transmission Case.>...
Page 296 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 3) Secure the ST on workbench. 2) Install the inner bearing inner race to drive pinion shaft using ST and press. ST 18664AA000 BASE ST 18723AA000 REMOVER 4) Lift the caulking of lock nut. 5) Install the ST3 to lock nut, then set drive pinion CAUTION: shaft to ST.
Page 297 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 5) Set the ST to drive pinion, then tighten the lock 7) Using the ST, caulk two portions on the lock nut to obtain dimension A 37 ± 0.5 mm (1.46 ± 0.02 in). nut.
Page 298 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 9) Calculate the following equation, then select one E: INSPECTION or two pieces of drive pinion shim from the table be- 1) Using the spring balancer, measure the starting low. torque. If the starting torque is out of specification, 6.5 ±...
Page 299 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL F: ADJUSTMENT 1) Inspect and adjust the backlash between hypoid driven gear and drive pinion. <Ref. to 6MT-114, HYPOID GEAR BACKLASH, ADJUSTMENT, Front Differential Assembly.> 2) Apply a uniform thin coat of red lead on both teeth surfaces of three or four teeth of the hypoid driven gear.
Page 300 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 5) Remove the drive pinion shaft assembly, and then check tooth contact. If it is inaccurate, adjust the back- lash or thickness of shim. Checking item Contact pattern Corrective action Tooth contact Tooth contact pattern is slightly shifted toward to under no-load rotation.
Page 301: Front Differential Assembly
FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 23.Front Differential Assembly 12) Wrap vinyl tape around the spline part of axle shaft. A: REMOVAL 1) Remove the manual transmission assembly. <Ref. to 6MT-37, REMOVAL, Manual Transmis- sion Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-42, Preparation for Overhaul.>...
Page 302 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 14) Using the ST, remove the differential side re- B: INSTALLATION tainer on both side. 1) Install the differential assembly into clutch hous- ST1 499787000 WRENCH ASSY (RIGHT ing. SIDE) 2) Apply oil to the threaded portion part of side re- ST2 18630AA000 WRENCH ASSY (LEFT SIDE) tainer.
Page 303 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 8) Mark an engagement point on the right and left 14) Apply liquid gasket to the clutch housing. side retainer and clutch housing. Liquid gasket: THREE BOND 1215 TR0828 9) Remove the differential side retainer from both TR0711 side.
Page 304 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL C: DISASSEMBLY 4) Using the ST, remove the hypoid driven gear side bearing. 1. DIFFERENTIAL CASE ST 399527700 PULLER SET 1) Secure the differential assembly on a vise, then remove the hypoid driven gear. G3M0668 5) Using a screw driver, make clearance of 2—3 TR0822...
Page 305 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 2. SIDE RETAINER 4) Remove the bearing outer race from side retain- 1) Remove the O-ring from side retainer. ST1 398527700 PULLER ASSY ST2 398527705 CLAW B3M2192 2) Remove the oil seal from side retainer. TR0938 (A) Shaft (B) Side retainer...
Page 306 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL D: ASSEMBLY NOTE: Always replace the inner race and outer race as a 1. DIFFERENTIAL CASE set. 1) Install the washer to bevel gear. NOTE: Face the chamfered side of washer toward gear. 2) Install the bevel gear and bevel pinion gear washer to differential case, and then insert the pin- ion shaft.
Page 307 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL E: INSPECTION 2) Apply a uniform thin coat of red lead on both tooth surfaces of three or four teeth of the hypoid Repair or replace the front differential in following driven gear. cases: •...
Page 308 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL F: ADJUSTMENT 2. HYPOID GEAR BACKLASH 1) Install the right and left side retainer. 1. BEVEL PINION GEAR BACKLASH ST1 499787000 WRENCH ASSY (RIGHT 1) Measure the bevel pinion gear backlash. <Ref. SIDE) to 6MT-113, BEVEL PINION GEAR BACKLASH, ST2 18630AA000 WRENCH ASSY (LEFT SIDE) INSPECTION, Front Differential Assembly.>...
Page 309 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 8) Using the ST, secure the drive pinion shaft. ST 18621AA000 ADAPTER WRENCH TR0829 9) After rotating the drive pinion shaft several times, measure the hypoid gear backlash using the ST1 498255400 PLATE ST2 498247001 MAGNET BASE ST3 498247100...
Page 310: Speedometer Gear
SPEEDOMETER GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 24.Speedometer Gear 15) Remove the oil seal, speedometer shaft and washer. A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-42, Preparation for Overhaul.>...
Page 311 SPEEDOMETER GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 3) Install the speedometer driven gear and snap ring. TR0831 (A) Snap ring (B) Speedometer driven gear 4) Install the vehicle speed sensor. <Ref. to 6MT- 34, INSTALLATION, Vehicle Speed Sensor.> 5) Install the front differential assembly. <Ref. to 6MT-108, INSTALLATION, Front Differential As- sembly.>...
Page 312 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 25.Shifter Fork and Rod ST 398791700 REMOVER A: REMOVAL 1) Remove the manual transmission assembly from vehicle. <Ref. to 6MT-37, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-42, Preparation for Overhaul.>...
Page 313 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 3) Using the ST, remove the 1st-2nd shifter arm 4. SHIFT ARM SHAFT and 1st-2nd shifter fork. Using the ST, remove the selector arm. ST 398791700 REMOVER ST 398791700 REMOVER TR0839 TR0842 (A) 1st-2nd shifter arm 5.
Page 314 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 3) Using the ST, remove the interlock arm. 2) Using the ST, install the reverse arm. ST 398791700 REMOVER ST 398791700 REMOVER NOTE: Make sure to install the reverse arm and rod in proper direction.
Page 315 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 2) Using the ST, install the 1st-2nd shifter arm. 5) Using the ST, install the 3rd-4th shifter fork. ST 398791700 REMOVER ST 398791700 REMOVER NOTE: NOTE: Make sure to install the 1st-2nd shifter arm and fork Make sure to install the 3rd-4th shifter fork in proper in proper direction.
Page 316 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 2) Using the ST, install the 5th-6th shifter fork. 5. STRIKING ROD ST 398791700 REMOVER 1) Using the ST, install the reverse interlock arm NOTE: and interlock arm. Make sure to install the 5th-6th shifter fork and arm ST 398791700 REMOVER in proper direction.
Page 317 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL F: ADJUSTMENT 4) Shift the 1st-2nd sleeve to 1st driven gear side, then press down to the stopper and measure “B1”. 1. SELECTION OF 1ST 2ND FORK ROD NOTE: Perform the following procedures when: •...
Page 318 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 6) Shift the 1st-2nd sleeve to 2nd driven gear side, 7) According to both measurements, calculate the then press down to the stopper and measure “B2”. 1st-2nd sleeve neutral position. Select the fork rod which applies to the calculated value from following equation.
Page 319 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 2. SELECTION OF 3RD 4TH FORK ROD 3) Using the height gauge, measure “C1” and “C2” shown in the figure. NOTE: Perform the following procedures when: • Replacing the main shaft. • Replacing the 3rd, 3rd to 6th drive gear and bush.
Page 320 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL NOTE: NOTE: • Set the indicator of height gauge near measuring • Set the indicator of height gauge near measuring object, then lock the dial (1) as shown in the figure. object, then lock the dial (1) as shown in the figure. Turn dial (2) to set the indicator to edge surface of •...
Page 321 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL NOTE: Lot No. (Mark) • Remove the remaining gasket on edge surface M.SFT M.SFT M.SFT with scraper, since the height gauge is set on Snap ring Snap ring Snap ring T mm (in) adapter plate during measurement.
Page 322 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL (1) Shift the 5th-6th sleeve to 6th main gear (3) Shift the 5th-6th sleeve to 5th main gear side, then press down to the stopper and mea- side, then press down to the stopper and mea- sure “D2”.
Page 323 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 2) Tighten the base COMPL fixing bolt. NOTE: The indicator is installed upside down compared to Tightening torque: the setting procedure of zero point. Add d1 [fixing 25 N·m (2.5 kgf-m, 18.1 ft-lb) value: 55 mm (2.17 in)] from the following figure to “D1”, to obtain measurement value of “D1”.
Page 324 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 4) Press the reverse sleeve to reverse side idler 5) According to measurement, calculate the re- gear No.2, then measure “T”. verse sleeve neutral position. Select the fork rod which applies to the calculated value from following equation.
Page 325 CLUTCH HOUSING MANUAL TRANSMISSION AND DIFFERENTIAL 26.Clutch Housing 9) Install the center differential. <Ref. to 6MT-62, INSTALLATION, Center Differential.> A: REMOVAL 10) Install the transfer driven gear. <Ref. to 6MT- 1) Remove the manual transmission assembly 60, INSTALLATION, Transfer Driven Gear.> from vehicle.
Page 326 CLUTCH HOUSING MANUAL TRANSMISSION AND DIFFERENTIAL D: ASSEMBLY 1) Install the oil seal into clutch housing without damaging. ST 399513600 INSTALLER TR0874 2) Install the clutch release bearing guide. Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) TR0872 E: INSPECTION 1) Make sure there is no damage or crack on the clutch housing.
Page 327: General Diagnostic Table
GENERAL DIAGNOSTIC TABLE MANUAL TRANSMISSION AND DIFFERENTIAL 27.General Diagnostic Table A: INSPECTION 1. MANUAL TRANSMISSION Symptom Possible cause Remedy 1. Gears are difficult to intermesh. (a) Worn, damaged or burred chamfer of Replace. internal spline of sleeve and reverse NOTE: The cause for difficulty in shifting gears driven gear can be classified into two kinds: one is...
Page 328 GENERAL DIAGNOSTIC TABLE MANUAL TRANSMISSION AND DIFFERENTIAL 2. DIFFERENTIAL Symptom Possible cause Remedy 1. Broken differential (case, gear, bear- (a) Insufficient or improper oil Disassemble differential and replace bro- ing, etc.) ken components and at the same time NOTE: check other components for any trouble, Abnormal noise will develop and finally it and replace if necessary.
Page 329 CLUTCH SYSTEM Page General Description ..................2 Clutch Disc and Cover Flywheel Release Bearing and Lever Operating Cylinder ..................5 Master Cylinder Clutch Pipe and Hose Clutch Fluid Clutch Fluid Air Bleeding Clutch Pedal Clutch Cable Clutch Switch General Diagnostic Table...
Page 330 GENERAL DESCRIPTION CLUTCH SYSTEM 1. General Description A: SPECIFICATIONS Model 1.6 L 2.0 L NON-TURBO 2.0 L TURBO 2.5 L Type Push type Pull type Push type Clutch cover Diaphragm set load kgf (lb) 450 (992) 830 (1,830) 550 (1,213) Facing material Woven (Non asbestos) 230 x 150 x 3.5...
Page 331 GENERAL DESCRIPTION CLUTCH SYSTEM B: COMPONENT 6. CLUTCH PIPE AND HOSE FOR TURBO MODEL • LHD MODEL (10) (11) TR0979 Operating cylinder (Except STi Pipe Tightening torque: N·m (kgf-m, ft-lb) model) Master cylinder ASSY T1: 8 (0.8, 5.8) Washer Clevis pin T2: 15 (1.5, 10.8) Clutch hose Snap pin...
Page 332 GENERAL DESCRIPTION CLUTCH SYSTEM • RHD MODEL (10) (11) (11) (13) (12) (10) (12) (10) (11) TR0980 Operating cylinder (Except STi Clevis pin Tightening torque: N·m (kgf-m, ft-lb) model) Snap pin T1: 7.5 (0.76, 5.53) Washer Pedal T2: 8 (0.8, 5.8) Clutch hose (10) Clamp...
Page 333: Operating Cylinder
OPERATING CYLINDER CLUTCH SYSTEM 5. Operating Cylinder • STi model A: REMOVAL 1) Remove the air cleaner case and air intake duct (Non-turbo model). <Ref. to IN-6, REMOVAL, Air Cleaner Case.> and <Ref. to IN-7, REMOVAL, Air Intake Duct.> 2) Remove the intercooler (Turbo model). <Ref. to IN(TURBO)-10, REMOVAL, Intercooler.>...
Page 334 OPERATING CYLINDER CLUTCH SYSTEM • STi model • STi model Tightening torque: T1: 18 N·m (1.8 kgf-m, 13.0 ft-lb) T2: 41 N·m (4.2 kgf-m, 30.2 ft-lb) TR0982 (A) Operating cylinder B: INSTALLATION TR0983 1) Install in the reverse order of removal. NOTE: NOTE: •...
Page 335 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
Page 337: Front Suspension
FRONT SUSPENSION Page General Description Wheel Alignment Front Transverse Link Front Ball Joint Front Strut ....................2 Front Stabilizer Front Crossmember Sub Frame General Diagnostic Table...
Page 338 FRONT STRUT FRONT SUSPENSION 5. Front Strut F: DISPOSAL 2. STI MODEL CAUTION: • Before handling gas filled struts, be sure to wear goggles to protect eyes from gas, oil and/ or filings. • Do not disassemble the strut damper or place into a fire.
Page 339: Rear Suspension
REAR SUSPENSION Page General Description Wheel Alignment Rear Stabilizer Rear Trailing Link Rear Strut....................2 Lateral link Rear Crossmember General Diagnostic Table...
Page 340 REAR STRUT REAR SUSPENSION 5. Rear Strut F: DISPOSAL 2. STI MODEL Refer to Front Strut as a guide for disposal proce- dures. <Ref. to FS-2, STI MODEL, DISPOSAL, Front Strut.> RS-2...
Page 341: Wheel And Tire System
WHEEL AND TIRE SYSTEM Page General Description ..................2 Tire Steel Wheel Aluminum Wheel Wheel Balancing “T-type” Tire Full Wheel Cap General Diagnostics Table...
Page 342 GENERAL DESCRIPTION WHEEL AND TIRE SYSTEM 1. General Description A: SPECIFICATIONS S4M0367A (1) Offset (2) P.C.D. Tire size Rim size Rim offset mm (in) P.C.D. mm (in) 14 × 5 1/2JJ 185/70R14 88H 15 × 6JJ 195/60R15 88H Except 16 × 6 1/2JJ OUTBACK 205/50 R16 87V 55 (2.17)
Page 343 DIFFERENTIALS Page General Description ..................2 Differential Gear Oil...................20 Front Differential Rear Differential for T-type................21 Rear Differential for VA-type Rear Differential Front Oil Seal Rear Differential Side Oil Seal Rear Differential Member General Diagnostic Table...
Page 344 GENERAL DESCRIPTION DIFFERENTIALS 1. General Description A: SPECIFICATIONS When replacing a rear differential assembly, select the correct one according to the following table. NOTE: Using the different rear differential assembly causes the drive line and tires to “drag” or emit abnormal noise when AWD is selected.
Page 345 GENERAL DESCRIPTION DIFFERENTIALS • Identification • Rear differential gear oil Recommended oil CAUTION: Each oil manufacturer has its base oil and addi- tives. Thus, do not mix two or more brands. DR0001 H3M1272A 1. SERVICE DATA Except STi 19 — 26 (1.9 — 2.6, 4.3 — 5.8) model T-type New bearing...
Page 346 GENERAL DESCRIPTION DIFFERENTIALS 2. ADJUSTING PARTS • VA-type Front and rear bearing preload at com- 12.7 — 32.4 New bearing panion flange bolt hole N (kgf, lb) (1.3 — 3.3, 2.9 — 7.3) Part No. Length 32288AA040 52.3 mm (2.059 in) 32288AA050 52.5 mm (2.067 in) 31454AA100...
Page 347 GENERAL DESCRIPTION DIFFERENTIALS 0.925 — 0.950 mm 803135011 (0.0364 — 0.0374 in) 0.950 — 0.975 mm 803135012 (0.0374 — 0.0384 in) 0.975 — 1.000 mm Side gear thrust washer 803135013 (0.0384 — 0.0394 in) 1.000 — 1.025 mm 803135014 (0.0394 — 0.0404 in) 1.025 —...
Page 348 GENERAL DESCRIPTION DIFFERENTIALS Part No. Thickness 383495200 3.09 mm (0.1217 in) 383505200 3.12 mm (0.1228 in) 383515200 3.15 mm (0.1240 in) 383525200 3.18 mm (0.1252 in) 383535200 3.21 mm (0.1264 in) 383545200 3.24 mm (0.1276 in) 383555200 3.27 mm (0.1287 in) 383565200 3.30 mm (0.1299 in) 383575200...
Page 349 GENERAL DESCRIPTION DIFFERENTIALS Part No. Length 383705200 2.59 mm (0.1020 in) 383715200 2.57 mm (0.1012 in) 383725200 2.55 mm (0.1004 in) 383735200 2.53 mm (0.0996 in) 383745200 2.51 mm (0.0988 in) 383755200 2.49 mm (0.0980 in) 383765200 2.47 mm (0.0972 in) Preload adjusting washer 383775200 2.45 mm (0.0965 in)
Page 350: Special Tools
GENERAL DESCRIPTION DIFFERENTIALS D: PREPARATION TOOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398477701 HANDLE Used for installing front and rear bearing cone. B3M1893 398477702 DRIFT Used press-fitting the bearing cone of differential carrier (rear). B3M1894 398217700 ATTACHMENT SET Stand for rear differential carrier disassembly and assembly.
Page 351 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498427200 FLANGE WRENCH Used for stopping rotation of companion flange when loosening and tightening self-lock nut. B3M1897 398467700 DRIFT Used for removing pinion, pilot bearing and front bearing cone. B3M1898 399780104 WEIGHT Used for installing front bearing cone, pilot bear- ing companion flange.
Page 352 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock REMOVER pin. B3M1901 498247001 MAGNET BASE • Used for measuring backlash between side gear and pinion, and hypoid gear. • Used with DIAL GAUGE (498247100). B3M1902 498247100 DIAL GAUGE...
Page 353 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398177700 INSTALLER • Used for installing rear bearing cone. • For T-type. B3M1905 398457700 ATTACHMENT • Used for removing side bearing retainer. • For T-type. B3M1906 398477703 DRIFT2 • Used for press-fitting the bearing race (rear) of differential carrier.
Page 354 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507702 DUMMY SHAFT • Used for adjusting pinion height and preload. • For T-type. B3M1909 398507703 DUMMY COLLAR • Used for adjusting pinion height and preload. • For T-type. B3M1910 398517700 REPLACER •...
Page 355 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507701 DIFFERENTIAL • Used for adjusting pinion height. CARRIER GAUGE • For T-type. B3M1913 398527700 PULLEY ASSY • Used for removing front oil seal. • Used for removing side bearing cup. (T-type) B3M1914 398527700 PULLER SET...
Page 356 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 28099PA090 OIL SEAL PROTEC- • Used for installing rear drive shaft into rear dif- ferential. • For protecting oil seal. B3M1917 398237700 GAUGE • Used for installing side bearing. • For T-type. B3M1918 28099PA100 DRIVE SHAFT...
Page 357 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499785500 WRENCH ASSY • Used for removing and installing side oil seal holder. • For VA-type. B3M1921 498447100 DRIFT • Used for installing oil seal. • For VA-type. B3M1922 399520105 SEAT • Used for removing side bearing cone. •...
Page 358 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498485400 DRIFT • Used for installing side bearing cone. • For VA-type. B3M1924 498505501 DIFFERENTIAL • Used for adjusting pinion height. CARRIER GAUGE • For VA-type. B3M1925 498447110 DRIFT • Used for press-fitting the bearing race (front) of differential carrier.
Page 359 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498515500 REPLACER • Used for removing rear bearing cone. • For VA-type. B3M1911 32285AA000 DUMMY COLLAR • Used for adjusting pinion height and preload. • For VA-type. B3M1977 499705404 SEAT • Used for removing side bearing race. •...
Page 360 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899874100 INSTALLER • Used for installing companion flange. B3M1931 899524100 PULLER SET • Used for removing side bearing cone of differ- ential. • For VA-type. (1) Puller (2) Cap B3M1932A 18759AA000 PULLER ASSY •...
Page 361 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18674AA000 INSTALLER • Used for installing rear bearing cone. (Newly adopted tool) • For T-type. (STi model) B3M1905 398417700 DRIFT • Used for installing side bearing race. (This special tool was prepared for the vehicles of 92MY and before.) DR0030...
Page 362: Differential Gear Oil
DIFFERENTIAL GEAR OIL DIFFERENTIALS 2. Differential Gear Oil 4) Fill the differential carrier with gear oil to the up- per plug level. B: REPLACEMENT NOTE: 1) Jack-up the vehicle and support it with sturdy Carefully refill oil while watching the level. Excess racks.
Page 363 REAR DIFFERENTIAL FOR T-TYPE DIFFERENTIALS 4. Rear Differential for T-type 4) Remove the rear cover by loosening the retain- ing bolts. C: DISASSEMBLY 2. STI MODEL To detect the real cause of trouble, inspect the fol- lowing items before disassembling. •...
Page 364 REAR DIFFERENTIAL FOR T-TYPE DIFFERENTIALS 7) When replacing the side bearing, pull the bear- 10) Hold the companion flange with ST and remove ing cup from side bearing retainer using ST. the drive pinion nut. ST 398527700 PULLER ASSY ST 498427200 FLANGE WRENCH S3M0534A G3M1052...
Page 365 REAR DIFFERENTIAL FOR T-TYPE DIFFERENTIALS 13) Remove the rear bearing cone from drive pin- 16) When replacing the bearings, tap the front ion. bearing cup and rear bearing cup in this order out of case by using a brass bar. DR0039 S3M0515A 14) Remove the front oil seal from differential carri-...
Page 366 REAR DIFFERENTIAL FOR T-TYPE DIFFERENTIALS 2) Press-fit the rear bearing race into differential NOTE: carrier using ST. If there is no punch mark, it means 0 (zero). ST 398417700 DRIFT DR0037 DR0034 (3) Obtain the thickness of pinion height adjust 3) Press-fit the front bearing race into differential shim to be inserted from the following formula, carrier using ST.
Page 367 REAR DIFFERENTIAL FOR T-TYPE DIFFERENTIALS 5) Install the selected pinion height adjusting shim 8) Press-fit the companion flange with ST1, ST2 on drive pinion, and press-fit the rear bearing cone and ST3. into position with ST. NOTE: ST 18674AA000 INSTALLER Be careful not to damage the bearing.
Page 368 REAR DIFFERENTIAL FOR T-TYPE DIFFERENTIALS 11) If bearing preload is out of specification, adjust 14) Fit a new oil seal with ST. to specification by selecting preload adjusting NOTE: washer and spacer from the following table. • Press-fit until the end of oil seal is 1 mm (0.04 in) inward from end of carrier.
Page 369 REAR DIFFERENTIAL FOR T-TYPE DIFFERENTIALS 17) Install the crown gear on differential case. 20) Adjusting side bearing retainer shims (1) The driven gear backlash and side bearing NOTE: preload can be determined by the side bearing Before installing the bolts, apply Lock Tite to bolt retainer shim thickness.
Page 370 REAR DIFFERENTIAL FOR T-TYPE DIFFERENTIALS (5) Tighten the side bearing retainer bolts. 21) Re-check the crown gear-to-pinion backlash. Tightening torque: Backlash: 10.3 N·m (1.05 kgf-m, 7.6 ft-lb) 0.10 — 0.20 mm (0.0039 — 0.0079 in) S3M0173 G3M1047 (6) Measure the crown gear-to-drive pinion 22) Check the crown gear runout on its back sur- backlash.
Page 371 REAR DIFFERENTIAL FOR T-TYPE DIFFERENTIALS TOOTH CONTACT PATTERN Condition Contact pattern Adjustment Correct tooth contact Tooth contact pattern slightly shifted towards toe under no load rotation. (When loaded, contact pattern moves — toward heel.) G3M0098A Face contact This may cause noise and chipping at Increase thickness of drive pinion height Backlash is too large.
Page 372 REAR DIFFERENTIAL FOR T-TYPE DIFFERENTIALS 26) Tighten the side bearing retainer bolts. NOTE: Before tightening the two side bearing retainer bolts, apply Lock Tite to bolt threads. Lock Tite: THREE BOND 1105 or equivalent Tightening torque: 10.3 N·m (1.05 kgf-m, 7.6 ft-lb) S3M0173 27) Install the rear cover and tighten the bolts to specified torque.
Page 373: Transfer Case
TRANSFER CASE Page General Description ..................2 Transfer Case and Extension for MT Transfer Clutch and Extension for AT Oil Seal......................3 Transfer Drive Gear (MT)................4 Transfer Driven Gear (MT)................5 Reduction Drive Gear without VTD Reduction Drive Gear with VTD Reduction Driven Gear without VTD Reduction Driven Gear with VTD Center Differential ..................6 Transfer Clutch Pressure Test...
Page 374 GENERAL DESCRIPTION TRANSFER CASE 1. General Description A: NOTE For general description refer to “AUTOMATIC TRANSMISSION” (a separate publication: Pub. No. G0864ZE) and “AT”, “MT” or “6MT” section. AT model: <Ref. to AT-2, General Description.> MT model: <Ref. to MT-2, General Description.> 6MT model: <Ref.
Page 375 OIL SEAL TRANSFER CASE 4. Oil Seal A: NOTE For removal, installation and inspection work, refer to “AT”, “MT” or “6MT” section. AT model: <Ref. to AT-27, Extension Case Oil Seal.> MT model: <Ref. to MT-42, Oil Seal.> 6MT model: <Ref.
Page 376 TRANSFER DRIVE GEAR (MT) TRANSFER CASE 5. Transfer Drive Gear (MT) A: NOTE For removal, installation and inspection work, refer to “MT” or “6MT” section. MT model: <Ref. to MT-52, Transfer Drive Gear.> 6MT model: <Ref. to 6MT-58, Transfer Drive Gear.> TC-4...
Page 377 TRANSFER DRIVEN GEAR (MT) TRANSFER CASE 6. Transfer Driven Gear (MT) A: NOTE For removal, installation and inspection work, refer to “MT” or “6MT” section. MT model: <Ref. to MT-54, Transfer Driven Gear.> 6MT model: <Ref. to 6MT-60, Transfer Driven Gear.> TC-5...
Page 378 CENTER DIFFERENTIAL TRANSFER CASE 11.Center Differential A: NOTE For removal, installation and inspection work, refer to “MT” or “6MT” section. MT model: <Ref. to MT-56, Center Differential.> 6MT model: <Ref. to 6MT-62, Center Differential.> TC-6...
Page 379 EXTENSION CASE FOR 6MT TRANSFER CASE 14.Extension Case for 6MT A: NOTE For removal, installation and inspection work, refer to “6MT” section. <Ref. to 6MT-49, Extension Case.> TC-7...
Page 380 EXTENSION CASE FOR 6MT TRANSFER CASE TC-8...
Page 381: Drive Shaft System
DRIVE SHAFT SYSTEM Page General Description ..................2 Propeller Shaft Front Axle Rear Axle Front Drive Shaft ..................9 Rear Drive Shaft General Diagnostic Table...
Page 382: Propeller Shaft
GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 1. General Description A: SPECIFICATIONS 1. PROPELLER SHAFT Model Turbo Non-turbo Propeller shaft type DOJ type UJ type 579 (22.79) 584 (22.99) — Front propeller shaft Joint-to-joint length: L mm (in) 638 (25.12) 643 (25.32) 584 (22.99) Rear propeller shaft Joint-to-joint length: L mm (in)
Page 383 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 2. FRONT DRIVE SHAFT ASSEMBLY SHAFT Model Type of drive shaft assembly Shaft diameter Non-turbo 26 mm (1.02 in) Except STi EBJ87+SFJ82 Turbo 28 mm (1.10 in) BJ92+DOJ87 28 mm (1.10 in) DR0025 EBJ87+SFJ82 BJ92+DOJ87 Measuring point DS-3...
Page 384 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 3. REAR DRIVE SHAFT ASSEMBLY φ D No. of identification Size Model protrusion on shaft (mm) (mm) EBJ82/DOJ82 Sedan RH 2 (Two) Sedan Turbo EBJ82/DOJ82 Sedan LH 1 (One) BJ79/DOJ79 Sedan R160RH 2 (Two) Sedan 2.0 L NA MT BJ79/DOJ79 Sedan R160LH 1 (One) BJ79/DOJ79 Sedan R152R/L...
Page 385 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM EBJ82/DOJ82 Sedan RH BJ79/DOJ79 Sedan R152R/L BJ79/DOJ79 Wagon R160RH EBJ82/DOJ82 Sedan LH BJ79/DOJ79 Wagon R152R/L BJ79/DOJ79 Wagon R160LH BJ79/DOJ79 Sedan R160RH EBJ82/DOJ82 Wagon RH Identification protrusion BJ79/DOJ79 Sedan R160LH EBJ82/DOJ82 Wagon LH BJ87/DOJ87 R/L DS-5...
Page 386 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM B: COMPONENT 1. PROPELLER SHAFT DR0024 Propeller shaft (Turbo model) Rear differential (VA-type) Tightening torque: N·m (kgf-m, ft-lb) Propeller shaft (Non-turbo model, Rear differential (T-type) T1: 31 (3.2, 23.1) STi model) Bush T2: 52 (5.3, 38.3) DS-6...
Page 387 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 4. FRONT AXLE (STI MODEL) (10) (11) (12) (13) (14) (20) (15) (16) (17) (22) (18) (19) (21) DR0027 Baffle plate (DOJ) (10) Boot (DOJ) (19) Oil seal (OUT) Spring pin (11) Boot (BJ) (20) Hub bolt Outer race (DOJ) (12)
Page 388 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 5. REAR AXLE (STI MODEL) (10) (11) (14) (12) (13) (20) (16) (15) (17) (18) (19) (22) (21) DR0028 Circlip (10) Boot (DOJ) (19) Tone wheel (With ABS) Baffle plate (DOJ) (11) Boot (BJ) (20) Hub bolt Outer race (DOJ) (12)
Page 389: Front Drive Shaft
FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM 5. Front Drive Shaft C: DISASSEMBLY 2. STI MODEL Refer to Rear Drive Shaft as a guide for disassem- bly procedures. <Ref. to DS-40, DISASSEMBLY, Rear Drive Shaft.> D: ASSEMBLY 2. STI MODEL Refer to Rear Drive Shaft as a guide for assembly procedures.
Page 390 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM DS-10...
Page 391 Page General Description ..................2 ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)....4 ABS Sequence Control Front ABS Sensor Rear ABS Sensor Front Tone Wheel Rear Tone Wheel G Sensor Lateral G Sensor ..................5...
Page 392 GENERAL DESCRIPTION 1. General Description A: SPECIFICATIONS Item Standard or remarks Front 0.3 — 0.8 mm (0.012 — 0.031 in) ABS sensor gap Rear 0.7 — 1.2 mm (0.028 — 0.047 in) Front 1.25±0.25 kΩ ABS sensor resistance Rear 1.0±0.2 kΩ ABS sensor White Front...
Page 393 GENERAL DESCRIPTION B: COMPONENT 1. SENSOR BR0111 G sensor Front ABS sensor LH Tightening torque: N·m (kgf-m, ft-lb) Rear ABS sensor RH Front ABS sensor RH T1: 7.4 (0.75, 5.4) ABS spacer Lateral G sensor (STi model only) T2: 32 (3.3, 24) Rear ABS sensor LH ABS-3...
Page 394 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) 2. ABS Control Module and Hy- draulic Control Unit (ABSCM&H/U) C: INSPECTION 1) Check the connected and fixed condition of con- nector. 2) Check specifications of the mark with ABSCM&H/U. Mark Model AT (Rear drum brake) MT (Rear drum brake) AT (Rear disc brake)
Page 395 LATERAL G SENSOR 9. Lateral G Sensor A: REMOVAL 1) Disconnect the ground cable from battery. G6M0095 2) Remove the console cover. <Ref. to EI-40, Console Box.> 3) Disconnect the connector from lateral G sensor. 4) Remove the lateral G sensor from body. CAUTION: Do not drop or bump the lateral G sensor.
Page 396 LATERAL G SENSOR C: INSPECTION Step Check CHECK SUBARU SELECT MONITOR. Do you have a SUBARU Go to step 5. Go to step 2. SELECT MONITOR? CHECK LATERAL G SENSOR. Is the voltage 2.5±0.2 V when Go to step 3.
Page 397 Subaru Select Monitor Read Diagnostic Trouble Code (DTC) Inspection Mode Clear Memory Mode ABS Warning Light Illumination Pattern List of Diagnostics Trouble Code (DTC) .............7 Diagnostics Chart with Diagnosis Connector ..........11 Diagnostics Chart with Subaru Select Monitor..........19 General Diagnostics Table...
Page 398 ELECTRICAL COMPONENTS LOCATION ABS (DIAGNOSTICS) 4. Electrical Components Location A: LOCATION BR0153 ABS control module and hydrau- Data link connector (for Subaru (10) Lateral G sensor (only STi model) lic control unit (ABSCM&H/U) Select Monitor) (11) Stop light switch Rear drum brake: Proportioning...
Page 399 ELECTRICAL COMPONENTS LOCATION ABS (DIAGNOSTICS) (13) BR0120 B4M1226B (14) (10) BR0154 B4M0231E BR0033 BR0057 ( 7 ) ( 8 ) BR0058 ABS-3...
Page 400 CONTROL MODULE I/O SIGNAL ABS (DIAGNOSTICS) 5. Control Module I/O Signal A: ELECTRICAL SPECIFICATION BR0121 1) ABS control module and hydraulic control unit (ABSCM&H/U) connector 2) Connector switch NOTE: • The terminal numbers in ABSCM&H/C connector are as shown in the figure. •...
Page 401 CONTROL MODULE I/O SIGNAL ABS (DIAGNOSTICS) Input/Output signal Terminal No. Contents (+)—(−) Measured value and measuring conditions Front left wheel 9—10 Front right wheel 11—12 ABS sensor*2 0.12 — 1 V (Wheel speed sensor) (When it is 20 Hz.) Rear left wheel 7—8 Rear right wheel 14—15...
Page 402 AT vehicle) Motor (26) Front right ABS sensor Front left inlet solenoid valve (17) Diagnosis connector (27) Rear left ABS sensor Front left outlet solenoid valve (18) Data link connector (for Subaru (28) Rear right ABS sensor Select Monitor) ABS-6...
Page 403 LIST OF DIAGNOSTICS TROUBLE CODE (DTC) ABS (DIAGNOSTICS) 11.List of Diagnostics Trouble Code (DTC) A: LIST 1. WITHOUT SUBARU SELECT MONITOR DTC No. Contents of diagnosis Index No. Start code • DTC is shown after start code. — • Only start code is shown in normal condition.
Page 404 LIST OF DIAGNOSTICS TROUBLE CODE (DTC) ABS (DIAGNOSTICS) DTC No. Contents of diagnosis Index No. <Ref. to ABS-57, DTC 31 — ABNORMAL INLET SOLENOID Front right inlet valve VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT RH) —, Diagnostics Chart with Diagnosis Connector.> <Ref.
Page 405 Subaru Select Monitor.> <Ref. to ABS-107, DTC 22 — FRONT RIGHT ABNORMAL ABS Front right ABS sen- Front right ABS sensor SENSOR SIGNAL —, Diagnostics Chart with Subaru Select Moni- sor abnormal signal abnormal signal tor.> Open or short circuit in Open or short circuit in <Ref.
Page 406 <Ref. to ABS-28, DTC 73 — ABNORMAL LATERAL G SENSOR Abnormal lateral G Abnormal lateral G HIGH m OUTPUT —, Diagnostics Chart with Subaru Select Moni- sensor high µ output sensor high µ output tor.> Detection of lateral G Detection of lateral G <Ref.
Page 407 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS (DIAGNOSTICS) 12.Diagnostics Chart with Diagnosis Connector AA:DTC 56 — ABNORMAL G SENSOR OUTPUT VOLTAGE — DIAGNOSIS: • Faulty G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABS CONTROL MODULE AND B301 HYDRAULIC CONTROL UNIT SHIELD JOINT...
Page 408 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS (DIAGNOSTICS) WIRING DIAGRAM: RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR : STi MODEL : EXCEPT STi MODEL 4 15 B200 ABS G SENSOR JOINT CONNECTOR (STi MODEL) B261 B257 B292 LATERAL G SENSOR...
Page 409 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS (DIAGNOSTICS) Step Check CHECK SPECIFICATIONS OF ABSCM&H/U. Does the vehicle specification Go to step 3. Replace the Check the specifications mark on ABSCM& and ABSCM&H/U specifica- ABSCM&H/U. H/U. tion match? <Ref. to ABS-4, CM: AT (Rear disc brake) ABS Control Mod- CN: MT (Rear disc brake) ule and Hydraulic...
Page 410 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS (DIAGNOSTICS) Step Check CHECK GROUND SHORT OF HARNESS. Is the resistance more than 1 Go to step 9. Repair the har- Measure the resistance between ABSCM&H/U MΩ? ness between G connector and chassis ground. sensor and Connector &...
Page 411 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS (DIAGNOSTICS) AI: DTC 73 — ABNORMAL LATERAL G SENSOR OUTPUT VOLTAGE — DIAGNOSIS: • Faulty lateral G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABS CONTROL MODULE AND B301 HYDRAULIC CONTROL UNIT SHIELD JOINT...
Page 412 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS (DIAGNOSTICS) WIRING DIAGRAM: RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR : STi MODEL : EXCEPT STi MODEL 4 15 B200 ABS G SENSOR JOINT CONNECTOR (STi MODEL) B261 B257 B292 LATERAL G SENSOR...
Page 413 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS (DIAGNOSTICS) Step Check CHECK SPECIFICATIONS OF ABSCM&H/U. Does the vehicle specification Go to step 3. Replace the Check the specifications mark on ABSCM& and ABSCM&H/U specifica- ABSCM&H/U. H/U. tion match? <Ref. to ABS-4, C9: MT (STi model) ABS Control Mod- ule and Hydraulic Control Unit...
Page 414 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS (DIAGNOSTICS) Step Check CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 8. Repair the har- 1)Turn the ignition switch to ON. ness between lat- 2)Measure the voltage between ABSCM&H/U eral G sensor and connector and chassis ground.
Page 415 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) 13.Diagnostics Chart with Subaru Select Monitor AI: DTC 73 — OPEN OR SHORT CIRCUIT IN LATERAL G SENSOR CIRCUIT — DIAGNOSIS: • Faulty lateral G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate.
Page 416 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) WIRING DIAGRAM: RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR : STi MODEL : EXCEPT STi MODEL 4 15 B200 ABS G SENSOR JOINT CONNECTOR (STi MODEL) B261...
Page 417: Diagnostics Chart With Subaru Select Monitor
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 3. nector between ABSCM&H/U nector. and lateral G sensor? CHECK ABSCM&H/U. Is the same DTC as in the cur- Replace the Go to step 4.
Page 418 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) Step Check CHECK LATERAL G SENSOR. Is the voltage between 1.3 and Go to step 11. Replace the lateral Measure the voltage between lateral G sensor 1.7 V when lateral G sensor is G sensor.
Page 419 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) AJ:DTC 73 — BATTERY SHORT IN LATERAL G SENSOR CIRCUIT — DIAGNOSIS: • Faulty lateral G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABS CONTROL MODULE AND...
Page 420 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) WIRING DIAGRAM: RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR : STi MODEL : EXCEPT STi MODEL 4 15 B200 ABS G SENSOR JOINT CONNECTOR (STi MODEL) B261...
Page 421 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 3. nector between ABSCM&H/U nector. and lateral G sensor? CHECK ABSCM&H/U. Is the same DTC as in current Replace the Go to step 4.
Page 422 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) Step Check CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 13. Repair the har- 1)Turn the ignition switch to ON. ness between lat- 2)Measure the voltage between ABSCM&H/U eral G sensor and connector and chassis ground.
Page 423 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) Step Check CHECK LATERAL G SENSOR. Is the voltage between 1.3 and Go to step 21. Replace the lateral Measure the voltage between lateral G sensor 1.7 V when lateral G sensor is G sensor.
Page 424 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) AK:DTC 73 — ABNORMAL LATERAL G SENSOR HIGH µ µ µ µ OUTPUT — DIAGNOSIS: • Faulty lateral G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL...
Page 425 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) WIRING DIAGRAM: RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR : STi MODEL : EXCEPT STi MODEL 4 15 B200 ABS G SENSOR JOINT CONNECTOR (STi MODEL) B261...
Page 426 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 3. Turn the ignition switch to OFF. nector between ABSCM&H/U nector. and lateral G sensor? CHECK ABSCM&H/U.
Page 427 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) Step Check CHECK ABSCM&H/U. Is the same DTC as in current Replace the Go to step 11. 1)Turn the ignition switch to OFF. diagnosis still being output? ABSCM&H/U. 2)Connect all connectors. <Ref. to ABS-4, 3)Erase the memory.
Page 428 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) AL:DTC 73 — DETECTION OF LATERAL G SENSOR STICK — DIAGNOSIS: • Faulty lateral G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABS CONTROL MODULE AND...
Page 429 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) WIRING DIAGRAM: RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR : STi MODEL : EXCEPT STi MODEL 4 15 B200 ABS G SENSOR JOINT CONNECTOR (STi MODEL) B261...
Page 430 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) Step Check CHECK OUTPUT OF LATERAL G SENSOR Is the lateral G sensor output Go to step 3. Go to step 8. USING SELECT MONITOR. on monitor display between 2.3 1)Select “Current data display & Save” on the and 2.7 V when the vehicle is...
Page 431 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) Step Check CHECK LATERAL G SENSOR. Is the voltage between 1.3 and Go to step 12. Replace the lateral Measure the voltage between lateral G sensor 1.7 V when lateral G sensor is G sensor.
Page 432 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) ABS-36...
Page 433 BRAKE Page General Description ..................2 Front Brake Pad ..................7 Front Disc Rotor ..................9 Front Disc Brake Assembly...............10 Rear Brake Pad..................12 Rear Disc Rotor..................13 Rear Disc Brake Assembly ...............14 Rear Drum Brake Shoe Rear Drum Brake Drum Rear Drum Brake Assembly Master Cylinder Brake Booster Proportioning Valve...
Page 434 GENERAL DESCRIPTION BRAKE 1. General Description A: SPECIFICATIONS Model GX, RS, OBK Size 14 inch type 15 inch type 16 inch type 17 inch type Type Disc (Floating type, ventilated) Disc (Fixed type, ventilated) Effective disc 210 mm (8.27 in) 228 mm (8.98 in) 255 mm (10.04 in) 268 mm (10.55 in)
Page 435 GENERAL DESCRIPTION BRAKE Model GX, RS, OBK 1,961 kPa Propor- Split point — — tioning (20 kg/cm , 285 psi) valve Reducing ratio — — Brake line Dual circuit system Brake fluid CAUTION: • Avoid mixing brake fluid of different brands to pre- vent the fluid performance from degrading.
Page 436 GENERAL DESCRIPTION BRAKE Fluid pressure Brake pedal force GX, RS, OBK Without ABS With ABS 686 kPa 686 kPa 588 kPa 147 N (7 kg/cm (7 kg/cm (15 kgf, 33 lb) (6 kg/cm , 85 psi) 100 psi) 100 psi) Brake fluid pressure without engine running 1,961 kPa...
Page 437 GENERAL DESCRIPTION BRAKE B: COMPONENT 15.17 INCH TYPE (10) (11) (13) (10) (12) (11) (14) (15) BR0151 Housing Piston boot (15) Disc cover Caliper body Piston Air bleeder screw (10) Piston seal Tightening torque: N·m (kgf-m, ft-lb) Guide plate (11) Pad shim T1: 18 (1.8, 13.3) Cross spring...
Page 438 GENERAL DESCRIPTION BRAKE 16.REAR DISC BRAKE (17 INCH TYPE) (10) (12) (11) (10) (15) (13) (14) (16) (17) (18) (19) (30) (21) (22) (23) (24) (25) (20) (26) (27) (29) (28) BR0152 Caliper body (13) Shoe hold-down pin (25) Primary shoe return spring Air bleeder screw (14) Cover...
Page 439: Front Brake Pad
FRONT BRAKE PAD BRAKE 2. Front Brake Pad 7) Remove the pad. A: REMOVAL 3. 17 INCH TYPE 1) Set the vehicle on a lift. 2) Loosen the wheel nuts. 3) Jack-up the vehicle, and then remove the front wheel. 4) Remove the clip.
Page 440 FRONT BRAKE PAD BRAKE C: INSPECTION 3. 17 INCH TYPE Check the pad thickness A. BR0147 Pad thickness Standard value 14.2 mm (0.559 in) (including back Wear limit 6.2 mm (0.244 in) metal) CAUTION: • Always replace the pads for both right and left wheels at the same time.
Page 441: Front Disc Rotor
FRONT DISC ROTOR BRAKE 3. Front Disc Rotor Standard Service Disc outer value limit dia. C: INSPECTION 24 mm 22 mm 260 mm 1) Secure the disc rotor by tightening five wheel 14″ (0.94 in) (0.87 in) (10.24 in) nuts. 24 mm 22 mm 277 mm...
Page 442: Front Disc Brake Assembly
FRONT DISC BRAKE ASSEMBLY BRAKE 4. Front Disc Brake Assembly 2) Apply a thin coat of Molykote AS880N (Part No. 26298AC000) to each pad side. A: REMOVAL 3. 17 INCH TYPE 1) Set the vehicle on a lift. 2) Loosen the wheel nuts. 3) Jack-up the vehicle, and then remove the front wheel.
Page 443 FRONT DISC BRAKE ASSEMBLY BRAKE 3) Gradually supply compressed air via inlet of the D: ASSEMBLY brake hose to force piston out. 3. 17 INCH TYPE CAUTION: 1) Clean the caliper body interior using brake fluid. Place a wooden block as shown in the figure to 2) Apply a coat of brake fluid to the piston seal and prevent damage to piston.
Page 444: Rear Brake Pad
REAR BRAKE PAD BRAKE 5. Rear Brake Pad B: INSTALLATION A: REMOVAL 3. 17 INCH TYPE 1) Apply a thin coat of Molykote AS880N (Part No. 3. 17 INCH TYPE 26298AC000) to frictional portion between pad and 1) Set the vehicle on a lift. pad inner shim.
Page 445: Rear Disc Rotor
REAR DISC ROTOR BRAKE 6. Rear Disc Rotor Standard Service Disc outer value limit dia. C: INSPECTION 10 mm 8.5 mm 266 mm 1) Secure the disc rotor by tightening five wheel 14″ (0.39 in) (0.335 in) (10.47 in) nuts. Disc rotor 18 mm 16 mm...
Page 446: Rear Disc Brake Assembly
REAR DISC BRAKE ASSEMBLY BRAKE 7. Rear Disc Brake Assembly 3) Connect the brake hose. Tightening torque: A: REMOVAL 18 N·m (1.8 kgf-m, 13.3 ft-lb) 3. 17 INCH TYPE CAUTION: • The brake hose must be connected without CAUTION: any twist. Do not allow brake fluid to come in contact with •...
Page 447 REAR DISC BRAKE ASSEMBLY BRAKE D: ASSEMBLY 3. 17 INCH TYPE 1) Clean the caliper body interior using brake fluid. 2) Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body. 3) Apply a coat of brake fluid to the entire inner sur- face of cylinder and outer surface of piston.
Page 448 REAR DISC BRAKE ASSEMBLY BRAKE BR-16...
Page 449: Parking Brake
PARKING BRAKE Page General Description ..................2 Parking Brake Lever Parking Brake Cable Parking Brake Assembly (Rear Disc Brake) General Diagnostic Table...
Page 450 GENERAL DESCRIPTION PARKING BRAKE 1. General Description A: SPECIFICATIONS Rear disc brake Model Rear drum brake Rear disc brake (STi model) Mechanical on rear Type Mechanical on rear brakes, drum in disc brakes Effective drum diameter mm (in) 228.6 (9) 170 (6.69) 190 (7.48) 218.8 ×...
Page 451: Body Section
BODY SECTION LIGHTING SYSTEM INSTRUMENTATION/DRIVER INFO EXTERIOR/INTERIOR TRIM This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reas-...
Page 453: Lighting System
LIGHTING SYSTEM Page General Description ..................2 Headlight and Tail Light System Front Fog Light System Rear Fog Light System Turn Signal and Hazard Light System Back-up Light System Stop Light System Interior Light System Headlight Beam Leveler System Combination Switch (Light) Headlight Assembly Headlight Bulb.....................3 Front Turn Signal Light Bulb ...............4...
Page 454 GENERAL DESCRIPTION LIGHTING SYSTEM 1. General Description A: SPECIFICATIONS Except STi model 12 V — 55 W/60 W (Halogen) Headlight High beam 12 V — 55 W (Halogen) model Low beam 12 V — 60 W (Halogen) Front turn signal light 12 V —...
Page 455: Headlight Bulb
HEADLIGHT BULB LIGHTING SYSTEM 12.Headlight Bulb HIGH BEAM BULB 6) Remove the bulb by turning it counterclockwise. A: REMOVAL 2. STI MODEL CAUTION: • Because the tungsten halogen bulb operates at a high temperature, dirt and oil on the bulb surface reduces the bulb's service life.
Page 456: Front Turn Signal Light Bulb
FRONT TURN SIGNAL LIGHT BULB LIGHTING SYSTEM 13.Front Turn Signal Light Bulb A: REMOVAL 2. STI MODEL 1) Remove the headlight assembly. <Ref. to LI-13, REMOVAL, Headlight Assembly.> 2) Turn the socket (A) and remove the bulb. BO0518 LI-4...
Page 457 CLEARANCE/PARKING LIGHT BULB LIGHTING SYSTEM 14.Clearance/Parking Light Bulb A: REMOVAL 2. STI MODEL 1) Remove the headlight assembly. <Ref. to LI-13, REMOVAL, Headlight Assembly.> 2) Turn the socket (A) and remove the bulb. BO0519 LI-5...
Page 458 CLEARANCE/PARKING LIGHT BULB LIGHTING SYSTEM LI-6...
Page 459 INSTRUMENTATION/DRIVER INFO Page General Description ..................2 Combination Meter System Combination Meter Assembly ..............3 Speedometer Tachometer Fuel Gauge Water Temperature Gauge Ambient Sensor...
Page 460 GENERAL DESCRIPTION INSTRUMENTATION/DRIVER INFO 1. General Description A: SPECIFICATIONS 2. STI MODEL Speedometer Electric pulse type Temperature gauge Thermistor cross coil type Fuel gauge Resistance cross coil type Tachometer Electric impulse type Turn signal indicator light 14 V — 1.4 W Charge indicator light Oil pressure indicator light ABS warning light...
Page 461 COMBINATION METER ASSEMBLY INSTRUMENTATION/DRIVER INFO 3. Combination Meter Assem- C: DISASSEMBLY 2. BULB REPLACEMENT (STI MODEL) (10) BO0509 (1) Speedometer (2) Speedometer and tachometer (3) Turn RH (4) HI-beam (5) Tachometer (6) Turn LH (7) Fuel gauge (8) Temperature gauge (9) LCD (Outside temperature indicator) (10) LCD (Odometer and tripmeter) IDI-3...
Page 462 COMBINATION METER ASSEMBLY INSTRUMENTATION/DRIVER INFO IDI-4...
Page 463 EXTERIOR/INTERIOR TRIM Page General Description ..................2 Front Grille ....................5 Hood Grille Front Under Cover Front Bumper ....................6 Rear Bumper Mud Guard Cowl Panel Roof Spoiler Rear Spoiler Side Sill Spoiler Front Door Trim Rear Door Trim Glove Box Roof Rail Console Box Instrument Panel Assembly Upper Inner Trim...
Page 464 GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 1. General Description A: COMPONENT 1. FRONT GRILLE • STi model BO0510 Front grille Front grille emblem Clip EI-2...
Page 465 GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 4. FRONT BUMPER • STi model BO0511 Bumper face Bumper energy absorber Tightening torque: N·m (kgf-m, ft-lb) Bumper corner bracket Bumper back beam T1: 32 (3.3, 24) License plate bracket T2: 69 (7.0, 51) EI-3...
Page 466 GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 9. REAR SPOILER • STi model BO0512 Rear spoiler Grommet Tightening torque: N·m (kgf-m, ft-lb) Protector Seal (only RH side) T: 7.4 (0.75, 5.46) High mount stop lamp EI-4...
Page 467 FRONT GRILLE EXTERIOR/INTERIOR TRIM 2. Front Grille A: REMOVAL 2. STI MODEL 1) Open the hood. 2) Remove the eight clips. BO0514 3) Remove the two hooks. BO0513 EI-5...
Page 468: Front Bumper
FRONT BUMPER EXTERIOR/INTERIOR TRIM 5. Front Bumper 6) Disconnect the fog light connector to remove bumper. A: REMOVAL 2. STI MODEL CAUTION: • Handle the bumper carefully to avoid damage to bumper face. • Do not damage the body during removal or installation of bumper.
Page 469 2002 IMPREZA STi SERVICE MANUAL QUICK REFERENCE INDEX WIRING SYSTEM SECTION WIRING SYSTEM This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures...
Page 471: Wiring System
WIRING SYSTEM Page Basic Diagnostics Procedure Working Precautions Super Multiple Junction (SMJ) Power Supply Routing.................3 Ground Distribution ...................18 Airbag System Air Conditioning System................29 Anti-lock Brake System ................38 A/T Control System Audio System Charging System Combination Meter..................45 Cruise Control System ................49 Door Lock System Engine Coolant Temperature Gauge System Engine Electrical System ................52...
Page 472: Table Of Contents
WIRING SYSTEM Overall Systems Front Wiring Harness ................90 Bulkhead Wiring Harness (In Engine Room) ..........96 Bulkhead Wiring Harness (In Compartment) ..........100 Engine Wiring Harness and Transmission Cord ........106 Instrument Panel Wiring Harness Rear Wiring Harness, Bulkhead wiring Harness, Roof Cord and Fuel Tank Cord Door Cord Rear Wiring Harness and Trunk Lid Cord ..........108 Rear Wiring Harness and Rear Gate Cord...
Page 473 POWER SUPPLY ROUTING WIRING SYSTEM 4. Power Supply Routing A: SCHEMATIC WI-3...
Page 474: Power Supply Routing
POWER SUPPLY ROUTING WIRING SYSTEM 1. LHD MODEL MAIN FUSE BOX (M/B) MAIN FAN FWD SWITCH MAIN MAIN RELAY SUB FAN RELAY-2 RELAY-1 RELAY-1 RELAY-2 No. 9 SBF-7 Horn No. 5 relay No. 1 No. 6 relay No. 8 No. 4 No.
Page 475 POWER SUPPLY ROUTING WIRING SYSTEM BATTERY BATTERY CURRENT CURRENT FROM IGNITION SWITCH IG TERMINAL OTHER CURRENTS CURRENT FROM IGNITION SWITCH ACC TERMINAL MAIN FUSE BOX (M/B) P-SUP(L)-03 P-SUP(L)-03 GENERATOR P-SUP(L)-03 HEAD- HEAD- LIGHT LIGHT RELAY RELAY SBF HOLDER P-SUP(L)-05 (BLACK) (GREEN) (BLACK) (BLACK)
Page 476 POWER SUPPLY ROUTING WIRING SYSTEM MAIN FUSE BOX (M/B) P-SUP(L)-02 P-SUP(L)-02 P-SUP(L)-02 HORN RELAY P-SUP(L)-05 P-SUP(L)-05 P-SUP(L)-05 P-SUP(L)-05 P-SUP(L)-04 P-SUP(L)-04 P-SUP(L)-05 P-SUP(L)-04 F68 (BLACK) F37 (BLACK) F39 (BLACK) 1 2 3 1 2 3 1 2 3 4 5 6 7 8 GL01-21C WI-6...
Page 477 POWER SUPPLY ROUTING WIRING SYSTEM P-SUP(L)-03 P-SUP(L)-05 P-SUP(L)-03 P-SUP(L)-03 FUSE & RELAY BOX (F/B) TAIL & REAR ILLUMI- DEFO- B271 NATION GGER RELAY RELAY B152 B158 TRAILER CONNECTOR (BLUE) (BROWN) (GRAY) B158 (GRAY) 1 2 3 4 4 5 6 7 8 6 7 8 8 9 10 6 7 8 9...
Page 478 POWER SUPPLY ROUTING WIRING SYSTEM IGNITION SWITCH ON ST P-SUP(L)-03 B108 P-SUP(L)-03 IGNITION RELAY WL 10 P-SUP(L)-04 P-SUP(L)-03 P-SUP(L)-03 B157 P-SUP(L)-03 REF. TO GND-02 FUSE & RELAY BOX (F/B) B271 B152 B158 P-SUP(L)-02 (BLACK) (BLUE) (BLUE) (BROWN) (GRAY) B158 (GRAY) 4 5 6 7 8 6 7 8 8 9 10...
Page 479 POWER SUPPLY ROUTING WIRING SYSTEM Load Load FB-10 Bright switch MB-1 Air conditioning relay holder FB-11 Combination meter MB-2 Combination meter Front fog light relay Headlight RH Front fog light switch MB-3 Headlight LH Headlight leveling switch MB-4 Horn Illumination light Rear fog light relay MB-5 Cruise control sub switch...
Page 480 POWER SUPPLY ROUTING WIRING SYSTEM Load FB-30 Mirror heater relay FB-31 Stop light switch FB-32 ABS control module FB-33 Front fog light relay FB-34 Blower motor relay FB-35 Door lock timer Keyless entry control module FB-36 Combination meter WI-10...
Page 481 POWER SUPPLY ROUTING WIRING SYSTEM 2. RHD MODEL MAIN FUSE BOX (M/B) MAIN FAN FWD SWITCH MAIN MAIN RELAY SUB FAN RELAY-2 RELAY-1 RELAY-2 RELAY-1 No. 9 SBF-7 Horn No. 5 relay No. 1 No. 6 No. 8 relay No. 4 No.
Page 482 POWER SUPPLY ROUTING WIRING SYSTEM BATTERY BATTERY CURRENT CURRENT FROM IGNITION SWITCH IG TERMINAL OTHER CURRENTS CURRENT FROM IGNITION SWITCH ACC TERMINAL MAIN FUSE BOX (M/B) P-SUP(R)-03 P-SUP(R)-03 GENERATOR P-SUP(R)-03 HEAD- HEAD- LIGHT LIGHT RELAY RELAY SBF HOLDER P-SUP(R)-05 (BLACK) (GREEN) (BLACK) (BLACK)
Page 483 POWER SUPPLY ROUTING WIRING SYSTEM MAIN FUSE BOX (M/B) P-SUP(R)-02 P-SUP(R)-02 P-SUP(R)-02 HORN RELAY B144 B186 B143 B145 P-SUP(R)-05 P-SUP(R)-05 P-SUP(R)-05 P-SUP(R)-05 P-SUP(R)-04 P-SUP(R)-04 P-SUP(R)-05 P-SUP(R)-04 B143 B186 (BLACK) B144 (BLACK) F39 (BLACK) 1 2 3 1 2 3 1 2 3 4 5 6 7 8 GR01-21C WI-13...
Page 484 POWER SUPPLY ROUTING WIRING SYSTEM P-SUP(R)-03 P-SUP(R)-05 P-SUP(R)-03 P-SUP(R)-03 FUSE & RELAY BOX (F/B) TAIL & REAR ILLUMI- DEFO- B271 NATION GGER RELAY RELAY B152 B158 B159 TRAILER CONNECTOR (BLUE) B159 (BROWN) B158 (GRAY) (GRAY) 1 2 3 4 4 5 6 7 8 6 7 8 8 9 10 6 7 8 9...
Page 485 POWER SUPPLY ROUTING WIRING SYSTEM IGNITION SWITCH ON ST P-SUP(R)-03 P-SUP(R)-03 IGNITION RELAY WL 38 P-SUP(R)-04 P-SUP(R)-03 GW 37 P-SUP(R)-03 B157 P-SUP(R)-03 REF. TO GND-07 FUSE & RELAY BOX (F/B) B271 B152 B158 E159 P-SUP(R)-02 (BLUE) (BLUE) B159 (BROWN) B158 (GRAY) (GRAY) 4 5 6 7 8...
Page 486 POWER SUPPLY ROUTING WIRING SYSTEM Load Load FB-10 Bright switch MB-1 Air conditioning relay holder FB-11 Combination meter MB-2 Combination meter Front fog light relay Headlight RH Front fog light switch MB-3 Headlight LH Headlight leveling switch MB-4 Horn Illumination control module Illumination light MB-5 Cruise control sub switch...
Page 487 POWER SUPPLY ROUTING WIRING SYSTEM Load FB-30 Mirror heater relay FB-31 Stop light switch FB-32 ABS control module FB-33 Front fog light relay FB-34 Blower motor relay FB-35 Door lock timer Keyless entry control module FB-36 Combination meter WI-17...
Page 488 GROUND DISTRIBUTION WIRING SYSTEM 5. Ground Distribution A: SCHEMATIC WI-18...
Page 489: Ground Distribution
GROUND DISTRIBUTION WIRING SYSTEM 1. LHD MODEL (GENERAL) HEADLIGHT LO RH (STi MODEL) POWER WINDOW FRONT DOOR LOCK MAIN SWITCH ACUTUATOR (DRIVER SIDE) HEADLIGHT LEVELING SWITCH HEADLIGHT LO LH (EXCEPT STi MODEL) (STi MODEL) REARVIEW MIRROR (DRIVER SIDE) DOOR LOCK SWITCH B132 MAIN FAN MOTOR HEADLIGHT LEVELER RH...
Page 490 GROUND DISTRIBUTION WIRING SYSTEM INTERCOOLER WATER SPRAY SWITCH (STi MODEL) B294 HEADLIGHT LEVELING SWITCH (STi MODEL) B132 REAR DEFOGGER TIMER RADIO AT SELECT LEVER B296 B120 B116 FRONT DOOR SWITCH (DRIVER SIDE) FRONT WIPER MOTOR AIR MIX ACTUATOR COMBINATION SWITCH (WIPER) B293 B267 INTERCOOLER WATER SPRAY...
Page 491 GROUND DISTRIBUTION WIRING SYSTEM FUEL PUMP ASSEMBLY REARVIEW MIRROR (PASSENGER SIDE) INTERCOOLER B101 WATER SPRAY MOTOR AND LEVEL SENSOR (STi MODEL) ROOM LIGHT FRONT FOG LIGHT LH SEAT BELT SWITCH B306 R145 SIDE TURN SIGNAL SPOT LIGHT LIGHT RH REAR DOOR SWITCH LH B305 ABS CONTROL MODULE...
Page 492 GROUND DISTRIBUTION WIRING SYSTEM RADIO RADIO SRS HARNESS B121 B120 REAR COMBINATION LIGHT RH (WAGON) TRAILER CONNECTOR REAR COMBINATION LIGHT LH (WAGON) LICENCE PLATE LIGHT TRUNK ROOM LIGHT REAR COMBINATION SWITCH (SEDAN) LIGHT RH (SEDAN) : WAGON : SEDAN REAR WIPER REAR COMBINATION INTERMITTENT MODULE LIGHT LH (SEDAN)
Page 493 GROUND DISTRIBUTION WIRING SYSTEM : WAGON : SEDAN REAR DEFOGGER (WITHOUT CHOKE COIL) HIGH-MOUNTED STOP LIGHT REAR GATE LATCH SWITCH HIGH-MOUNTED STOP REAR DEFOGGER LIGHT (REAR SPOILER) (WITH CHOKE COIL) REAR WIPER MOTOR GND-04 GG04-22E WI-23...
Page 494 GROUND DISTRIBUTION WIRING SYSTEM 2. RHD MODEL (GENERAL) HEADLIGHT LEVELER RH HEADLIGHT LEVELER LH (STi MODEL) (STi MODEL) POWER WINDOW FRONT DOOR LOCK MAIN SWITCH ACTUATOR (DRIVER SIDE) HEADLIGHT LEVELING SWITCH (EXCEPT STi MODEL) HEADLIGHT LO LH (STi MODEL) REARVIEW MIRROR (DRIVER SIDE) B132 DOOR LOCK SWITCH...
Page 495 GROUND DISTRIBUTION WIRING SYSTEM HEADLIGHT LEVELING SWITCH INTERCOOLER WATER SPRAY (STi MODEL) SWITCH (STi MODEL) B132 B294 COMBINATION METER DIAGNOSIS CONNECTOR REAR DEFOGGER TIMER B296 RADIO AT SELECT LEVER FRONT WIPER MOTOR GND-08 B120 B116 COMBINATION SWITCH (WIPER) FRONT DOOR SWITCH (DRIVER SIDE) CRUISE CONTROL ACTUATOR B267 COMBINATION SWITCH (LIGHTING)
Page 496 GROUND DISTRIBUTION WIRING SYSTEM REARVIEW MIRROR (PASSENGER SIDE) FUEL PUMP ASSEMBLY B101 SEAT BELT SWITCH GND-07 INTERCOOLER WATER SPRAY MOTOR AND LEVEL SENSOR REAR DOOR SWITCH LH (STi MODEL) R145 FUEL PUMP CONTROLLER R122 REAR DOOR SWITCH RH MANUAL HI-MOUNTED STOP FAN CONTROL AMP.
Page 497 GROUND DISTRIBUTION WIRING SYSTEM RADIO RADIO SRS HARNESS B121 B120 REAR COMBINATION LIGHT RH (WAGON) TRAILER CONNECTOR REAR COMBINATION LIGHT LH (WAGON) LICENCE PLATE LIGHT TRUNK ROOM LIGHT REAR COMBINATION SWITCH (SEDAN) LIGHT RH (SEDAN) : WAGON : SEDAN REAR WIPER REAR COMBINATION INTERMITTENT MODULE LIGHT LH (SEDAN)
Page 498 GROUND DISTRIBUTION WIRING SYSTEM : WAGON : SEDAN REAR GATE LATCH SWITCH REAR DEFOGGER HIGH-MOUNTED STOP LIGHT (REAR SPOILER) HIGH-MOUNTED STOP LIGHT REAR WIPER MOTOR GND-09 GG04-22J WI-28...
Page 499 AIR CONDITIONING SYSTEM WIRING SYSTEM 7. Air Conditioning System A: SCHEMATIC WI-29...
Page 500: Air Conditioning System
AIR CONDITIONING SYSTEM WIRING SYSTEM 1. AUTO A/C LHD MODEL TO POWER SUPPLY ROUTING FB-19 FB-20 FB-34 F/B FUSE NO. 17 F/B FUSE NO. 17 F/B FUSE NO. 1 (B) (IG) (IG) F/B FUSE NO. 2 (B) : TURBO ENGINE MODEL : NON-TURBO ENGINE MODEL BLOWER MOTOR RELAY...
Page 501 AIR CONDITIONING SYSTEM WIRING SYSTEM VEHICLE SPEED SENSOR (MT) TO POWER SUPPLY ROUTING FB-8 FB-9 FB-27 FB-17 TRANSMISSION M/B FUSE NO. 2 F/B FUSE NO. 2 F/B FUSE NO. 9 F/B FUSE NO. 18 CONTROL (ACC) (IG) MODULE (AT) B209 : TURBO ENGINE MODEL : NON-TURBO ENGINE MODEL : STi TURBO ENGINE MODEL...
Page 502 AIR CONDITIONING SYSTEM WIRING SYSTEM B282 B: B283 AUTO A/C CONTROL MODULE B256 -COM LCD(OUT TEMP) AMBIENT SENSOR EVAPORATION SUNLOAD COMBINATION THERMO SWITCH SENSOR METER B282 (GRAY) (GRAY) B256 B283 (BLACK) (BLACK) 6 7 8 9 10 11 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5...
Page 503 AIR CONDITIONING SYSTEM WIRING SYSTEM A: B282 B: B283 AUTO A/C CONTROL MODULE B209 B293 FRESH/RECIRC REF. TO GND-02 REF. TO GND-02 THERMOMETER ACTUATOR B282 (GRAY) (GRAY) (BLACK) (LIGHT GRAY) (BLACK) B283 B293 (LIGHT GRAY) 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 504 AIR CONDITIONING SYSTEM WIRING SYSTEM 2. AUTO A/C RHD MODEL TO POWER SUPPLY ROUTING FB-19 FB-20 FB-34 F/B FUSE NO. 17 F/B FUSE NO. 17 F/B FUSE NO. 1 (B) (IG) (IG) F/B FUSE NO. 2 (B) : TURBO ENGINE MODEL BLOWER MOTOR : NON-TURBO ENGINE MODEL RELAY...
Page 505: Air Conditioning System
AIR CONDITIONING SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING VEHICLE SPEED SENSOR (MT) MB-10 FB-27 FB-17 M/B FUSE NO. 2 F/B FUSE NO. 9 F/B FUSE NO. 18 (ACC) (IG) TRANSMISSION CONTROL MODULE (AT) WITH ILLUMINATION CONTROL MODEL : YL WITHOUT ILLUMINATION CONTROL MODEL : STi TURBO ENGINE MODEL...
Page 506 AIR CONDITIONING SYSTEM WIRING SYSTEM B: B283 AUTO A/C CONTROL MODULE B282 B256 -COM LCD(OUT TEMP) AMBIENT SENSOR EVAPORATION SUNLOAD COMBINATION THERMO SWITCH SENSOR METER (BLACK) B282 (GRAY) (GRAY) B283 (GREEN) B256 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7...
Page 507 AIR CONDITIONING SYSTEM WIRING SYSTEM A: B282 B: B283 AUTO A/C CONTROL MODULE B293 : TURBO ENGINE MODEL : NON-TURBO ENGINE MODEL FRESH/RECIRC ACTUATOR REF. TO GND-07 THERMOMETER : (BLACK) B282 (GRAY) (GRAY) (LIGHT GRAY) (BLACK) B283 : (LIGHT GRAY) B293 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10...
Page 508 ANTI-LOCK BRAKE SYSTEM WIRING SYSTEM 8. Anti-lock Brake System A: SCHEMATIC WI-38...
Page 509 ANTI-LOCK BRAKE SYSTEM WIRING SYSTEM 1. LHD MODEL TO POWER SUPPLY ROUTING FB-32 SBF-8 MB-13 FB-17 FB-36 FB-31 F/B FUSE NO. 8 SBF HOLDER SBF-4 F/B FUSE NO. 18 F/B FUSE NO. 13 F/B FUSE NO.16 (IG) (IG) STOP LIGHT B108 SWITCH RELAY HOLDER...
Page 510 ANTI-LOCK BRAKE SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING : TURBO ENGINE MODEL MB-9 SBF-5 : NON-TURBO ENGINE MODEL TRANSMISSION : STi MODEL CONTROL MODULE DIAGNOSIS DIAGNOSIS CONNECTOR CONNECTOR : EXCEPT STi MODEL CHECK CONNECTOR ABS(L)-01 DATA LINK REF. TO GND-02 CONNECTOR B209 B301...
Page 511 ANTI-LOCK BRAKE SYSTEM WIRING SYSTEM ABS CONTROL MODULE B301 SHIELD JOINT CONNECTOR : STi MODEL : EXCEPT STi MODEL : STi : RW EXCEPT STi : STi : VW EXCEPT STi B303 ABS G SENSOR JOINT CONNECTOR (STi MODEL) B261 B198 B292 B257...
Page 512 ANTI-LOCK BRAKE SYSTEM WIRING SYSTEM 2. RHD MODEL TO POWER SUPPLY ROUTING FB-17 FB-32 MB-13 FB-36 SBF-8 FB-31 F/B FUSE NO.18 F/B FUSE NO.8 SBF-4 F/B FUSE NO.13 SBF HOLDER F/B FUSE NO.16 (IG) (IG) STOP LIGHT SWITCH RELAY HOLDER : WC B225 B255...
Page 513 ANTI-LOCK BRAKE SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING MB-9 : STi MODEL SBF-5 : EXCEPT STi MODEL CHECK CONNECTOR ABS(R)-01 TRANSMISSION CONTROL MODULE DIAGNOSIS DIAGNOSIS CONNECTOR CONNECTOR REF. TO GND-07 DATA LINK CONNECTOR ABS(R)-01 GW 12 REF. TO GND-07 GW 13 B200 ABS CONTROL MODULE...
Page 514 ANTI-LOCK BRAKE SYSTEM WIRING SYSTEM ABS CONTROL MODULE SHIELD JOINT CONNECTOR : STi MODEL : EXCEPT STi MODEL B200 ABS G SENSOR JOINT CONNECTOR (STi MODEL) B261 B292 B257 FRONT FRONT REAR REAR ABS LATERAL G SENSOR G SENSOR SENSOR LH SENSOR RH SENSOR LH SENSOR RH...
Page 515 COMBINATION METER WIRING SYSTEM 12.Combination Meter A: SCHEMATIC To C: (GREEN) To B: (GREEN) To A: (GREEN) GG64-22A WI-45...
Page 516: Combination Meter
COMBINATION METER WIRING SYSTEM METER-03 METER-04 GG64-22B WI-46...
Page 517 COMBINATION METER WIRING SYSTEM METER-02 METER-04 METER-04 METER-04 GG64-22C WI-47...
Page 518 COMBINATION METER WIRING SYSTEM : AT MODEL : MT MODEL : WITH AUTO A/C MODEL : WITH ILLUMINATION CONTROL MODEL : WITHOUT ILLUMINATION CONTROL MODEL METER-03 TACHOMETER SPEEDOMETER METER-03 DRIVER DRIVER CUSTOM CPU DRIVER TRIP CHANGE – TRIP ODO/TRIP LCD OUT TEMP RESET SWITCH BACK LIGHT...
Page 519 CRUISE CONTROL SYSTEM WIRING SYSTEM 13.Cruise Control System A: SCHEMATIC TO POWER SUPPLY ROUTING FB-31 FB-17 MB-5 F/B FUSE NO.16 F/B FUSE NO.18 HORN RELAY (IG) CRUISE CONTROL SUB SWITCH STOP LIGHT AND BRAKE SWITCH (SET) (RESUME) (CANCEL) AT : YG : YR CRUISE CONTROL MAIN SWITCH...
Page 520 CRUISE CONTROL SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING CRUISE CONTROL MODULE MB-9 SBF-5 C/C-01 VEHICLE SPEED SENSOR (MT) TRANSMISSION CONTROL MODULE (AT) : AT MODEL : MT MODEL TURBO ENGINE MODEL NON-TURBO ENGINE MODEL STi TURBO ENGINE MODEL AND NON-TURBO ENGINE MODEL NORMAL TURBO ENGINE MODEL...
Page 521 CRUISE CONTROL SYSTEM WIRING SYSTEM CRUISE CONTROL MODULE STARTER MOTOR TO BATTERY TERMINAL INHIBITOR SWITCH C/C-01 REF. TO GND-06 REF. TO GND-07 CRUISE CONTROL ACTUATOR B94 (BLACK) (BLACK) 1 2 3 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 5 6 7 8 7 8 9 10 11 12...
Page 522 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM 16.Engine Electrical System A: SCHEMATIC WI-52...
Page 523 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM 3. LHD DOHC TURBO MODEL TO POWER SUPPLY ROUTING FB-21 F/B FUSE NO. 11 (IG) FUEL PUMP RELAY E/G(LTB)-03 E/G(LTB)-10 REF. TO GND-02 R122 FUEL LEVEL SENSOR E/G(LTB)-02 FUEL SUB LEVEL SENSOR ENGINE CONTROL A: B134 B135 B136 MODULE...
Page 524 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB-36 FB-17 F/B FUSE NO. 13 F/B FUSE NO. 18 (IG) (IG) SPEEDO- TACHO- METER METER E/G(LTB)-05 COMBINATION METER CUSTOM CPU VEHICLE SPEED SENSOR E/G(LTB)-01 E/G(LTB)-05 E/G(LTB)-10 E/G(LTB)-09 STi TURBO ENGINE MODEL E/G(LTB)-08 NORMAL TURBO ENGINE MODEL...
Page 525 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING MB-9 SBF-5 IGNITION SWITCH (ST) E/G(LTB)-01 MAIN RELAY E/G(LTB)-05 E/G(LTB)-06 E/G(LTB)-06 STARTER MOTOR TO BATTERY TERMINAL REF. TO GND-02 ENGINE CONTROL MODULE B134 B137 B47 (BROWN) A: B134 D: B137 1 2 3 4 1 2 3 4 7 8 9 5 6 7 8...
Page 526 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM B: B135 D: B137 B134 ENGINE CONTROL MODULE A: B134 B135 D: B137 1 2 3 4 7 8 9 10 11 12 14 15 11 12 13 14 15 16 17 18 19 10 11 12 13 14 15 16 17 19 20 21 16 17...
Page 527 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM A: B134 ENGINE CONTROL MODULE NEUTRAL POSITION SWITCH B128 E/G(LTB)-03 E/G(LTB)-02 E/G(LTB)-10 E/G(LTB)-02 TEST MODE CONNECTOR B126 B125 B300 REF. TO GND-02 CHECK CONNECTOR LINE END CHECK DATA LINK CONNECTOR LINE END CONNECTOR CONNECTOR B79 (GRAY) B75 (GREEN) B128 B300...
Page 528 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM B: B135 C: B136 D: B137 E: B84 ENGINE CONTROL MODULE E/G(LTB)-03 E/G(LTB)-09 E/G(LTB)-03 E/G(LTB)-11 NT : NORMAL TURBO ENGINE MODEL B127 B279 AIRFLOW WASTEGATE EXHAUST GAS FRONT OXYGEN REAR OXYGEN SENSOR SOLENOID TEMPERATURE SENSOR (A/F) SENSOR SENSOR (NORMAL TURBO MODEL)
Page 529 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM B: B135 E: B84 ENGINE CONTROL MODULE : STi TURBO ENGINE MODEL AVCS CAMSHAFT AVCS CAMSHAFT CRANKSHAFT CAMSHAFT KNOCK POSITION SENSOR RH POSITION SENSOR LH POSITION SENSOR POSITION SENSOR SENSOR (STi TURBO MODEL) (STi TURBO MODEL) (LIGHT GRAY) (LIGHT GRAY) B135...
Page 530 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM ENGINE CONTROL MODULE B136 B135 : NORMAL TURBO ENGINE MODEL E/G(LTB)-02 B209 E/G(LTB)-11 E/G(LTB)-10 TGV LH TGV RH IDLE AIR CONTROL (NORMAL (NORMAL SOLENOID VALVE TURBO MODEL) TURBO MODEL) OIL PRESSURE SWITCH POWER STEERING OIL PRESSURE SWITCH (BLACK) (BLACK)
Page 531 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM B135 ENGINE CONTROL MODULE STi TURBO E/G(LTB)-06 ENGINE MODEL NORMAL TURBO E/G(LTB)-02 ENGINE MODEL B209 PRESSURE AVCS SOLENOID AVCS SOLENOID ENGINE COOLANT THROTTLE TGV ANGLE TGV ANGLE SENSOR VALVE LH VALVE RH TEMPERATURE POSITION SENSOR RH SENSOR LH (STi TURBO (STi TURBO...
Page 532 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM B134 B136 B137 ENGINE CONTROL MODULE E/G(LTB)-02 E/G(LTB)-05 E/G(LTB)-01 B209 E/G(LTB)-08 IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL NO.1 NO.2 NO.3 NO.4 (BROWN) A: B134 C: B136 D: B137 1 2 3 4 1 2 3 4 7 8 9 5 6 7 8 10 11 12...
Page 533 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM ENGINE CONTROL MODULE B136 B137 E/G(LTB)-06 B209 E/G(LTB)-08 PURGE CONTROL SOLENOID FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR VALVE NO. 1 NO. 2 NO. 3 NO. 4 (BLACK) (DARK GRAY) (BROWN) C: B136 D: B137 (DARK GRAY) 1 2 3 4 1 2 3 4...
Page 534 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM 6. RHD DOHC TURBO MODEL TO POWER SUPPLY ROUTING MB-9 FB-21 SBF-5 F/B FUSE NO. 11 (IG) FUEL PUMP RELAY E/G(RTB)-03 E/G(RTB)-10 REF. TO GND-07 R122 FUEL LEVEL SENSOR E/G(RTB)-02 FUEL SUB LEVEL SENSOR ENGINE CONTROL A: B134 B135 B136...
Page 535 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB-36 FB-17 F/B FUSE NO. 13 F/B FUSE NO. 18 (IG) (IG) E/G(RTB)-05 SPEEDO- TACHO- METER METER COMBINATION METER CUSTOM CPU TRANSMISSION CONTROL MODULE (AT) VEHICLE SPEED SENSOR (MT) E/G(RTB)-01 E/G(RTB)-05 E/G(RTB)-10 E/G(RTB)-09 STi TURBO...
Page 536 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING IGNITION SWITCH AT MODEL : WR (ST) MT MODEL : WB INHIBITOR SWITCH (AT) E/G(RTB)-01 MAIN RELAY E/G(RTB)-05 E/G(RTB)-06 E/G(RTB)-06 STARTER MOTOR TO BATTERY TERMINAL REF. TO GND-07 ENGINE CONTROL MODULE B134 B137 B47 (BROWN)
Page 537 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM B: B135 D: B137 B134 ENGINE CONTROL MODULE A: B134 B135 D: B137 1 2 3 4 7 8 9 10 11 12 14 15 11 12 13 14 15 16 17 18 19 10 11 12 13 14 15 16 17 19 20 21 16 17...
Page 538 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM A: B134 ENGINE CONTROL MODULE NEUTRAL POSITION SWITCH B128 E/G(RTB)-03 E/G(RTB)-02 E/G(RTB)-10 E/G(RTB)-02 TEST MODE CONNECTOR B126 B125 B300 REF. TO GND-07 CHECK CONNECTOR LINE END CONNECTOR DATA LINK CONNECTOR LINE END CHECK CONNECTOR (GRAY) B79 (GRAY) B75 (GREEN) B128...
Page 539 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM B: B135 C: B136 D: B137 E: B84 ENGINE CONTROL MODULE B259 B260 E/G(RTB)-03 E/G(RTB)-09 E/G(RTB)-03 E/G(RTB)-11 : NORMAL TURBO ENGINE MODEL B127 B279 AIRFLOW FRONT OXYGEN REAR OXYGEN WASTEGATE EXHAUST GAS SENSOR (A/F) SENSOR SENSOR SOLENOID TEMPERATURE SENSOR...
Page 540 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM B: B135 E: B84 ENGINE CONTROL MODULE : STi TURBO ENGINE MODEL AVCS CAMSHAFT AVCS CAMSHAFT CRANKSHAFT CAMSHAFT KNOCK POSITION SENSOR LH POSITION SENSOR RH POSITION SENSOR POSITION SENSOR SENSOR (STi TURBO MODEL) (STi TURBO MODEL) (LIGHT GRAY) (LIGHT GRAY) B135...
Page 541 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM ENGINE CONTROL MODULE B136 B135 : NORMAL TURBO E/G(RTB)-02 ENGINE MODEL E/G(RTB)-11 E/G(RTB)-10 TGV LH TGV RH IDLE AIR CONTROL (NORMAL (NORMAL SOLENOID VALVE TURBO MODEL) TURBO MODEL) OIL PRESSURE SWITCH POWER STEERING OIL PRESSURE SWITCH (BLACK) (BROWN) (BLACK)
Page 542 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM ENGINE CONTROL MODULE B135 STi TURBO ENGINE MODEL NORMAL TURBO ENGINE MODEL E/G(RTB)-06 E/G(RTB)-02 PRESSURE AVCS SOLENOID AVCS SOLENOID ENGINE COOLANT THROTTLE TGV ANGLE TGV ANGLE SENSOR VALVE LH VALVE RH TEMPERATURE POSITION SENSOR LH SENSOR RH (STi TURBO (STi TURBO...
Page 543 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM ENGINE CONTROL MODULE B134 B136 B137 E/R(RTB)-02 E/R(RTB)-05 E/R(RTB)-01 E/R(RTB)-08 IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL NO.1 NO.2 NO.3 NO.4 (BROWN) A: B134 C: B136 D: B137 1 2 3 4 1 2 3 4 7 8 9 5 6 7 8 10 11 12...
Page 544 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM ENGINE CONTROL MODULE B136 B137 E/G(RTB)-06 E/G(RTB)-08 PURGE CONTROL SOLENOID FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR VALVE NO. 1 NO. 2 NO. 3 NO. 4 (DARK GRAY) (BLACK) (BROWN) C: B136 D: B137 (DARK GRAY) 1 2 3 4 7 8 9...
Page 545 HEADLIGHT BEAM LEVELER SYSTEM WIRING SYSTEM 20.Headlight Beam Leveler System A: SCHEMATIC WI-75...
Page 546 HEADLIGHT BEAM LEVELER SYSTEM WIRING SYSTEM 2. STI MODEL TO POWER SUPPLY ROUTING FB-11 FB-18 TAIL & ILLUMI- FB FUSE NO.18 NATION RELAY HEADLIGHT LEVELING SWITCH B132 LHD MODEL : REF. TO GND-01 RHD MODEL : REF.TO GND-06 B209 LHD MODEL : REF.
Page 547 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM 25.Clearance Light and Illumination Light System A: SCHEMATIC WI-77...
Page 548 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM 1. LHD MODEL TO POWER SUPPLY ROUTING FB-14 FB-12 FB-13 FB-3 FB-10 FB-11 F/B FUSE NO.7 TAIL & ILLUMI- TAIL & ILLUMI- F/B FUSE NO.5 F/B FUSE NO.12 F/B FUSE NO.12 NATION RELAY NATION RELAY PARKING SWITCH B136...
Page 549 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB-36 F/B FUSE NO.13 (IG) ILM(L)-01 ILM(L)-01 HAZARD SWITCH ILLUMI. LIGHT CLOCK OrW 2 DIMMER CIRCUIT DIMMER CIRCUIT DRIVER COMBINATION METER ILM(L)-01 (BLACK) (GREEN) (GREEN) 1 2 3 4 5 6 1 2 3 4 1 2 3 4...
Page 550 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB-6 FB-7 F/B FUSE NO.5 F/B FUSE NO.5 FRONT CLEARANCE LIGHT LH TRAILER LICENSE PLATE LIGHT CONNECTOR FRONT CLEARANCE LIGHT RH REF. TO GND-01 REAR COMBINATION REAR COMBINATION LIGHT LH (WAGON) LIGHT LH (SEDAN) REAR COMBINATION...
Page 551 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM 2. RHD WITHOUT ILLUMINATION CONTROL MODEL TO POWER SUPPLY ROUTING FB-14 FB-12 FB-13 FB-3 FB-10 FB-11 F/B FUSE NO.7 TAIL & ILLUMI- TAIL & ILLUMI- F/B FUSE NO.5 F/B FUSE NO.12 F/B FUSE NO.12 NATION RELAY NATION RELAY PARKING SWITCH...
Page 552 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB-36 F/B FUSE NO.13 (IG) ILM(ROI)-01 ILM(ROI)-01 HAZARD SWITCH ILLUMI. LIGHT CLOCK DIMMER CIRCUIT DIMMER CIRCUIT DRIVER COMBINATION METER ILM(ROI)-01 (GREEN) (BLACK) (BLACK) (GREEN) 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 10 20 21 22...
Page 553 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB-6 FB-7 F/B FUSE NO.5 F/B FUSE NO.5 FRONT CLEARANCE LIGHT LH TRAILER LICENSE PLATE LIGHT CONNECTOR FRONT CLEARANCE LIGHT RH REF. TO GND-06 REAR COMBINATION REAR COMBINATION LIGHT LH (SEDAN) LIGHT LH (WAGON) REAR COMBINATION...
Page 554 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM 3. RHD WITH ILLUMINATION CONTROL MODEL TO POWER SUPPLY ROUTING FB-36 F/B FUSE NO.13 (IG) ILM(RWI)-01 HAZARD SWITCH ILLUMI. LIGHT CLOCK DIMMER CIRCUIT DIMMER CIRCUIT DRIVER COMBINATION METER ILM(RWI)-01 ILM(RWI)-01 (BLACK) (GREEN) (BLACK) (GREEN) 1 2 3 4...
Page 555 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB-36 F/B FUSE NO.13 (IG) ILM(RWI)-01 HAZARD SWITCH ILLUMI. LIGHT CLOCK DIMMER CIRCUIT DIMMER CIRCUIT DRIVER COMBINATION METER ILM(RWI)-01 ILM(RWI)-01 (GREEN) (BLACK) (BLACK) (GREEN) 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 10 20 21 22...
Page 556 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB-6 FB-7 F/B FUSE NO.5 F/B FUSE NO.5 FRONT CLEARANCE LIGHT LH TRAILER LICENSE PLATE LIGHT CONNECTOR FRONT CLEARANCE LIGHT RH REF. TO GND-06 REAR COMBINATION REAR COMBINATION LIGHT LH (WAGON) LIGHT LH (SEDAN) REAR COMBINATION...
Page 557 HEADLIGHT SYSTEM WIRING SYSTEM 27.Headlight System A: SCHEMATIC WI-87...
Page 558 HEADLIGHT SYSTEM WIRING SYSTEM 3. LHD 4-LIGHTS MODEL TO POWER SUPPLY ROUTING MB-8 MB-2 MB-3 HEADLIGHT M/B FUSE NO.9 M/B FUSE NO.8 RELAY HEADLIGHT RH HIGH HEADLIGHT LH HIGH COMBINATION METER HI-BEAM INDICATOR LIGHT LW B30 DIMMER & PASSING B: i11 REF.
Page 559 HEADLIGHT SYSTEM WIRING SYSTEM 4. RHD 4-LIGHTS MODEL TO POWER SUPPLY ROUTING MB-8 MB-2 MB-3 HEADLIGHT M/B FUSE NO.9 M/B FUSE NO.8 RELAY HEADLIGHT RH HIGH : WITH REAR FOG LIGHT MODEL : WITHOUT REAR FOG LIGHT MODEL FOR EUROPE MODEL : RW HEADLIGHT LH OTHER MODEL REF.
Page 560 FRONT WIRING HARNESS WIRING SYSTEM 45.Front Wiring Harness A: LOCATION 1. LHD MODEL Connector Connecting to Pole Color Area Name Gray Front clearance light RH and front turn signal light RH Black Horn Headlight RH (2-Lights) Brown Headlight RH (4-Lights Lo) Black Sub fan motor (Non-turbo model) Black...
Page 561: Front Wiring Harness
FRONT WIRING HARNESS WIRING SYSTEM Connector Connecting to Pole Color Area Name Black Gray B209 Bulkhead wiring harness (SMJ) Black Ambient sensor Gray A/C pressure switch Gray ABS front sensor LH Black Headlight LH (4-Lights Hi) Black Headlight RH (4-Lights Hi) #: Non-colored WI-91...
Page 562 FRONT WIRING HARNESS WIRING SYSTEM GB-1 GB-2 BO0487 WI-92...
Page 563 FRONT WIRING HARNESS WIRING SYSTEM 2. RHD MODEL Connector Connecting to Pole Color Area Name Gray Front clearance light RH and front turn signal light RH Black Horn Black Front fog light RH Headlight RH (2-Lights) Black Headlight RH (4-Lights Lo) Black Sub fan motor (Non-turbo model) Black...
Page 564 FRONT WIRING HARNESS WIRING SYSTEM Connector Connecting to Pole Color Area Name Black Headlight RH (4-Lights Hi) #: Non-colored WI-94...
Page 565 FRONT WIRING HARNESS WIRING SYSTEM GB-1 GB-2 BO0488 WI-95...
Page 566 BULKHEAD WIRING HARNESS (IN ENGINE ROOM) WIRING SYSTEM 46.Bulkhead Wiring Harness (In Engine Room) A: LOCATION 2. LHD TURBO ENGINE MODEL Connector Connecting to Pole Color Area Name Gray Mass airflow sensor Front wiper motor Starter (Magnet) Gray ABS front sensor RH Gray Brake fluid level switch Vehicle speed sensor (MT-STi)
Page 567 BULKHEAD WIRING HARNESS (IN ENGINE ROOM) WIRING SYSTEM B305 B279 B301 B303 B127 B128 B302 B306 BO0470 WI-97...
Page 568 BULKHEAD WIRING HARNESS (IN ENGINE ROOM) WIRING SYSTEM 4. RHD TURBO ENGINE MODEL Connector Connecting to Pole Color Area Name Gray Mass airflow sensor Black Cruise control actuator Gray Front wiper motor Black Transmission (AT) White Starter (Magnet) Gray Brake fluid level switch Vehicle speed sensor (MT-STi) Vehicle speed sensor (MT-Except STi) Front oxygen (A/F) sensor...
Page 569 BULKHEAD WIRING HARNESS (IN ENGINE ROOM) WIRING SYSTEM B279 B127 B148 B143 B144 B186 B147 B146 B128 B145 B255 BO0478 WI-99...
Page 570 BULKHEAD WIRING HARNESS (IN COMPARTMENT) WIRING SYSTEM 47.Bulkhead Wiring Harness (In Compartment) A: LOCATION 1. LHD MODEL Connector Connecting to Connector Connecting to Pole Color Area Name Pole Color Area Name Blower fan motor Front door cord LH Evaporator ther- Yellow SRS (Airbag) harness Brown...
Page 571 BULKHEAD WIRING HARNESS (IN COMPARTMENT) WIRING SYSTEM Connector Connecting to Pole Color Area Name B196 Diode (Rear fog light) Ground joint connec- B198 GB-9 B208 Glove box light Front wiring harness B209 (SMJ) Ignition switch illumi- B224 nation B225 Fuse (Relay box) B256 Evaporator sensor ABS lateral G sensor...
Page 572 BULKHEAD WIRING HARNESS (IN COMPARTMENT) WIRING SYSTEM B137 B275 B304 B157 GB-4 B225 B171 GB-5 B196 B135 B141 Relay block B101 B293 B108 B286 B296 B209 B256 B208 B131 B126 B136 B264 B153 B176 B125 B125 B129 B294 B120 B126 B134 B119 B122...
Page 573 BULKHEAD WIRING HARNESS (IN COMPARTMENT) WIRING SYSTEM 2. RHD MODEL Connector Connecting to Connector Connecting to Pole Color Area Name Pole Color Area Name Shield&sensor ground Front door cord RH joint connector (E/G) Yel- (Non-turbo with OBD SRS (Airbag) harness model) Black Turn &...
Page 574 BULKHEAD WIRING HARNESS (IN COMPARTMENT) WIRING SYSTEM Connector Connecting to Connector Connecting to Pole Color Area Name Pole Color Area Name B134 Shield joint connector B299 (AT) (Turbo model) B135 Engine control module Line end check con- B136 B300 nector B137 #: Non-colored Immobilizer control...
Page 575 BULKHEAD WIRING HARNESS (IN COMPARTMENT) WIRING SYSTEM B275 B199 B208 GB-4 B225 B171 B196 B157 B141 GB-5 B198 B107 B135 B136 Relay block B101 B293 B200 B256 B261 B286 B131 B137 B296 B129 B264 B125 B299 B126 B176 B126 B294 B125 B120 B134...
Page 576 ENGINE WIRING HARNESS AND TRANSMISSION CORD WIRING SYSTEM 48.Engine Wiring Harness and Transmission Cord A: LOCATION 3. DOHC TURBO MODEL Connector Connecting to Pole Color Area Name Light gray Bulkhead wiring harness Front wiring harness (LHD model) Black Bulkhead wiring harness (RHD model) Front wiring harness (LHD model) Brown Bulkhead wiring harness (RHD model)
Page 577 ENGINE WIRING HARNESS AND TRANSMISSION CORD WIRING SYSTEM MT-STI MT-EXCEPT STI BO0484 WI-107...
Page 578 REAR WIRING HARNESS AND TRUNK LID CORD WIRING SYSTEM 52.Rear Wiring Harness and Trunk Lid Cord A: LOCATION Connector Connecting to Pole Color Area Name Rear door switch RH Black Rear defogger High-mounted stop light Black Trunk room light Trunk lid cord Rear combination light RH Trunk room light switch Rear combination light LH...
Page 579 REAR WIRING HARNESS AND TRUNK LID CORD WIRING SYSTEM R145 R130 R145 R122 BO0485 WI-109...
Page 580: Intercooler Water Spray System
INTERCOOLER WATER SPRAY SYSTEM WIRING SYSTEM 54.Intercooler Water Spray System A: SCHEMATIC TO POWER SUPPLY ROUTING FB-36 FB-28 FB-10 FB-11 F/B FUSE NO.13 F/B FUSE NO.4 F/B FUSE NO.12 F/B FUSE NO.12 (IG) (ACC) INTERCOOLER WATER SPRAY TIMER B286 INTERCOOLER WATER SPRAY SWITCH COMBI- NATION...

Subaru Impreza 2002 Service Manual

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