Page 1 SERVICE MANUAL SERVICE MANUAL NEW CAR INFORMATION SECTION NEW CAR INFORMATION SECTION ENGLISH...
Page 2 ME (TURBO) This manual has been prepared to provide information for the construction, operation and other technical de- tails of SUBARU vehicles. Control System Read this manual thoroughly and make the most of it to give better service to your customers and improve Manual Transmission your knowledge of vehicle maintenance.
Page 3 All right reserved. This book may not be reproduced or copied, in whole or in part, without the written permis- sion of FUJI HEAVY INDUSTRIES LTD., TOKYO JA- SUBARU, are trademarks of FUJI HEAVY INDUSTRIES LTD.  Copyright 2001 FUJI HEAVY INDUSTRIES LTD.
Page 4 SPECIFICATIONS Page 1. Impreza ................
Page 5 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 CW) mm (in) 1,465 (57.7), 1,475 (58.1), 1,440 (56.7) 1,440 (56.7) 1,485 (58.5)L4 1,495 (58.9)L4...
Page 6 IMPREZA Specifications C: ELECTRICAL Model Non-Turbo 1.6 L Turbo 2.0 L 2.5 L 2.0 L MT: 10° ± Ignition timing at idling speed BTDC/rpm 10°/700 5° ± 10°/700 10° ± 10°/700 12° ± 10°/750 12° ± 10°/700 AT: 15° ± 10°/700 Spark plug Type and...
Page 7 IMPREZA Specifications D: TRANSMISSION Model Non-Turbo 1.6 L Turbo 2.0 L 2.5 L 2.0 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 3.166L1 1.947, 2.062 1.545 2.062 1.545 1.545 2.062...
Page 8 IMPREZA Specifications F: SUSPENSION Front Macpherson strut type, Independent, Coil spring Rear Dual-link type, Independent, Coil spring 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...
Page 9 IMPREZA Specifications J: WEIGHT 1. LHD VEHICLE Sedan Option codeL1 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 10 IMPREZA Specifications Option codeL1 Model 2.0 L Curb weight (C.W.) Front kgf (lb) (1,643) (1,698) (1,687) (1,742) (1,676) (1,753) (1,653) (1,720) Rear kgf (lb) (1,179) (1,168) (1,168) (1,157) (1,157) (1,168) (1,213) (1,202) Total kgf (lb) 1,280 1,300 1,295 1,315 1,285 1,325 1,300 1,325...
Page 11 IMPREZA Specifications Wagon Option codeL1 Model 1.6 L Curb weight (C.W.) Front kgf (lb) (1,620) (1,654) (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 12 IMPREZA Specifications Option codeL1 Model 2.0 L Curb weight (C.W.) Front kgf (lb) (1,664) (1,698) (1,709) (1,742) (1,720) (1,753) (1,676) (1,720) Rear kgf (lb) (1,257) (1,246) (1,246) (1,235) (1,257) (1,246) (1,279) (1,268) Total kgf (lb) 1,325 1,335 1,340 1,350 1,350 1,360 1,340 1,355...
Page 13 IMPREZA Specifications 2. RHD VEHICLE Sedan Option codeL1 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 14 IMPREZA Specifications Option codeL1 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...
Page 15 IMPREZA Specifications Wagon Option codeL1 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 16 IMPREZA Specifications Option codeL1 Model 2.0 L 2.0 L Turbo OUTBACK Unladen mass (U. M.) Front kgf (lb) (1,676) (1,709) (1,653) (1,687) (1,819) (1,874) Rear kgf (lb) (1,257) (1,246) (1,257) (1,257) (1,290) (1,290) Total kgf (lb) 1,330 1,340 1,320 1,335 1,410 1,435 (2,932)
Page 17 IMPREZA Specifications MEMO SPC-14...
Page 18 FUEL INJECTION (TURBO) (FUEL SYSTEM) Page 1. General 2. Air Line ................3.
Page 19 AIR LINE Fuel Injection (Fuel System) 2. Air Line G: TUMBLE GENERATOR VALVES 2. STi MODEL The STi model’s engine is not provided with a tumble generation control function. Although it is fitted with a tumble generator housing, there are no sensor and valve actuator on the housing. FU-2...
Page 20 SENSORS AND SWITCHES Fuel Injection (Fuel System) 4. Sensors and Switches D: EXHAUST GAS TEMPERATURE SENSOR 2. STi MODEL The STi model is not provided with an exhaust gas temperature sensor. I: VARIABLE VALVE TIMING CAMSHAFT POSITION SENSORS NOTE: The variable valve timing camshaft position sensors are installed only on the STi model’s engine. The variable valve timing camshaft position sensors are installed one each on the rear ends of the right and left bank cylinder heads.
Page 21 CONTROL SYSTEM Fuel Injection (Fuel System) 5. Control System B: INPUT AND OUTPUT SIGNALS Signal Unit Function Pressure sensor Detects the amount of intake air (Measures the absolute pressure). Mass air flow and intake air tempera- Detects the temperature and amount of intake air. ture sensor Throttle position sensor Detects the throttle valve position.
Page 22 (TURBO) Page 1. System Overview ..............2.
Page 23 SYSTEM OVERVIEW Emission Control (Aux. Emission Control Devices) 1. System Overview There are three emission control systems which are as follows: Crankcase emission control system Exhaust emission control system Three-way catalyst system Air/fuel (A/F) control system Ignition control system Evaporative emission control system NOTE: The STi model is not provided with a precatalytic converter.
Page 24 (TURBO) INTAKE (INDUCTION) Page 1. Intake System 2. Turbocharger System ............. . .
Page 25: Turbocharger System
TURBOCHARGER SYSTEM Intake (Induction) 2. Turbocharger System I: INTERCOOLER WATER SPRAY Water is sprayed from the nozzle in the intercooler duct to cool down the intercooler with water spray when the intake air temperature becomes high so that the air temperature is lowered and air intake efficiency is increased.
Page 26: Table Of Contents
(TURBO) MECHANICAL Page 1. General 2. Timing Belt 3. Automatic Belt Tension Adjuster 4. Belt Cover 5. Camshaft ................6.
Page 27: Mechanical
CAMSHAFT Mechanical 5. Camshaft The DOHC engine uses four camshafts in all; intake and exhaust camshafts on each of the right and left banks. The cam lobe noses are finished by “chill” treatment to increase wear resistance and anti-scuffing properties. Each camshaft is supported at its three journals and held in position by three camshaft caps.
Page 28 CYLINDER HEAD Mechanical 6. Cylinder Head The cylinder head is made of aluminium die casting. Each combustion chamber in the cylinder head is a compact, pentroof design. The spark plug is located at the center of the combustion chamber, which contributes to creation of a wide “squish area”...
Page 29 CYLINDER BLOCK Mechanical 7. Cylinder Block With all the engines except that for the STi model, the cylinder block is made of aluminum die casting. Its open-deck design provides it with such advantageous features as relatively small weight, high rigidity and excellent cooling efficiency. With the engine for the STi model that generates increased torque outputs, the cylinder block uses a semi-closed deck design which can hold the cylinder liners with higher rigidity.
Page 30 PISTON Mechanical 9. Piston The pistons are of a slipper skirt design for reduced weight and friction. The oil control ring groove utilizes a thermal design. The piston pin is offset either downward (Nos. 1 and 3 pistons) or upward (Nos. 2 and 4 pistons). The piston head has recesses to prevent interference with the intake and exhaust valves.
Page 31 VARIABLE VALVE TIMING SYSTEM Mechanical 11. Variable Valve Timing System The STi model’s engine has the variable valve timing system, which adjusts the opening and clos- ing timings of the intake valves optimally by continuously changing the phase angle of the cam- shaft sprocket relative to the camshaft.
Page 32 VARIABLE VALVE TIMING SYSTEM Mechanical B: PHASE ANGLE RETARDS In response to a retard signal from the ECM, the oil flow control valve moves its spool such that hydraulic pressure is applied to the retard chamber in the camshaft sprocket. The sprocket is then turned in the direction in which its phase angle retards relative to the camshaft.
Page 33 VARIABLE VALVE TIMING SYSTEM Mechanical C: A CERTAIN PHASE ANGLE IS RETAINED When the ECM issues a signal to keep the phase angle unchanged, the oil flow control valve moves its spool to the position at which the hydraulic pressures to/from both the chambers are blocked. The pressures in the chambers are thus maintained, so the phase angle does not change and the intake valves’...
Page 34 SODIUM-FILLED EXHAUST VALVES Mechanical 12. Sodium-filled Exhaust Valves The STi model’s engine uses sodium-filled exhaust valves. Each exhaust valve contains pure sodium in its hollow stem. Sodium has high thermal conductivity. The entrapped sodium will liquefy at high temperatures and move inside the stem as the valve is operated.
Page 35 SODIUM-FILLED EXHAUST VALVES Mechanical MEMO ME-10...
Page 36 CONTROL SYSTEM Page 1. Gear Shift Lever 2. Select Lever 3. Dual Range Selector Lever 4. 6MT Gear Shift lever ..............
Page 37 6MT GEAR SHIFT LEVER Control System 4. 6MT Gear Shift Lever A: GENERAL The six-speed manual transmission’s control system has a gear shift lever specially designed for the use with it. The gearshift lever is complete with a parallel-link gear shift mechanism as is the case with the five-speed transmission’s gearshift lever.
Page 38 6MT GEAR SHIFT LEVER Control System B: OPERATION When shifting gear into reverse, the driver pulls the slider up (toward the knob). This causes the reverse check cable to move the reverse lever on the six-speed transmission to the lock release position.
Page 39 6MT GEAR SHIFT LEVER Control System MEMO CS-4...
Page 40 MANUAL TRANSMISSION AND DIFFERENTIAL Page 1. General ................2.
Page 41 The oil pump incorporated in the transmission case ensures improved lubricating and cooling performance. An optional SURETRAC type limited slip differential has been introduced for the front differential. The center differential uses a viscous coupling of the type whose high performance has already been proven with the preceding SUBARU models. 6MT-2...
Page 42: General
GENERAL Manual Transmission and Differential NF0598 (1) Main shaft (9) Transfer driven gear (17) 3rd driven gear (2) Reverse idler gear (10) Extesion case (18) 2nd driven gear (3) 1st drive gear (11) Transfer drive gear (19) Oil pan (4) 2nd drive gear (12) Center differential assembly (20) Oil strainer (5) 3rd drive gear...
Page 43 TRIPLE-CONE SYNCHRONIZER Manual Transmission and Differential 2. Triple-Cone Synchronizer A: CONSTRUCTION The triple-cone synchronizer has three frictional interfaces - in addition to the two coaxial inter- faces between the synchronizer cone and the inner and outer balk rings (which are same as those with a double-cone synchronizer), it has a third frictional interface between the inner surface of the inner balk ring and the cone on the 2nd driven gear.
Page 44 REVERSE IDLER GEAR ASSEMBLY (WITH SYNCHRONIZING MECHANISM) Manual Transmission and Differential 3. Reverse Idler Gear Assembly (with Synchronizing Mechanism) A constant-mesh type reverse gearing is used in the six-speed manual transmission. The reverse idler gear assembly is provided with a double-cone synchronizer. Soon after disengagement of the clutch, the reverse gear remains rotating by an inertial force.
Page 45 REVERSE IDLER GEAR ASSEMBLY (WITH SYNCHRONIZING MECHANISM) Manual Transmission and Differential To prevent rattling noise that may occur with the constant-mesh type reverse gearing, No.1 re- verse idler gear is fitted with a subgear that has the same number of teeth as the No. 1 reverse idler gear.
Page 46 SHIFT AND SELECT MECHANISM Manual Transmission and Differential 4. Shift and Select Mechanism Each of the shifter and fork rods has a detent mechanism using a plunger with a ball in it and is supported with a slidable ball bearing. The detent mechanisms give the driver distinctive detent feeling and the slidable ball bearings help reduce the shift lever operating force.
Page 47 SHIFT AND SELECT MECHANISM Manual Transmission and Differential A: MECHANISMS 1. SHIFT DETENT MECHANISM The shift detent mechanism allows the driver to distinctively feel the shift into a gear. The mecha- nism also prevents the transmission from jumping out of gear. The shift detent mechanism uses a plunger with a check ball in it.
Page 48 SHIFT AND SELECT MECHANISM Manual Transmission and Differential 2. SELECT RETURN MECHANISM The select return mechanism allows the shift lever to return to the neutral position. The neutral set spring pinches between its two arms the four pins on the No. 1 selector arm to hold the shift lever always in the neutral position.
Page 49 SHIFT AND SELECT MECHANISM Manual Transmission and Differential 3. INTERLOCK MECHANISM (DOUBLE-MESHING PREVENTION MECHANISM) The interlock mechanism makes it impossible to shift the transmission into two gears at once. When the interlock arm selects the shifter arm corresponding to the gear into which the driver is going to make a shift, the interlock blocks also move in the same select direction, preventing the other shifter arms from being selected.
Page 50 SHIFT AND SELECT MECHANISM Manual Transmission and Differential When “double meshing” is prevented NF0606 [A] Preventing 3rd and 5th double meshing [B] Preventing 6th and reverse double meshing (1) Interlock arm (5) 1st-2nd shifter arm (2) Interlock block (6) Reverse interlock block (3) 5th-6th shifter arm (7) Reverse shifter arm (4) 3rd-4th shifter arm...
Page 51 REVERSE CHECK MECHANISM Manual Transmission and Differential 5. Reverse Check Mechanism The reverse check mechanism prevent the reverse gear from being accidentally engaged when the driver makes a shift into the 5th or 6th gear. This mechanism is provided with a fail-safe function which enable shifting into reverse if the reverse check cable should be broken.
Page 52 REVERSE CHECK MECHANISM Manual Transmission and Differential B: OPERATION 1. MAKING SHIFT INTO 5TH/6TH When the shift lever is moved into the 5th or 6th position, the No. 1 selector arm comes into contact with the reverse check plunger, trying to move the reverse check plug. However, one end of the plunger is in contact with the cam lobe on the reverse check shaft and the other end is held in the groove in the reverse check plug, so the selector arm cannot move in the reverse gear selecting direction.
Page 53 REVERSE CHECK MECHANISM Manual Transmission and Differential 2. MAKING SHIFT INTO REVERSE When making a shift into reverse, the driver lifts the slider on the shift lever. The upward movement of the slider causes, via the reverse check cable, the reverse check shaft to turn such that the cam lobe on the reverse check shaft becomes clear of the plunger.
Page 54 REVERSE CHECK MECHANISM Manual Transmission and Differential 3. FAIL-SAFE OPERATION Should the reverse check cable be broken, the reverse check shaft turns counterclockwise by a spring force, making the plunger get clear of the cam lobe of the reverse check shaft. The plunger can now move toward the reverse check shaft, allowing the selector arm to turn in the reverse selecting direction.
Page 55 CENTER DIFFERENTIAL Manual Transmission and Differential 6. Center Differential A: CONSTRUCTION The center differential consists of a set of bevel gears and a viscous coupling. The center differential has the following two functions: distributing the engine torque to the front and rear wheel drive shafts and absorbing the difference in rotating speed between the front and rear wheels.
Page 56 CENTER DIFFERENTIAL Manual Transmission and Differential B: MECHANISM OF VISCOUS COUPLING The viscous coupling consists of a number of alternately arranged inner and outer plates and air- and-silicone oil mixture filled into a sealed space that is formed by the center differential case and the rear side gear of the differential gear set.
Page 57 CENTER DIFFERENTIAL Manual Transmission and Differential 1. TORQUE CHARACTERISTICS When a speed difference occurs between the center differential case and the rear side gear, a shear force is generated in the silicone oil placed between the outer and inner plates. The torque is then transmitted by the silicone oil between the center differential case and the rear side gear.
Page 58 CENTER DIFFERENTIAL Manual Transmission and Differential C: FUNCTION When there is no speed difference between the front and rear wheels, the center differential deliv- ers the engine torque to the front and rear wheels at a ratio of 50:50. When a rotating speed difference occurs between the front and rear wheels, the center differential operates to absorb it in a controlled way by the function of the viscous coupling.
Page 59 CENTER DIFFERENTIAL Manual Transmission and Differential 2. DURING TURNS AT LOW SPEEDS During turns at low speeds, rotating speed difference occurs between the front and rear wheels, as well as between the left and right wheels. More particularly, the front wheels rotate faster than the rear wheels.
Page 60 CENTER DIFFERENTIAL Manual Transmission and Differential 3. DRIVING ON ROUGH OR SLIPPERY ROADS When front wheels are on a slippery surface When the front wheels begin to spin, the resulting speed difference between the front and rear drive shafts causes the viscous coupling to generate significant amount of shear torque. As a re- sult, the torque distributed to the rear wheels becomes much larger than that distributed to the spinning front wheels.
Page 61 OIL PUMP Manual Transmission and Differential 7. Oil Pump A: CONSTRUCTION The lubricating oil pump incorporated in the transmission case is of a trochoid type. The pump consists of an inner rotor having four teeth, outer rotor having five teeth, oil pump cover and oil pump driven gear, which are all located at the rear of the transmission case.
Page 62 LUBRICATION SYSTEM Manual Transmission and Differential 8. Lubrication System A forced lubrication system using an oil pump has been employed to ensure adequate supply of oil to the components of the six-speed transmission. The oil (gear oil) from the oil pump is distributed to the oil chamber, main shaft, drive pinion shaft, transfer gears, and other components.
Page 63 FRONT DIFFERENTIAL (SURETRAC TYPE LIMITED SLIP DIFFERENTIAL) Manual Transmission and Differential 9. Front Differential (SURETRAC Type Limited Slip Differential) A: OUTLINE The limited slip differential (LSD) automatically limits the differential action and distributes torque to the left and right wheels adequately to enhance driving stability when the left and right wheels are rotating at speeds different from each other during driving on a slippery road (muddy, snow- covered or slushy road) or cornering.
Page 64 FRONT DIFFERENTIAL (SURETRAC TYPE LIMITED SLIP DIFFERENTIAL) Manual Transmission and Differential NF0578 (1) Cage (2) Cam follower (3) Face cam 6MT-25...
Page 65 FRONT DIFFERENTIAL (SURETRAC TYPE LIMITED SLIP DIFFERENTIAL) Manual Transmission and Differential C: OPERATION 1. WHEN RIGHT AND LEFT WHEELS ROTATE AT DIFFERENT SPEEDS If the left and right wheels move relative to each other in the direction of arrow Z and in the direction of arrow Y, respectively, the cam follower A is pushed by the slope B of the left face cam, moving to the right.
Page 66 FRONT DIFFERENTIAL (SURETRAC TYPE LIMITED SLIP DIFFERENTIAL) Manual Transmission and Differential 2. WHEN RIGHT AND LEFT WHEELS ROTATE AT THE SAME SPEED During normal straight-ahead driving where the right and left wheels rotate at the same speed, the cage and cam followers rotate together, just as in conventional differentials. As a result, driving torque is distributed equally to the right and left side gears.
Page 67 FRONT DIFFERENTIAL (SURETRAC TYPE LIMITED SLIP DIFFERENTIAL) Manual Transmission and Differential 3. WHEN TRACTION IS DIFFERENT BETWEEN RIGHT AND LEFT WHEELS For example, if the left wheel spins on a slippery surface and loses traction, the left face cam starts rotating at a speed faster than the right wheel.
Page 68 TRANSMISSION MOUNTING Manual Transmission and Differential 10. Transmission Mounting NF0628 (1) Pitching stopper (2) Cushion rubber (3) Cross member (4) Dynamic damper (Europe model) 6MT-29...
Page 69 TRANSMISSION MOUNTING Manual Transmission and Differential MEMO 6MT-30...
Page 70 CLUTCH Page 1. Outline 2. Operation 3. Cross Sectional View ..............4.
Page 71 CROSS SECTIONAL VIEW Clutch 3. Cross Sectional View E: STi MODEL NF0621 (1) Spring bracket (5) Flywheel (9) Ball bearing (2) Spring (6) Clutch cover (10) Release bearing (3) Release lever (7) Clutch disc (4) Operating cylinder (8) Transmission main shaft CL-2...
Page 72 FLUID CONTROL SYSTEM (STi MODEL) Clutch 7. Fluid Control System (STi Model) The clutch operating cylinder incorporates a temperature sensitive orifice unit which controls the clutch engaging speed depending on the fluid temperature to ensure smooth standing starts irre- spective of atmospheric temperatures. A: CONSTRUCTION The orifice unit consists of an orifice retainer, an orifice valve, and two springs that support the ori- fice valve.
Page 73 FLUID CONTROL SYSTEM (STi MODEL) Clutch B: OPERATION The No. 1 spring is made of a shape memory alloy that contracts and loses the tension when the temperature is low. When the temperature is high, the orifice valve is kept in a raised position by the No. 1 spring, so the fluid passage is narrow.
Page 74 FRONT SUSPENSION Page 1. Front Suspension ..............
Page 75 FRONT SUSPENSION Front Suspension 1. Front Suspension A: OUTLINE 1. STi MODEL The struts are of an upside-down type, which can provide increased rigidity. They also improve the steering stability. FS-2...
Page 76 FRONT SUSPENSION Front Suspension B: CONSTRUCTION 3. UPSIDE-DOWN-TYPE STRUTS (STi MODEL) Compared with a conventional suspension strut, the upside-down-type strut has a shock absorber with its top and bottom reversed. This arrangement is advantageous in increasing rigidity as it al- lows the diameter of the damping tube (which corresponds to the piston rod in the conventional arrangement) to be increased to an almost same diameter as the strut’s outer tube diameter.
Page 77 FRONT SUSPENSION Front Suspension MEMO FS-4...
Page 78 REAR SUSPENSION Page 1. Rear Suspension ..............
Page 79 REAR SUSPENSION Rear Suspension 1. Rear Suspension A: OUTLINE 1. STi MODEL As is the case with the front suspension, the rear suspension uses upside-down struts. RS-2...
Page 80 DIFFERENTIALS Page 1. Rear Differential ..............2.
Page 81 REAR DIFFERENTIAL Differentials 1. Rear Differential B: T-TYPE 2. STi MODEL The drive gear is a hypoid gear with a nominal diameter of 180 mm (7.09 in). The drive pinion shaft is supported by three bearings. The bearing preload is adjusted by selecting a spacer and washer combination of a proper thickness.
Page 82 DRIVE SHAFT SYSTEM Page 1. Propeller Shaft ............... 2.
Page 83 PROPELLER SHAFT Drive Shaft System 1. Propeller Shaft C: STi MODEL The propeller shaft is of a two-piece design that uses three joints. NF0558 (1) Center bearing (A) Transmission side (B) Rear differential side DS-2...
Page 84 FRONT AXLE Drive Shaft System 2. Front Axle A: GENERAL 2. STi MODEL The inboard end of the axle shaft is connected to the transmission via a constant velocity joint (double offset joint: DOJ) which is flexible in the axial directions, while the outboard end is con- nected via a bell joint (BJ) to the wheel hub which is supported by a taper roller bearing located inside the axle housing.
Page 85 FRONT AXLE Drive Shaft System B: FRONT DRIVE SHAFT 2. STi MODEL A double offset joint (DOJ) is used on the differential side of each front drive shaft. The DOJ can be disassembled for maintenance. It provides a maximum operating angle of 25° and can be moved in the axial directions.
Page 86 REAR AXLE Drive Shaft System 3. Rear Axle C: AWD TURBO MODELS 2. STi MODEL The inboard end of each axle shaft is connected to the transmission via a double offset joint (DOJ) which can extend and retract in the axial directions. The outboard end is supported by taper roller bearings located inside the axle housing via a bell joint (BJ) which features a large operating angle.
Page 87 REAR AXLE Drive Shaft System D: REAR DRIVE SHAFT 3. TURBO MODELS (STi MODEL) A double offset joint (DOJ) is used on the differential side of each rear drive shaft. The DOJ can be disassembled for maintenance. It provides a maximum operating angle of 23° and can be moved in the axial directions.
Page 88 Page 1. Anti-lock Brake System (ABS) ........... . .
Page 89 ANTI-LOCK BRAKE SYSTEM (ABS) 1. Anti-lock Brake System (ABS) A: FEATURE The 5.3i type ABS used in the Impreza has a hydraulic control unit, an ABS control module, a valve relay and a motor relay integrated into a single unit (called “ABSCM & H/U”) for circuit sim- plicity and reduced weight.
Page 90 (ABSCM & H/U) (2) Diagnosis connector (6) G sensor (10) ABS sensor (3) Data link connector (7) Lateral G sensor (Only STi model) (11) Brake switch (for SUBARU select monitor) (4) ABS warning light (8) Tone wheel (12) Master cylinder ABS-3...
Page 91 D Whenever the ignition switch is placed at ON, the module performs a self diagnosis sequence. If anything wrong is detected, the module cuts off the system. D It communicates with the SUBARU select monitor. D When the ABS is active, the H/U changes fluid passages to the wheel cylin- H/U section ders in response to commands from the ABSCM.
Page 92 ANTI-LOCK BRAKE SYSTEM (ABS) NF0587 (1) ABS control module and hydraulic (11) Rear left outlet solenoid valve (21) Lateral G sensor (Only STi model) control unit (2) ABS control module section (12) Rear right inlet solenoid valve (22) Front left ABS sensor (3) Valve relay (13) Rear right outlet solenoid valve (23) Front right ABS sensor...
Page 93 ANTI-LOCK BRAKE SYSTEM (ABS) J: LATERAL G SENSOR (STi MODEL) The lateral G sensor senses variation in the lateral acceleration while the vehicle is making a turn. Its construction and operation are the same as those of the conventional G sensor, which converts changes in the piezoresistivity into changes in the output voltage to the ABSCM.
Page 94 BRAKES Page 1. Front and Rear Disc Brakes ............2.
Page 95 FRONT AND REAR DISC BRAKES Brakes 1. Front and Rear Disc Brakes C: STi MODEL The brakes of the STi model use Brembo’s 17-inch calipers and ventilated disc rotors that pro- vide improved braking performance. The brake calipers for the front brakes are of a four-pod-piston type, while those for the rear brakes are of a two-pod-piston type.
Page 96 INSTRUMENTATION/DRIVER INFO Page 1. Combination Meter ..............2.
Page 97 COMBINATION METER Instrumentation/Driver Info 1. Combination Meter A: WARNING AND INDICATOR LIGHTS 2. STi MODEL NF0592 (1) CHECK ENGINE warning light This light illuminates when a fault occurs in the MFI (Multiple point Fuel Injection) system. (2) Brake fluid level warning / parking brake indicator light This light illuminates when the fluid level in the brake reservoir tank lowers below the specified level and/or when the parking brake is applied.
Page 98 COMBINATION METER Instrumentation/Driver Info If everything is normal, the warning and indicator lights should be ON or OFF as shown below ac- cording to ignition switch positions. Warning/Indicator light Ignition switch position LOCK/ACC While engine is running (1) CHECK ENGINE (2) Brake fluid level / parking brake (3) AIRBAG (4) ABS...
Page 99 COMBINATION METER Instrumentation/Driver Info B: TELLTALE (GRAPHIC MONITOR) 2. STi MODEL NF0593 (1) Turn signal indicator light This light blinks in unison with the corresponding turn signal lights when the turn signal switch is operated. (2) REV indicator light This light illuminates when a preset engine speed is exceeded. (3) Seat belt warning light This light stays illuminated for about 6 seconds after the ignition switch has been turned ON if the driver’s seat belt is not fastened.
Page 100 COMBINATION METER Instrumentation/Driver Info If everything is normal, the telltales should be ON, OFF or in other states as shown below according to ignition switch positions. Telltale light Ignition switch position LOCK/ACC While engine is running (1) Turn signal Blink Blink Blink (2) REV...
Page 101 COMBINATION METER Instrumentation/Driver Info E: TACHOMETER 2. REV INDICATOR LIGHT The REV indicator light operates together with a buzzer when the engine starts operating at a speed exceeding the speed the driver has set as desired, giving him or her a warning. The light remains illuminated as long as the engine speed is above the set speed.
Page 102 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 104 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 106 SPECIFICATIONS Page Impreza .......................2...
Page 107 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 108 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 109 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 110 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 111 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 112 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 113 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 114 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 115 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 116 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 117 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 118 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 119 IMPREZA SPECIFICATIONS SPC-14...
Page 120 IDENTIFICATION Page Identification ....................2...
Page 121 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 122 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 123 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 124 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 125 IDENTIFICATION IDENTIFICATION ID-6...
Page 126 (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 128 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 129 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 130 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 131 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 132 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 133 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 134 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 135 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 136 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 137 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 138 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 139 INTERCOOLER WATER TANK INTAKE (INDUCTION) IN(TURBO)-4...
Page 140 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 141 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 142 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 143 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 144 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 145: 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 146 GENERAL DESCRIPTION MECHANICAL ME(STi)-7...
Page 147 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 148 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 149 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 150 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 151 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 152 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 153 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 154 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 155 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 156 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 157 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 158 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 159 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 160 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 161 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 162 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 163 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 164 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 165 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 166 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 167 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 168 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 169 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 170 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 171 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 172 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 173 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 174 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 175 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 176 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 177 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 178 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 179 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 180 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 181 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 182 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 183 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 184 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 185: Belt Cover 5. Camshaft
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 186 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 187 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 188 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 189 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 190 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 191 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 192 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 193 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 194 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 195 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 196 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 197 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 198 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 199 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 200 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 201 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 202 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 203 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 204 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 205 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 206 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 207: Cylinder Head
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 208 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 209 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 210 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 211 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 212: Cylinder Block
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 213 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 214 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 215 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 216 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 217 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 218 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 219 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 220 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 221 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 222 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 223 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 224 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 225: Piston
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 226 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 227 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 228 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 229 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 230 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 231 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 232 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 233 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 234 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 235 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 236 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 237 ENGINE NOISE MECHANICAL ME(STi)-98...
Page 238 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 239 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 240 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN0718 B3M1575A EN0716 EN1425 EN(TURBO)-3...
Page 241 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 242 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN1009 EN1008 EN1010 EN1011 EN1012 EN1013 EN1014 EN1015 EN1525 EN(TURBO)-5...
Page 243 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 244 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN1016 EN1017 EN0949 EN1018 EN0950 EN(TURBO)-7...
Page 245 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) LHD model EN1019 RHD model EN1020 Fuel level sensor Fuel sub level sensor EN1036 EN1037 EN(TURBO)-8...
Page 246 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN(TURBO)-9...
Page 247 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 248 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) EN1021 EN1022 EN1023 EN1024 EN0952 EN1527 EN(TURBO)-11...
Page 249 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 250 ELECTRICAL COMPONENTS LOCATION ENGINE (DIAGNOSTICS) LHD model EN0953 EN1027 RHD model EN1028 EN1029 EN0954 EN1030 EN(TURBO)-13...
Page 251 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 252: Engine Mounting
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 253 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 254 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 255 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 256: Variable Valve Timing System
Subaru Select • Engine oil sage. Monitor and OBD-II general scan tool. (amount, con- Replace the...
Page 257 Subaru Select • Engine oil sage. Monitor and OBD-II general scan tool. (amount, con- Replace the...
Page 258 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(TURBO)-21...
Page 259 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 260 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 261 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 262 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(TURBO)-25...
Page 263 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 264 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 265 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 266 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(TURBO)-29...
Page 267 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 268 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 269 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 270 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 271 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 272 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 273 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 274 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 275 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) ENGINE (DIAGNOSTICS) EN(TURBO)-38...
Page 276 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 278 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 279 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 280: General Description
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 281 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 282 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 283 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 284 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 285 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 286 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 287 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 288 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 289 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 290 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 291 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 292 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 293 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 294 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 295 REVERSE CHECK CABLE CONTROL SYSTEMS CS-18...
Page 296: Center Differential
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 297 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 298 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 299 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 300 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 301: Oil Pump
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 302 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 303 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 304 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 305 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 306 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 307 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 308 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 309: Transmission Mounting
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 310 • 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 311 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 312 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 313 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 314 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 315 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 316 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 317 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 318 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 319 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 320 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 321 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 322 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 323 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 324 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 325 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 326 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 327 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 328: Propeller Shaft
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 329 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 330 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 331 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 332 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 333 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 334 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 335 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 336 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 337 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 338 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 339 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 340 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 341 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 342 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 343 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 344 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 345 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 346 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 347 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 348 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 349 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 350 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 351 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 352 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 353 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 354 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 355 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 356 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 357 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 358 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 359 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 360 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 361 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 362 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 363 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 364 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 365 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 366 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 367 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 368 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 369 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 370 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 371 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 372 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 373 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 374 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 375 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 376 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 377 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 378 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 379 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 380 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 381 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 382 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 383 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 384 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 385 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 386 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 387 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 388 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 389 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 390 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 391 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 392 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 393 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 394 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 395 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 396 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 397 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 398 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 399 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 400 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 401 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 402 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 403 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 404 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 405 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 406 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 407 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 408 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 409 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 410 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 411 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 412 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 413 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 414 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 415 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 416 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 417 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 418 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 419 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 420 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 421 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 422 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 423 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 424 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 425 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 426 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 427 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 428 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 429 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 430 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 431 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 432 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 433 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 434 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 435 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 436 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 438 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 439 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 440 REAR SUSPENSION Page General Description Wheel Alignment Rear Stabilizer Rear Trailing Link Rear Strut....................2 Lateral link Rear Crossmember General Diagnostic Table...
Page 441 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 442 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 443 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 444 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 445 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 446 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 447 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 448 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 449 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 450 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 451 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 452 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 453 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 454 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 455 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 456 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 457 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 458 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 459 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 460 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 461 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 462 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 463 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 464 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 465 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 466 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 467 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 468 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 469 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 470 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 471 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 472 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 473 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 474 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 475 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 476 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 477 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 478 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 479 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 480 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 481 EXTENSION CASE FOR 6MT TRANSFER CASE TC-8...
Page 482: Front Axle
DRIVE SHAFT SYSTEM Page General Description ..................2 Propeller Shaft Front Axle Rear Axle Front Drive Shaft ..................9 Rear Drive Shaft General Diagnostic Table...
Page 483 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 484 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 485 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 486 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 487 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 488 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 489: Rear Axle
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 490 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 491 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM DS-10...
Page 492 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 493 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 494 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 495 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 496 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 497 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 498 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 499 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 500 ELECTRICAL COMPONENTS LOCATION ABS (DIAGNOSTICS) (13) BR0120 B4M1226B (14) (10) BR0154 B4M0231E BR0033 BR0057 ( 7 ) ( 8 ) BR0058 ABS-3...
Page 501 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 502 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 503 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 504 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 505 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 506 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 507 <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 508 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 509 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 510 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 511 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 512 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 513 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 514 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 515 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 516 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 517 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 518 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 519 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 520 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 521 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 522 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 523 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 524 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 525 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 526 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 527 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 528 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 529 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 530 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 531 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 532 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 533 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS (DIAGNOSTICS) ABS-36...
Page 534 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 535 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 536 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 537 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 538 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 539 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 540 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 541 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 542 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 543 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 544 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 545 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 546 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 547 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 548 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 549 REAR DISC BRAKE ASSEMBLY BRAKE BR-16...
Page 550 PARKING BRAKE Page General Description ..................2 Parking Brake Lever Parking Brake Cable Parking Brake Assembly (Rear Disc Brake) General Diagnostic Table...
Page 551 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 552 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 554 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 555 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 556 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 557 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 558 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 559 CLEARANCE/PARKING LIGHT BULB LIGHTING SYSTEM LI-6...
Page 560 INSTRUMENTATION/DRIVER INFO Page General Description ..................2 Combination Meter System Combination Meter Assembly ..............3 Speedometer Tachometer Fuel Gauge Water Temperature Gauge Ambient Sensor...
Page 561 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 562 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 563 COMBINATION METER ASSEMBLY INSTRUMENTATION/DRIVER INFO IDI-4...
Page 564 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 565 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 566 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 567 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 568 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 569 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 570 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 572 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 573 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 574 POWER SUPPLY ROUTING WIRING SYSTEM 4. Power Supply Routing A: SCHEMATIC WI-3...
Page 575 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 576 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 577 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 578 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 579 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 580 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 581 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 582 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 583 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 584 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 585 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 586 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 587 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 588 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 589 GROUND DISTRIBUTION WIRING SYSTEM 5. Ground Distribution A: SCHEMATIC WI-18...
Page 590 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 591 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 592 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 593 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 594 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 595 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 596 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 597 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 598 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 599 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 600 AIR CONDITIONING SYSTEM WIRING SYSTEM 7. Air Conditioning System A: SCHEMATIC WI-29...
Page 601 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 602 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 603 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 604 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 605 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 606 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 607 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 608 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 609 ANTI-LOCK BRAKE SYSTEM WIRING SYSTEM 8. Anti-lock Brake System A: SCHEMATIC WI-38...
Page 610 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 611 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 612 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 613 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 614 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 615 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 616 COMBINATION METER WIRING SYSTEM 12.Combination Meter A: SCHEMATIC To C: (GREEN) To B: (GREEN) To A: (GREEN) GG64-22A WI-45...
Page 617 COMBINATION METER WIRING SYSTEM METER-03 METER-04 GG64-22B WI-46...
Page 618 COMBINATION METER WIRING SYSTEM METER-02 METER-04 METER-04 METER-04 GG64-22C WI-47...
Page 619 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 620 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 621 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 622 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 623 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM 16.Engine Electrical System A: SCHEMATIC WI-52...
Page 624 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 625 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 626 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 627 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 628 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 629 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 630 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 631 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 632 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 633 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 634 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 635 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 636 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 637 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 638 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 639 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 640 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 641 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 642 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 643 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 644 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 645 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 646 HEADLIGHT BEAM LEVELER SYSTEM WIRING SYSTEM 20.Headlight Beam Leveler System A: SCHEMATIC WI-75...
Page 647 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 648 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM 25.Clearance Light and Illumination Light System A: SCHEMATIC WI-77...
Page 649 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 650 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 651 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 652 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 653 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 654 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 655 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 656 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 657 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 658 HEADLIGHT SYSTEM WIRING SYSTEM 27.Headlight System A: SCHEMATIC WI-87...
Page 659 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 660 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 661 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 662 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 663 FRONT WIRING HARNESS WIRING SYSTEM GB-1 GB-2 BO0487 WI-92...
Page 664 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 665 FRONT WIRING HARNESS WIRING SYSTEM Connector Connecting to Pole Color Area Name Black Headlight RH (4-Lights Hi) #: Non-colored WI-94...
Page 666 FRONT WIRING HARNESS WIRING SYSTEM GB-1 GB-2 BO0488 WI-95...
Page 667 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 668 BULKHEAD WIRING HARNESS (IN ENGINE ROOM) WIRING SYSTEM B305 B279 B301 B303 B127 B128 B302 B306 BO0470 WI-97...
Page 669 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 670 BULKHEAD WIRING HARNESS (IN ENGINE ROOM) WIRING SYSTEM B279 B127 B148 B143 B144 B186 B147 B146 B128 B145 B255 BO0478 WI-99...
Page 671 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 672 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 673 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 674 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 675 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 676 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 677 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 678 ENGINE WIRING HARNESS AND TRANSMISSION CORD WIRING SYSTEM MT-STI MT-EXCEPT STI BO0484 WI-107...
Page 679 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 680 REAR WIRING HARNESS AND TRUNK LID CORD WIRING SYSTEM R145 R130 R145 R122 BO0485 WI-109...
Page 681 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...
Page 682 2002 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G1840GE1) ENGINE 1 SECTION (Pub.No.G1840GE2) ENGINE 2 SECTION (Pub.No.G1840GE3) TRANSMISSION SECTION (Pub.No.G1840GE4) CHASSIS SECTION (Pub.No.G1840GE5) BODY SECTION (Pub.No.G1840GE6) WIRING SYSTEM SECTION (Pub.No.G1840GE7)
Page 684 SECTION FOREWORD HOW TO USE THIS MANUALS SPECIFICATIONS PRECAUTION This service manual has been prepared to provide SUBARU service personnel NOTE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. IDENTIFICATION This manual includes the procedures...
Page 686 FOREWORD Page Foreword .....................2...
Page 687 FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair, or diagnosis of the Subaru IMPRE- Applied model: GG***** and GD***** from 2002MY. The additional manuals below are also available: AUTOMATIC TRANSMISSION SERVICE MANU- AL (Pub. No. G0864ZE) The manuals contain the latest information at the time of publication.
Page 688: How To Use This Manuals
HOW TO USE THIS MANUALS Page How to Use This Manuals ................2...
Page 689 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 1. How to Use This Manuals A: HOW TO USE THIS MANUALS 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com- ponent.
Page 690 SPECIFICATIONS Page Impreza SA08731 ..................2...
Page 691 IMPREZA SPECIFICATIONS 1. Impreza SA08731 A: DIMENSIONS SA08731G28 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) Overall height (at C.W.) mm (in) 1,465 (57.7), 1,475 (58.1), 1,440 (56.7) 1,485 (58.5)#4 1,495 (58.9)#4 Compartment...
Page 692 IMPREZA SPECIFICATIONS C: ELECTRICAL SA08731G30 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 idling speed AT: 15°±10°/700 Spark Type and Without NGK: BKR6E NGK: BKR6E NGK: BKR6E (without plug manufacturer (without catalyst)
Page 693 IMPREZA SPECIFICATIONS E: STEERING SA08731G32 Model Turbo 2.0 L, 2.5 L OUTBACK OTHERS Type Rack and Pinion Turns, lock to lock RHD: 2.7 LHD: 3.0 Minimum turning circle m (ft) Curb to curb 11.0 (36.1) 10.8 (35.4) 10.4 (34.1) Wall to wall 12.0 (39.4) 11.6 (38.1) 11.2 (36.7)
Page 694 IMPREZA SPECIFICATIONS J: WEIGHT SA08731G37 1. LHD VEHICLE SA08731G3703 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...
Page 695 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) Rear kgf (lb) 535 (1,179) 530 (1,168) 550 (1,213) Total kgf (lb) 1,295 (2,855) 1,315 (2,899) 1,365 (3,009) Maximum permissible Front kgf (lb)
Page 696 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 697 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 698 IMPREZA SPECIFICATIONS 2. RHD VEHICLE SA08731G3704 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)
Page 699 IMPREZA SPECIFICATIONS Option code#1 Model 2.0 L 2.5 L 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,653) (1,709) (1,720) (1,775) (1,830) (1,885) (1,830) Rear kgf (lb) (1,179) (1,168) (1,191) (1,179) (1,235) (1,224) (1,235) Total kgf (lb) 1,285 1,305 1,320 1,340 1,390...
Page 700 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 701 IMPREZA SPECIFICATIONS Option code#1 Model 2.0 L OUT BACK Curb weight (C.W.) Front kgf (lb) 760 (1,676) 775 (1,709) 750 (1,653) 765 (1,687) Rear kgf (lb) 570 (1,257) 565 (1,246) 570 (1,257) 570 (1,257) Total kgf (lb) 1,330 (2,932) 1,340 (2,954) 1,320 (2,910) 1,335 (2,943) Maximum permissible...
Page 702 PRECAUTION Page Precaution ....................2...
Page 703 PRECAUTION PRECAUTION 1. Precaution 7. AIRBAG MODULE Adhere to the following when handing and storing A: PRECAUTION the airbag module to prevent bodily injury from un- Please clearly understand and adhere to the follow- expected deployment: ing general precautions. They must be strictly fol- •...
Page 704 NOTE Page Note......................2...
Page 705 ECM from rush current. 4. SERVICE PARTS Use authentic service parts for maximum perfor- mance and maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor perfor- mance resulting from the use of parts not specified by a genuine dealer. NT-2...
Page 706 NOTE NOTE 5. LIFTS AND JACKS When using a lift or jack-ridged rack to raise a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make sure the vehicle is balanced before raising it.
Page 707 NOTE NOTE Front Front crossmember Rear Rear differential GI0121 NT-4...
Page 708 NOTE NOTE 6. TIE DOWNS Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only to the specified points on the vehicle. Hook for tie-down Hook for towing Hook for towing Hook for tie-down and tie-down GI0122 NT-5...
Page 709 NOTE NOTE GI0103 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 45˚ 45˚ 45˚ 45˚ : Tie-down range GI0123 7. TOWING Avoid towing vehicles except when the vehicle can- not be driven. For vehicles with AWD, AT, or VTD, use a loader instead of towing. When towing other vehicles, to prevent excessive weight from damag- ing the hook or vehicle: •...
Page 710 For information about training, contact a dealer or Using general scan tools will greatly improve effi- agent. ciency of repairing engine electronic controls. The Subaru Select Monitor can be used to diagnose the engine and also the ABS, the air conditioner, and other parts. NT-7...
Page 711 NOTE NOTE NT-8...
Page 712 IDENTIFICATION Page Identification ....................2...
Page 713 IDENTIFICATION IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The VIN (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification Emisson control label Vacuum hose piping label ID plate (Europe model) ADR compliance plate (Australia model) Tire inflation pressure label...
Page 714 IDENTIFICATION IDENTIFICATION GI0010A GI0011A ID-3...
Page 715 IDENTIFICATION IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the VIN is as follows: • Europe, Australia and General (Except GCC) ]JF1GD5LJ31G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passenger car, FHI made Car line IMPREZA...
Page 716 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. GD9AL7R Digits Code...
Page 717 IDENTIFICATION IDENTIFICATION • Transmission TV1B4VYAAA 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: MT 1B: AT Series 4: 5MT 4: AT Transmission specifica-...
Page 718 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-7...
Page 719 IDENTIFICATION IDENTIFICATION ID-8...
Page 720 RECOMMENDED MATERIALS Page Recommended Materials ................2...
Page 721 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 1. Recommended Materials A: RECOMMENDED MATERIALS 1. GENERAL To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or that of equivalent quality. 2. FUEL Always use a gasoline of the same or higher octane value than specified in the owner's manual.
Page 722 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 3. LUBRICANTS Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct SAE viscosity. Lubricant Recommended Alternative API Spec. CCMC Spec. ACEA Spec. Engine oil SL or SJ Grade “Energy conserving” G4 or G5 A1, A2 or A3 API: SH or SG...
Page 723 — 5. COOLANT Use genuine coolant to protect the engine. The table below shows the ratio of coolant to distilled water. Coolant Recommended Item number Alternative Coolant SUBARU coolant 000016218 None Water for dilution Distilled water — Tap water RM-4...
Page 724 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 6. REFRIGERANT Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any air compressor oil except for DH-PR. Air conditioner Recommended Item number Alternative Refrigerant HFC134a —...
Page 725 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 9. SEAL MATERIAL Use seal material shown in the table below, or equivalent. Seal material Application point Recommended Item number Alternative Seal material • Engine case Three Bond 1215 004403007 Dow Corning’s No. 7038 • Torque converter clutch case Transmission Three Bond 1217B...
Page 726 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
Page 727 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. Pre-delivery Inspection A: GENERAL The purposes of the pre-delivery inspection (PDI) are as follows. • Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state. •...
Page 728 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION B: PDI PROCEDURE Follow the procedures shown in the table below. Static Checks Just After Vehicle Receipt Step Check point 1. Appearance check (1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents.
Page 729 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION Checks with the Engine Running Step Check point 24. Read memory and test mode connectors (1) Read memory and test mode connectors 25. Starting condition (2) Start the engine and check that the engine starts smoothly. 26.
Page 730 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER HARNESS • If the vehicle is covered with protective coating, visually check the vehicle body for damage and A vehicle just delivered has its air conditioner har- dents. ness disconnected to protect the air conditioner •...
Page 731 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 5. CHECK THE DOORS FOR LOCK/UN- 6. CHECK THE TRUNK LID FOR OPEN/ LOCK AND OPEN/CLOSE OPERATIONS. CLOSE OPERATIONS. Using the key, lock and unlock the door several • Operate the trunk lock release lever and verify times to check for normal operation.
Page 732 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 9. ACCESSORY CHECK 10.OPERATION CHECK OF HOOD LOCK RELEASE SYSTEM Check that the following accessories are provided in the luggage compartment or cargo area. Operate the hood release knob (A) and check that • Owner's manual the hood is unlocked normally.
Page 733 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 11.BATTERY 15.AT FRONT DIFFERENTIAL OIL Check the battery terminals to make sure that no Check the AT front differential oil amount. If the rust or corrosions due to fluid leaks are found. amount is insufficient, check that no leaks are Check that the battery caps are securely tightened.
Page 734 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 20.KEYLESS ENTRY SYSTEM 24.READ MEMORY AND TEST MODE CON- NECTORS Check the keyless entry system operations as fol- lows. Turn the ignition switch to ON and check that the • Remove the key from the ignition switch and check-engine light starts blinking.
Page 735 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 30.CIGARETTE LIGHTER 36.PARKING BRAKE Check the cigarette lighter operations. Check the parking brake for normal operations. 31.LIGHTING SYSTEM 37.AT SHIFT CONTROL • Check the headlight operations. Set the AT select lever to each gear position while checking that the demanded gear position is cor- •...
Page 736 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 42.POWER STEERING FLUID LEVEL 44.WATER LEAK TEST Check that the power steering fluid level is normal. Spray the vehicle with water and check that no wa- If insufficient, check that no leaks are found. Then ter enters the passenger compartment. add the necessary amount of the specified power •...
Page 737 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PI-12...
Page 738 PERIODIC MAINTENANCE SERVICES Page General Description ..................2 Schedule .....................3 Engine Oil....................6 Engine Oil Filter...................8 Spark Plugs....................9 Drive Belt(s) ....................10 Camshaft Drive Belt ..................12 Fuel Line ....................15 Fuel Filter ....................16 Air Cleaner Element ..................17 Cooling System ..................18 Coolant......................19 Idle Mixture....................21 Clutch System ...................22 Hill-holder System ..................24 Transmission Oil ..................25 ATF ......................26...
Page 739 GENERAL DESCRIPTION PERIODIC MAINTENANCE SERVICES 1. General Description A: GENERAL Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious. PM-2...
Page 740 SCHEDULE PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. MAINTENANCE SCHEDULE 1 – (1) For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 50,000 km (30,000 miles) or 48 months.
Page 741 SCHEDULE PERIODIC MAINTENANCE SERVICES Maintenance Interval [Number of months or km (miles), whichever occurs first] Months Remarks × 1,000 km × 1,000 miles Axle boots & joints Steering system (Power steering) Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation. NOTE: (1) Periodic inspection and replacement of the camshaft drive chains on the 3.0 liter models are not required.
Page 742 SCHEDULE PERIODIC MAINTENANCE SERVICES B: MAINTENANCE SCHEDULE 2 Item Every Repeat short Repeat Extremely Salt or other High humid- Repeat tow- distance drive rough/muddy cold weather corrosive ity or moun- ing trailer road drive area used or tain area coastal area Engine oil Replace Replace...
Page 743 API classification 3) Replace the drain plug gasket. and SAE viscosity No. designated by SUBARU. 4) Tighten the engine oil drain plug after draining • If vehicle is used in desert areas with very high engine oil.
Page 744 ENGINE OIL PERIODIC MAINTENANCE SERVICES B: INSPECTION 1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation.
Page 745 ENGINE OIL FILTER PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter A: REPLACEMENT 1) Remove the oil filter with ST. ST 498547000 OIL FILTER WRENCH GI0012A 2) Get a new oil filter and apply a thin coat of engine oil to the seal rubber. 3) Install the oil filter by turning it by hand, being careful not to damage the seal rubber.
Page 746 SPARK PLUGS PERIODIC MAINTENANCE SERVICES 5. Spark Plugs A: REPLACEMENT 1) Remove the intake duct and intake chamber. 2) Remove the washer tank and put it aside. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a plug-wrench. GI0018A 5) Set the new spark plug.
Page 747 DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 6. Drive Belt(s) B: REPLACEMENT A: INSPECTION 1. V-BELT COVER 1) Replace the belts, if cracks, fraying or wear is 1) Remove the V-belt cover. found. 2) Check the drive belt tension and adjust it if nec- essary by changing the generator installing position and/or idler pulley installing position.
Page 748 DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 3. REAR SIDE BELT (DRIVING AIR CONDI- TIONER) NOTE: • Wipe off any oil or water on the belt and pulley. • Before removing the rear side belt, remove the front side belt. 1) Loosen the lock nut (A). 2) Loosen the slider bolt (B).
Page 749 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 7. Camshaft Drive Belt 10) Turn the crankshaft and align alignment marks on crankshaft, and right and left camshaft sprock- A: REPLACEMENT ets with notches of belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET 1.
Page 750 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 2. DOHC MODEL 10) Turn the crankshaft and align alignment marks on crankshaft, and right and left camshaft sprock- 1) Remove the radiator fan and air conditioner fan. ets with notches of belt cover and cylinder block. To turn the crankshaft, use ST.
Page 751 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES B: INSTALLATION C: INSPECTION 1. SOHC MODEL 1. SOHC MODEL Install in the reverse order of removal. <Ref. to ME- 1) Remove the belt covers (RH) and (LH). 49, Timing Belt Assembly.> 2) While cranking the engine at least four rotations, check the timing belt back surface for cracks or 2.
Page 752 FUEL LINE PERIODIC MAINTENANCE SERVICES 8. Fuel Line A: INSPECTION The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose bands, etc. If faulty parts are found, repair or replace them. <Ref. to FU-71, Fuel Delivery, Return and Evaporation Lines.>...
Page 753 FUEL FILTER PERIODIC MAINTENANCE SERVICES 9. Fuel Filter A: REPLACEMENT For fuel filter replacement procedures, refer to “FU” section. <Ref. to FU-68, Fuel Filter.> or <Ref. to FU(w/ oOBD)-65, Fuel Filter.> or <Ref. to FU(TURBO)- 65, Fuel Filter.> PM-16...
Page 754 AIR CLEANER ELEMENT PERIODIC MAINTENANCE SERVICES 10.Air Cleaner Element 2. TURBO MODEL A: REPLACEMENT NOTE: Do not attempt to clean the air cleaner element. The filter paper of the element is wetted with a spe- cial non-inflammable slow-evaporating viscous liq- uid.
Page 755 COOLING SYSTEM PERIODIC MAINTENANCE SERVICES 11.Cooling System 2) Check the radiator cap valve open pressure us- ing radiator cap tester. A: INSPECTION NOTE: 1) Check the radiator for leakage, filling it with cool- Rust or dirt on the cap may prevent the valve from ant and attach the radiator cap tester to filler neck.
Page 756 Approx. 7.0 2 (7.4 US qt, 6.2 Imp qt) NOTE: The SUBARU Genuine Coolant containing anti- freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crank- EN0073 case. Always use SUBARU Genuine Coolant, 5) For quick draining, open the radiator cap.
Page 757 The concentration and safe operating temperature tion in the above diagram and replace the of the SUBARU coolant is shown in the diagram. necessary amount of coolant with an undiluted so- Measuring the temperature and specific gravity of lution of SUBARU genuine coolant (concentration the coolant will provide this information.
Page 758 IDLE MIXTURE PERIODIC MAINTENANCE SERVICES 13.Idle Mixture A: INSPECTION AND ADJUSTMENT 1. IDLE MIXTURE Before measuring the idle mixture, make sure that the ignition timing and the engine idle speed are within specifications. 1) Set the gear position at “Neutral” for MT, or “N” or “P”...
Page 759: Clutch System
CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 14.Clutch System 2) Pedal-to-floor plate gap in disengaged position. (1) With the engine idling, pull the parking brake A: INSPECTION AND ADJUSTMENT lever completely. (2) Slowly depress the clutch pedal while mov- 1. MECHANICAL CLUTCH TYPE ing shift lever into reverse.
Page 760 CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 5) Check the fluid level using the scale on the out- side of the clutch master cylinder tank (A). If the lev- el is below “MIN” (B), add clutch fluid to bring it up to “MAX” (C). Recommended clutch fluid: FMVSS No.
Page 761 HILL-HOLDER SYSTEM PERIODIC MAINTENANCE SERVICES 15.Hill-holder System A: INSPECTION AND ADJUSTMENT 1) Confirm the stopping and starting performance by activating the hill-holder on an uphill road of 3° or higher inclination. (1) When the vehicle does not stop; Tighten the adjusting nut of PHV cable. (2) When the vehicle does not start properly;...
Page 762 TRANSMISSION OIL PERIODIC MAINTENANCE SERVICES 16.Transmission Oil A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain the gear oil by removing drain plug after al- lowing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well. GI0041 2) Reinstall the drain plug after draining gear oil and tighten it to the specified torque.
Page 763 PERIODIC MAINTENANCE SERVICES 17.ATF 4) Fluid temperature rising speed • By idling the engine A: INSPECTION Time for temperature rise to 70°C (158°F) with at- 1) Raise the ATF temperature to 70 to 80°C (158 to mospheric temperature of 0°C (32°F): More than 176°F) from 20 to 30°C (68 to 86°F) (when cold) by 25 minutes driving a distance of 5 to 10 km (3 to 6 miles).
Page 764 PERIODIC MAINTENANCE SERVICES B: REPLACEMENT 2. ATF FILTER NOTE: 1. AUTOMATIC TRANSMISSION FLUID ATF filter is a maintenance free part. ATF filter 1) Drain the ATF (Automatic Transmission Fluid) needs replacement, when it has physically dam- by removing drain plug after allowing the engine to aged or ATF leaked.
Page 765 FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 18.Front & Rear Differential Oil 3. REAR DIFFERENTIAL 1) Drain the oil by removing drain plug. A: REPLACEMENT 2) Remove the filler plug for quick draining oil. 1. FRONT DIFFERENTIAL (MANUAL 3) Reinstall the drain plug after draining oil. TRANSMISSION) NOTE: •...
Page 766 FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 5) Install the filler plug onto rear differential gear case firmly. NOTE: • Apply fluid packing to the filler plug before instal- lation in Except Non-turbo AT model. • Non-turbo AT model uses a new aluminum gas- ket.
Page 767 BRAKE LINE PERIODIC MAINTENANCE SERVICES 19.Brake Line B: CHECKING A: INSPECTION 1. SERVICE BRAKE 1) Check the free play of brake pedal with a force of 1. BRAKE LINE less than 10 N (1 kgf, 2 lb). 1) Check scratches, swelling, corrosion and/or Brake pedal free play: traces of fluid leakage on the brake hoses or pipe 1 —...
Page 768 BRAKE LINE PERIODIC MAINTENANCE SERVICES 3) Check the pedal stroke. 4) Check valve is built into the vacuum hose. Dis- connect the vacuum hose to inspect function of While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 lb) load and measure the check valve.
Page 769 BRAKE FLUID PERIODIC MAINTENANCE SERVICES 20.Brake Fluid NOTE: • Cover the bleeder with waste cloth, when loosen- A: REPLACEMENT ing it, to prevent brake fluid from being splashed 1) Either jack-up the vehicle and place a safety over surrounding parts. stand under it, or lift-up the vehicle.
Page 770 DISC BRAKE PADS AND DISCS PERIODIC MAINTENANCE SERVICES 21.Disc Brake Pads and Discs 3) Check the disc rotor, and correct or replace if it is damaged or worn. A: INSPECTION • Non-turbo MODEL 1. DISC BRAKE PAD AND DISC Brake disc thickness mm (in) Front Rear...
Page 771 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 22.Brake Linings and Drums 3) Check the brake drum for wear, dents or other damage. A: INSPECTION If the inside surface of brake drum is streaked, cor- rect the surface with emery cloth (#200 or more). If 1.
Page 772 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 2) Check the brake drum for wear, dents or other B: ADJUSTMENT damage. If the inside surface of brake drum is 1. REAR DRUM BRAKE streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn, tapered, or The main brake is adjusted automatically, and so the outside surface of brake drum is damaged, cor- there is no need to adjust it.
Page 773 SUSPENSION PERIODIC MAINTENANCE SERVICES 23.Suspension 5) Damage of dust seal Visually inspect the ball joint dust seal. If it is dam- A: INSPECTION aged, remove the transverse link. <Ref. to FS-16, Front Transverse Link.> And measure free play of 1. SUSPENSION BALL JOINT ball joint.
Page 774 SUSPENSION PERIODIC MAINTENANCE SERVICES 3. WHEEL ARCH HEIGHT 5. WHEEL ALIGNMENT OF REAR SUS- PENSION 1) Unload cargoes and set the vehicle in curb weight (empty) condition. 1) Check the alignment of rear suspension to en- 2) Then, check the wheel arch height of front and sure that following items are within standard val- rear suspensions to ensure that they are within ues.
Page 775 SUSPENSION PERIODIC MAINTENANCE SERVICES 8. DAMAGE TO SUSPENSION PARTS 1) Check the following parts and the fastening por- tion of the vehicle body for deformation or exces- sive rusting which impairs the suspension. If necessary, replace the damaged parts with new ones.
Page 776 WHEEL BEARING PERIODIC MAINTENANCE SERVICES 24.Wheel Bearing 6) While supporting the rear drive shaft horizontally with one hand, turn the hub COMPL with the other A: INSPECTION to check for noise or binding. If the hub COMPL is noisy or binds, disassemble 1.
Page 777 AXLE BOOTS & JOINTS PERIODIC MAINTENANCE SERVICES 25.Axle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS Inspect the front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, re- place them with new ones. <Ref. to DS-33, Front Drive Shaft.>...
Page 778 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 26.Steering System (Power 2. STEERING SHAFT JOINT Steering) 1) When the steering wheel free play is excessive, disconnect the universal joint of steering shaft and A: INSPECTION check it for any play and yawing torque (at the point of the crossing direction).
Page 779 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES (3) Apply liquid packing to at least 1/3 of entire 5. POWER STEERING FLUID LEVEL perimeter of adjusting screw thread. NOTE: The fluid level must be checked when the temper- ature of reservoir tank surface is approx. 20°C (68°F).
Page 780 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 7. HOSES OF OIL PUMP FOR DAMAGES Check the pressure hose and return hose of oil pump for crack, swell or damage. Replace the hose with a new one if necessary. NOTE: Prevent the hoses from revolving and/or turning when installing hoses.
Page 781 SUPPLEMENTAL RESTRAINT SYSTEM PERIODIC MAINTENANCE SERVICES 27.Supplemental Restraint System A: INSPECTION Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnostic Procedure.> 1) Ensure that airbag connectors are connected. If not, properly connect. When the ignition switch is turned ON with the connector(s) disconnected, the airbag warning light blinks to identify the fault.
Page 782 FUEL INJECTION (FUEL SYSTEMS) EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) MECHANICAL This service manual has been prepared to provide SUBARU service personnel EXHAUST with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. COOLING...
Page 784 FUEL INJECTION (FUEL SYSTEMS) Page General Description ..................2 Throttle Body.....................16 Intake Manifold..................17 Engine Coolant Temperature Sensor............31 Crankshaft Position Sensor...............32 Camshaft Position Sensor.................33 Knock Sensor....................34 Throttle Position Sensor................35 Intake Air Temperature and Pressure Sensor...........37 Atmospheric Pressure Sensor ..............38 Idle Air Control Solenoid Valve ..............39 Air Assist Injector Solenoid Valve .............40 Fuel Injector ....................41 Front Oxygen (A/F) Sensor ...............47...
Page 785 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS Model 1600 cc and 2000 cc 2500 cc 50 2 (13.2 US gal, 11.0 Imp gal) 60 2 (15.9 US gal, 13.2 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure...
Page 786 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) FU-3...
Page 787 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (25) (26) (21) (27) (14) (10) (21) (15) (17) (24) (11) (23) (22) (28) (16) (20) (19) (24) (12) (19) (13) (18) (20) (20) (19) EN1383 FU-4...
Page 788 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Intake manifold gasket RH (15) O-ring (28) Accelerator cable bracket Fuel injector pipe (16) Plug cord holder LH Fuel injector (17) Fuel pipe protector RH Tightening torque: N·m (kgf-m, ft-lb) O-ring (18) Fuel pipe ASSY T1: 1.5 (0.15, 1.1) O-ring (19)
Page 789 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM B2M3455C Gasket Throttle body Tightening torque: N·m (kgf-m, ft-lb) Throttle position sensor T1: 1.6 (0.16, 1.2) Idle air control solenoid valve T2: 22 (2.2, 16.2) FU-6...
Page 790 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS B2M2282B Crankshaft position sensor Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) Knock sensor Camshaft position sensor support T1: 6.4 (0.65, 4.7) T2: 24 (2.4, 17.4) FU-7...
Page 791 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK • 1600 CC and 2000 CC MODEL (25) (16) (10) (11) (11) (11) (14) (13) (24) (12) (24) (11) (11) (15) (11) (17) (19) (18) (20) (11) (21) (11) (22) (18) (19) (11) (23)
Page 792 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat shield cover (11) Clip (21) Fuel pipe ASSY Fuel tank band (12) Evaporation hose B (22) Evaporation hose F Protector RH (13) Joint pipe (23) Fuel return hose B Fuel tank (14) Evaporation hose C (24) Evaporation hose G Fuel pump gasket...
Page 793 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) • 2500 CC MODEL (30) (17) (10) (11) (12) (12) (12) (15) (14) (29) (29) (13) (12) (12) (28) (16) (12) (12) (18) (21) (20) (22) (19) (27) (12) (12) (26) (23) (12) (24) (20) (12) (25)
Page 794 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Heat shield cover (13) Evaporation hose B (25) Fuel return hose B Fuel tank band (14) Joint pipe (26) Fuel sub meter gasket Protector LH (15) Evaporation hose C (27) Jet pump filter Protector RH (16) Evaporation pipe ASSY (28)
Page 795 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE (19) (18) (17) (24) (20) (16) (25) (15) (24) (22) (13) (21) (23) (14) (12) (1) (1) (10) (10) (11) EN0440 FU-12...
Page 796 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A Fuel delivery hose A (12) Grommet (22) Connector Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B Fuel filter holder (14) Canister (24)
Page 797 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE (10) (11) EN0441 Fuel filler pipe ASSY Air vent pipe (11) Filler pipe protector Evaporation hose holder Air vent pipe holder Clip Filler pipe packing Tightening torque: N·m (kgf-m, ft-lb) Clamp Filler ring T: 7.5 (0.76, 5.53)
Page 798 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) C: CAUTION • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Wear working clothing, including a cap, protec- • Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.
Page 799 THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 6) Disconnect the air by-pass hose from air assist injector solenoid valve. A: REMOVAL 1) Disconnect the ground cable from battery. B2M3457A (A) Throttle position sensor G6M0095 (B) Idle air control solenoid valve 2) Remove the air cleaner case.
Page 800 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold (3) Remove the bolts which hold power steering pipes onto intake manifold protector. A: REMOVAL NOTE: 1) Release the fuel pressure. Do not disconnect the power steering hose. <Ref. to FU-54, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.>...
Page 801 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (7) Place the power steering pump and tank on 12) Remove the air cleaner case stay RH and en- right side wheel apron. gine harness bracket, and disconnect the engine harness connectors from bulkhead harness con- nectors.
Page 802 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Disconnect the connector from oil pressure 19) Remove the bolts which hold intake manifold switch. onto cylinder heads. B2M1253 B2M4128 17) Disconnect the connector from camshaft posi- 20) Remove the intake manifold. tion sensor. B2M0160 B2M4263 B: INSTALLATION...
Page 803 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 2) Connect the fuel hoses. 6) Connect the knock sensor connector. S2M0500F B2M4262 7) Connect the connectors to engine coolant tem- (A) Fuel delivery hose perature sensor. (B) Return hose (C) Evaporation hose 3) Connect the connector to camshaft position sen- sor.
Page 804 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 10) Connect the engine coolant hose to throttle (3) Tighten the bolts which install power steer- body. ing pump on bracket. Tightening torque: 22 N·m (2.2 kgf-m, 16.2 ft-lb) B2M4255 11) Connect the PCV hose to intake manifold. B2M3151 (4) Install the power steering pipes onto right side intake manifold protector.
Page 805 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 15) Connect the cruise control cable (B). (With C: DISASSEMBLY cruise control models) 1) Disconnect the engine ground cable from intake manifold. B2M4254A B2M4265 16) Install the air intake duct and air cleaner as- sembly.
Page 806 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 5) Remove the intake air temperature and pressure 10) Disconnect the air by-pass hoses from air as- sensor from intake manifold. sist solenoid valve. B2M3475 B2M4266 6) Disconnect the connectors from throttle position 11) Remove the air assist injector solenoid valve sensor and idle air control solenoid valve.
Page 807 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 14) Remove the fuel pipe protector RH. 20) Remove the purge control solenoid valve. B2M4130 B2M3487 15) Disconnect the connectors from fuel injectors. 21) Remove the bolt which installs injector pipe on intake manifold as shown in the figure. B2M4270 H2M2965 16) Disconnect the connector from purge control...
Page 808 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 24) Remove the fuel injectors. 27) Loosen the clamp which holds front right side fuel hose to injector pipe, and remove the pipe from (1) Remove the fuel injector securing clip. fuel hose. B2M3488 B2M4274 (2) Remove the fuel injector while lifting up the 28) Remove the fuel injector pipe.
Page 809 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) D: ASSEMBLY 5) Connect the left side fuel hose to injector pipe, and tighten the clamp screw. 1) Install the fuel pipe assembly and pressure reg- ulator, etc. to intake manifold. 2) Tighten the bolt which installs fuel pipes on in- take manifold.
Page 810 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 7) Install the fuel injectors. 9) Tighten the two bolts which install fuel pipes on the left side of intake manifold. NOTE: Always use new O-rings. Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) B2M3492G B2M4272 (A) O-ring...
Page 811 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 12) Connect the hoses to purge control solenoid 16) Install the fuel pipe protector RH. valve. Tightening torque: CAUTION: 19 N·m (1.9 kgf-m, 14.0 ft-lb) Carefully connect the evaporation hoses. B2M4130 B2M1893E 17) Install the fuel pipe protector LH. (A) To fuel pipe Tightening torque: (B) To intake manifold...
Page 812 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 19) Install the air assist injector solenoid valve to 23) Connect the connector to throttle position sen- bracket. sor and idle air control solenoid valve. Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) B2M3479 24) Connect the air by-pass hose to throttle body.
Page 813 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 26) Connect the connector to intake air tempera- ture and pressure sensor. 27) Install the ignition coil and ignitor assembly. B2M3473 28) Connect the connector to ignition coil and igni- tor assembly. 29) Install the engine ground cable to intake mani- fold.
Page 814 ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature B: INSTALLATION Install in the reverse order of removal. Sensor Tightening torque: A: REMOVAL 16 N·m (1.6 kgf-m, 11.8 ft-lb) 1) Disconnect the ground cable from battery. B2M4275 G6M0095 2) Remove the air intake duct and air cleaner as- sembly.
Page 815 CRANKSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) G6M0095 B2M1252B 2) Remove the bolt which installs crankshaft posi- tion sensor to cylinder block.
Page 816 CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 5) Remove the camshaft position sensor and cam- shaft position sensor support as a unit. A: REMOVAL 6) Remove the camshaft position sensor itself. 1) Disconnect the ground cable from battery. B2M2322 G6M0095 B: INSTALLATION...
Page 817 KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install the knock sensor to cylinder block. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 24 N·m (2.4 kgf-m, 17.4 ft-lb) NOTE: The extraction area of the knock sensor cord must be positioned at a 60°...
Page 818 THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) CAUTION: When installing the throttle position sensor, ad- just to the specified data.
Page 819 Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) B2M3148 5) Turn the ignition switch to ON, and Subaru Se- lect Monitor switch to ON. B2M3765 6) Select the {2. Each System Check} in Main 4) When using the Subaru Select Monitor;...
Page 820 INTAKE AIR TEMPERATURE AND PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Intake Air Temperature and B: INSTALLATION Install in the reverse order of removal. Pressure Sensor Tightening torque: A: REMOVAL 3.4 N·m (0.35 kgf-m, 2.5 ft-lb) 1) Disconnect the ground cable from battery. B2M3497 G6M0095 NOTE:...
Page 821: Atmospheric Pressure Sensor
ATMOSPHERIC PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 10.Atmospheric Pressure Sen- B: INSTALLATION Install in the reverse order of removal. Tightening torque: A: REMOVAL 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect the ground cable from battery. EN1001 G6M0095 2) Disconnect the connector from atmospheric pressure sensor.
Page 822 IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 11.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL Always use a new gasket. 1) Disconnect the ground cable from battery. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) G6M0095 2) Disconnect the connector from idle air control...
Page 823: Air Assist Injector Solenoid Valve
AIR ASSIST INJECTOR SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 12.Air Assist Injector Solenoid B: INSTALLATION Install in the reverse order of removal. Valve Tightening torque: A: REMOVAL 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) 1) Disconnect the ground cable from battery. B2M3503 G6M0095 2) Disconnect the connector from air assist injector...
Page 824 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 13.Fuel Injector (3) Remove the bolts which install power steer- ing pump to bracket. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU-54, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.> 2) Open the fuel filler flap lid and remove fuel filler cap.
Page 825 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 7) Remove the fuel pipe protector RH. 10) Remove the fuel injector from intake manifold. (1) Remove the fuel injector securing clip. B2M4130 B2M4283 8) Disconnect the connector from fuel injector. (2) Remove the fuel injector while lifting up the fuel injector pipe.
Page 826 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 2. LH SIDE 8) Move the washer tank, and secure it away from working area. 1) Release the fuel pressure. <Ref. to FU-54, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.> 2) Open the fuel filler flap lid and remove fuel filler cap.
Page 827 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 12) Remove the bolt which installs injector pipe to (2) Remove the fuel injector while lifting up the intake manifold. fuel injector pipe. B2M4133 H2M3241 B: INSTALLATION 1. RH SIDE Install in the reverse order of removal. NOTE: Replace the O-rings with a new one.
Page 828 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 2. LH SIDE 19 N·m (1.9 kgf-m, 14.0 ft-lb) Install in the reverse order of removal. NOTE: Replace the O-rings with a new one. B2M4132 Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) B2M3492G (A) O-ring (B) Fuel injector...
Page 829 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) B2M4133 Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) B2M4129 FU-46...
Page 830 21 N·m (2.1 kgf-m, 15.2 ft-lb) B2M4243 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to the threaded portion of front oxygen (A/F) sensor, and leave it for 1 minute or more. SUBARU CRC (Part No. 004301003) 5) Remove the front oxygen (A/F) sensor.
Page 831 FRONT OXYGEN (A/F) SENSOR FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. G6M0095 FU-48...
Page 832 Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb) B2M4244 3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to the threaded portion of rear oxygen sensor, and leave it for 1 minute or more. SUBARU CRC (Part No. 004301003) 5) Remove the rear oxygen sensor.
Page 833 REAR OXYGEN SENSOR FUEL INJECTION (FUEL SYSTEMS) 5) Connect the battery ground cable to battery. G6M0095 FU-50...
Page 834 ENGINE CONTROL MODULE FUEL INJECTION (FUEL SYSTEMS) 16.Engine Control Module B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage to fuel injection system.
Page 835 MAIN RELAY FUEL INJECTION (FUEL SYSTEMS) 17.Main Relay B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. G6M0095 2) Remove the passenger’s side front side sill cov- 3) Remove the bolt which holds main relay bracket on body.
Page 836 FUEL PUMP RELAY FUEL INJECTION (FUEL SYSTEMS) 18.Fuel Pump Relay B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from battery. G6M0095 2) Remove the passenger’s side front side sill cov- 3) Remove the bolt which holds fuel pump relay bracket on body.
Page 837 FUEL FUEL INJECTION (FUEL SYSTEMS) 19.Fuel 5) Drain fuel from the fuel tank. Set a container under the vehicle and remove the A: OPERATION drain plug from fuel tank. • 1600 cc and 2000 cc MODEL 1. RELEASING OF FUEL PRESSURE WARNING: •...
Page 838 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 20.Fuel Tank 9) Loosen the clamp and disconnect the fuel filler hose and air vent hose from fuel filler pipe. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Set the vehicle on a lift.
Page 839 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION 5) Connect the fuel hoses, and secure them with clips and quick connector. 1) Support the fuel tank with transmission jack and <Ref. to FU-73, INSTALLATION, Fuel Delivery, push the fuel tank harness into access hole with Return and Evaporation Lines.>...
Page 840 FUEL TANK FUEL INJECTION (FUEL SYSTEMS) 10) Connect the connector to fuel pump relay. EN0344 C: INSPECTION 1) Make sure there are no cracks, holes, or other damage on the fuel tank. 2) Make sure that the fuel hoses and fuel pipes are not cracked and that connections are tight.
Page 841 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 21.Fuel Filler Pipe 9) Drain fuel from the fuel tank. Set a container un- der the vehicle and remove the drain plug from fuel A: REMOVAL tank. • 1600 cc and 2000 cc MODEL WARNING: •...
Page 842 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 11) Remove the fuel filler pipe protector. 16) Move the clip and separate air vent hose (B). EN0544 EN0548 12) Separate the evaporation hoses from clip of 17) Remove the fuel filler pipe to under side of the fuel filler pipe.
Page 843 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 4) Install the air vent pipe. 7) Insert the air vent hose approx. 25 to 30 mm (0.98 to 1.18 in) into the lower end of air vent pipe and hold clip. L = 27.5 ± ± ± ± 2.5 mm (1.083 ± ± ± ± 0.098 in) EN0549 5) Connect the air vent hose to fuel filler pipe.
Page 844 FUEL FILLER PIPE FUEL INJECTION (FUEL SYSTEMS) 10) Install the fuel filler pipe protector. EN0544 11) Install the rear right wheel. B2M1748 12) Lower the vehicle. 13) Tighten the wheel nuts. 14) Connect the connector to fuel pump relay. EN0344 15) Connect the battery ground cable to battery.
Page 845 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 22.Fuel Pump 6) Tighten the fuel drain plug. Tightening torque: A: REMOVAL 26 N·m (2.7 kgf-m, 19.2 ft-lb) WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. NOTE: Fuel pump assembly consists of fuel pump and fuel level sensor.
Page 846 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 11) Move the clip and then disconnect the fuel re- 5) Drain fuel from the fuel tank. Set a container un- turn hose (B). der the vehicle and remove the drain plug from fuel tank.
Page 847 FUEL PUMP FUEL INJECTION (FUEL SYSTEMS) 10) Disconnect the quick connector and then dis- • 2500 cc MODEL connect fuel delivery hose (A). <Ref. to FU(TUR- BO)-68, Fuel Delivery, Return and Evaporation Lines.> 11) Move the clips, and then disconnect the fuel re- turn hose (B) and jet pump hose (C).
Page 848 FUEL LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 23.Fuel Level Sensor 3) Remove the bolt which installs fuel level sensor on mounting bracket. A: REMOVAL • 1600 cc and 2000 cc MODEL WARNING: • Place “NO FIRE” signs near the working area. •...
Page 849 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) 24.Fuel Sub Level Sensor 6) Remove the service hole cover. A: REMOVAL NOTE: Fuel sub level sensor is equipped to only 2500 cc model. WARNING: • Place “NO FIRE” signs near the working area. •...
Page 850 FUEL SUB LEVEL SENSOR FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) B2M3178 FU-67...
Page 851 FUEL FILTER FUEL INJECTION (FUEL SYSTEMS) 25.Fuel Filter A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Release the fuel pressure. <Ref. to FU-54, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.>...
Page 852 FUEL CUT VALVE FUEL INJECTION (FUEL SYSTEMS) 26.Fuel Cut Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: WARNING: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Remove the fuel tank.
Page 853 FUEL DAMPER VALVE FUEL INJECTION (FUEL SYSTEMS) 27.Fuel Damper Valve B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Release the fuel pressure. <Ref. to FU-54, RELEASING OF FUEL PRES- SURE, OPERATION, Fuel.> 2) Remove the fuel damper valve from fuel return line.
Page 854 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 28.Fuel Delivery, Return and 3) Open the fuel filler flap lid and remove fuel filler cap. Evaporation Lines 4) Remove the floor mat. <Ref. to EI-53, REMOV- AL, Floor Mat.> A: REMOVAL 5) Remove the fuel delivery pipes and hoses, fuel 1) Set the vehicle on a lift.
Page 855 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 6) In the engine compartment, detach the fuel de- 9) Separate the quick connector on fuel delivery livery hoses, return hoses and evaporation hose. and return line. (1) Clean the pipe and connector, if they are covered with dust.
Page 856 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) B: INSTALLATION CAUTION: • Pull the connector to ensure it is connected 1) Connect the quick connector on fuel delivery securely. line. • Ensure the two retainer pawls are engaged in NOTE: their mating positions in the connector.
Page 857 FUEL DELIVERY, RETURN AND EVAPORATION LINES FUEL INJECTION (FUEL SYSTEMS) 3) Connect the evaporation hose to pipe by approx. 15 mm (0.59 in) from the hose end. L = 17.5 ± ± ± ± 2.5 mm (0.689 ± ± ± ± 0.098 in) CAUTION: Be sure to inspect the hoses and their connec- tions for any leakage of fuel.
Page 858 FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) 29.Fuel System Trouble in General A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and tighten ❍...
Page 859 FUEL SYSTEM TROUBLE IN GENERAL FUEL INJECTION (FUEL SYSTEMS) FU-76...
Page 860 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) Page General Description ..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................6 Canister.......................7 Purge Control Solenoid Valve ..............8 Two-way Valve....................9...
Page 861 GENERAL DESCRIPTION EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. •...
Page 862 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter 7) Separate the center exhaust pipe from rear ex- haust pipe. A: REMOVAL CAUTION: 1) Set the vehicle on a lift. Be careful, the exhaust pipe is hot. 2) Disconnect the ground cable from battery.
Page 863 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 10) Separate the front catalytic converter from front 3) Tighten the nuts which hold front exhaust pipe exhaust pipe. onto cylinder heads. NOTE: Tightening torque: The rear catalytic converter is integrated with front 30 N·m (3.1 kgf-m, 22.4 ft-lb) catalytic converter.
Page 864 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 7) Lower the vehicle. 8) Connect the front oxygen (A/F) sensor connec- tor. B2M4243 9) Connect the connector to rear oxygen sensor connector. B2M4244 10) Connect the battery ground cable to battery. G6M0095 NOTE: The rear catalytic converter is integrated with front...
Page 865 REAR CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL The front and rear catalytic converter and center exhaust pipe are integrated into one unit. There- fore, the removal and installation procedures are the same as the those for the front catalytic con- verter.
Page 866 CANISTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. Canister A: REMOVAL 1) Lift-up the vehicle. 2) Loosen the two clamps which hold two canister hoses, and disconnect the three evaporation hoses from canister. EN0898 3) Remove the canister from body. B2M4166 B: INSTALLATION 1) Install in the reverse order of removal.
Page 867 PURGE CONTROL SOLENOID VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Purge Control Solenoid Valve B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 16 N·m (1.6 kgf-m, 11.6 ft-lb) G6M0095 H2M2985 2) Remove the bolt which installs purge control so-...
Page 868 TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6. Two-way Valve A: REMOVAL 1) Lift-up the vehicle. 2) Remove the canister from body. <Ref. to EC-7, REMOVAL, Canister.> 3) Remove the two-way valve with bracket as a sin- gle unit from body. EN0901 4) Remove the two-way valve from bracket.
Page 869 TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC-10...
Page 870 INTAKE (INDUCTION) Page General Description ..................2 Air Cleaner Element ..................5 Air Cleaner Case..................6 Air Intake Duct.....................7 Resonator Chamber..................8...
Page 871 GENERAL DESCRIPTION INTAKE (INDUCTION) 1. General Description A: COMPONENT (11) (11) (20) (19) (20) (13) (19) (11) (14) (10) (12) (16) (18) (17) (15) EN1336 IN-2...
Page 872 GENERAL DESCRIPTION INTAKE (INDUCTION) Spacer (11) Clip (20) Spacer Bush (12) Air cleaner element Resonator chamber (13) Air cleaner case B Tightening torque: N·m (kgf-m, ft-lb) Cushion rubber (14) Air cleaner case stay LH (MT vehi- T1: 33 (3.4, 24.6) cles) Air intake duct A (1600 cc and T2: 6.5 (0.66, 4.8)
Page 873 GENERAL DESCRIPTION INTAKE (INDUCTION) B: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 874 AIR CLEANER ELEMENT INTAKE (INDUCTION) 2. Air Cleaner Element A: REMOVAL 1) Remove the clip (A) above the air cleaner case. H2M2947B 2) Remove the air cleaner element. B: INSTALLATION Install in the reverse order of removal. CAUTION: Fasten with a clip after inserting the lower tab of the case.
Page 875 AIR CLEANER CASE INTAKE (INDUCTION) 3. Air Cleaner Case A: REMOVAL 1) Loosen the clamp which connects air cleaner case to throttle body. H2M2946 2) Disconnect the hoses and intake duct from air cleaner case. 3) Remove the bolts which install air cleaner case to stays.
Page 876 AIR INTAKE DUCT INTAKE (INDUCTION) 4. Air Intake Duct • 2500 cc MODEL A: REMOVAL 1) Remove the bolts which install air intake duct A on the front side of body. • 1600 cc and 2000 cc MODEL B6M1224 B: INSTALLATION Install in the reverse order of removal.
Page 877 RESONATOR CHAMBER INTAKE (INDUCTION) 5. Resonator Chamber B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Remove the air intake duct. <Ref. to IN-7, RE- 33 N·m (3.4 kgf-m, 24.6 ft-lb) MOVAL, Air Intake Duct.> 2) Remove the resonator chamber.
Page 878 MECHANICAL Page General Description ..................2 Compression .....................24 Idle Speed ....................25 Ignition Timing...................26 Intake Manifold Vacuum................27 Engine Oil Pressure ..................28 Fuel Pressure....................29 Valve Clearance..................30 Engine Assembly ..................34 Engine Mounting ..................42 Preparation for Overhaul................43 V-belt......................44 Crankshaft Pulley ..................46 Belt Cover ....................48 Timing Belt Assembly................49 Camshaft Sprocket..................54 Crankshaft Sprocket..................56 Valve Rocker Assembly ................57...
Page 879 GENERAL DESCRIPTION MECHANICAL 1. General Description A: SPECIFICATIONS Model 1600 cc 2000 cc 2500 cc Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline Type engine Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder 87.9 x 65.8 99.5 x 79.0 Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95) (3.46 x 2.591)
Page 880 GENERAL DESCRIPTION MECHANICAL Bend limit 0.025 mm (0.0010 in) 0.030 — 0.090 mm (0.0012 — 0.0035 in) Thrust clearance Limit 0.10 mm (0.0039 in) 39.378 — 39.478 mm (1.5503 — 1.5542 in) Intake Limit 39.278 mm (1.5464 in) 1600 cc 39.565 —...
Page 881 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) 87.905 — 87.915 mm (3.4608 — 3.4612 in) 1600 cc 87.895 — 87.905 mm (3.4604 — 3.4608 in) 92.005 — 92.015 mm (3.6222 — 3.6226 in) Cylinder bore 2000 cc 91.995 —...
Page 882 GENERAL DESCRIPTION MECHANICAL 0.010 — 0.038 mm (0.0004 — 0.0015 in) 1600 cc 2000 cc Limit 0.05 mm (0.0020 in) Oil clearance 0.012 — 0.037 mm (0.0005 — 0.0015 in) 2500 cc Limit 0.05 mm (0.0020 in) 1.492 — 1.501 mm (0.0587 — 0.0591 in) 0.03 mm (0.0012 in) 1.510 —...
Page 883 GENERAL DESCRIPTION MECHANICAL 1.998 — 2.011 mm (0.0787 — 0.0792 in) 0.03 mm (0.0012 in) 2.017 — 2.020 mm (0.0794 — 0.0795 in) #1, #3 0.05 mm (0.0020 in) 2.027 — 2.030 mm (0.0798 — 0.0799 in) 0.25 mm (0.0098 in) 2.127 —...
Page 884 GENERAL DESCRIPTION MECHANICAL B: COMPONENT 1. TIMING BELT B2M3122A Belt cover No. 2 (RH) Automatic belt tension adjuster Tightening torque: N·m (kgf-m, ft-lb) ASSY Timing belt guide (MT vehicles T1: 5 (0.5, 3.6) only) (10) Belt idler No. 2 T2: 10 (1.0, 7.2) Crankshaft sprocket (11) Camshaft sprocket No.
Page 885 GENERAL DESCRIPTION MECHANICAL 2. CYLINDER HEAD AND CAMSHAFT B2M1954D Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N·m (kgf-m, ft-lb) Intake valve rocker ASSY (12) Camshaft (LH) T1: <Ref. to ME-63, Installation, Cylinder Head Assembly.> Exhaust valve rocker ASSY (13) Camshaft cap (LH) Camshaft cap (RH)
Page 886 GENERAL DESCRIPTION MECHANICAL 3. VALVE ROCKER ASSEMBLY B2M1956A Intake valve rocker arm Intake rocker shaft Tightening torque: N·m (kgf-m, ft-lb) Valve rocker nut Exhaust rocker shaft T1: 5 (0.5, 3.6) Valve rocker adjust screw Exhaust valve rocker arm T2: 10 (1.0, 7.2) Spring T3: 25 (2.5, 18.1) Rocker shaft support...
Page 887 GENERAL DESCRIPTION MECHANICAL 4. CYLINDER HEAD AND VALVE ASSEMBLY B2M1955D Exhaust valve Intake valve oil seal Exhaust valve oil seal Intake valve Valve spring Valve guide Retainer Valve spring seat Retainer key ME-10...
Page 888 GENERAL DESCRIPTION MECHANICAL 5. CYLINDER BLOCK EN1498 Oil pressure switch (14) Baffle plate Tightening torque: N·m (kgf-m, ft-lb) Cylinder block (RH) (15) Oil filter connector T1: 5 (0.5, 3.6) Service hole plug (16) Oil strainer T2: 6.4 (0.65, 4.7) Gasket (17) Gasket T3: 10 (1.0, 7.2)
Page 889 GENERAL DESCRIPTION MECHANICAL 6. CRANKSHAFT AND PISTON B2M3429A ME-12...
Page 890 GENERAL DESCRIPTION MECHANICAL Flywheel (MT) Circlip (17) Crankshaft bearing #2, #4 Reinforcement (AT) (10) Connecting rod bolt (18) Crankshaft bearing #5 Drive plate (AT) (11) Connecting rod Top ring (12) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb) Second ring (13) Connecting rod cap T1: 44.6 (4.55, 32.9)
Page 891 GENERAL DESCRIPTION MECHANICAL 7. ENGINE MOUNTING EN1005 Front cushion rubber Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 42 (4.3, 31.0) T3: 85 (8.7, 63) ME-14...
Page 892 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 893 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 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 498267800 CYLINDER •...
Page 894 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 498547000 OIL FILTER Used for removing and installing oil filter.
Page 895 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498857100 VALVE OIL Used for press-fitting of intake and exhaust valve SEAL GUIDE guide oil seals. B2M3855 499017100 PISTON PIN Used for installing piston pin, piston and connect- GUIDE ing rod. B2M3856 499037100 CONNECTING Used for removing and installing connecting rod...
Page 896 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499097700 PISTON PIN Used for removing piston pin. REMOVER ASSY B2M3858 499207400 CAMSHAFT Used for removing and installing camshaft SPROCKET sprocket. (RH side) WRENCH B2M4158 499497000 TORX PLUS Used for removing and installing camshaft cap. B2M3873 499587100 OIL SEAL...
Page 897 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499587200 CRANKSHAFT • Used for installing crankshaft oil seal. OIL SEAL • Used with CRANKSHAFT OIL SEAL GUIDE INSTALLER (499597100). B2M3861 499587500 OIL SEAL Used for installing camshaft oil seal. INSTALLER B2M3874 499587700 CAMSHAFT OIL Used for installing cylinder head plug.
Page 898 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499597100 CRANKSHAFT • Used for installing crankshaft oil seal. OIL SEAL GUIDE • Used with CRANKSHAFT OIL SEAL INSTALLER (499587200). B2M3863 499718000 VALVE SPRING Used for removing and installing valve spring. REMOVER B2M3864 499767200 VALVE GUIDE...
Page 899 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499767700 VALVE GUIDE Used for installing valve guides. (Intake side) ADJUSTER 499767800 (Exhaust side) B2M3865 499817100 ENGINE STAND • Stand used for engine disassembly and assem- bly. • Used with ENGINE STAND ADAPTER RH (498457000) &...
Page 900 GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499987500 CRANKSHAFT Used for rotating crankshaft. SOCKET B2M3871 2. GENERAL PURPOSE TOOLS TOOL NAME REMARKS Compression Gauge Used for measuring compression. Tachometer (Secondary pick-up type) Used for measuring idle speed. Timing Light Used for measuring ignition timing.
Page 901: Compression
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 the fuel pressure.
Page 902: Idle Speed
2) Warm-up the engine. 3) Stop the engine, and then turn the igintion switch to OFF. 4) When using the SUBARU SELECT MONITOR <Ref. to ME-15, SPECIAL TOOLS, PREPARA- TION TOOL, General Description.> (1) Insert the cartridge to SUBARU SELECT B2M3131 MONITOR.
Page 903: Ignition Timing
IGNITION TIMING MECHANICAL 4. Ignition Timing A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measure- ment. 1) Warm-up the engine. 2) To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, and illuminate the timing mark with timing light.
Page 904: Intake Manifold Vacuum
INTAKE MANIFOLD VACUUM MECHANICAL 5. Intake Manifold Vacuum A: INSPECTION 1) Warm-up the engine. 2) Disconnect the brake vacuum hose, and then in- stall the vacuum gauge to hose fitting on manifold. 3) Keep the engine at idle speed, and then read the vacuum gauge indication.
Page 905: Engine Oil Pressure
ENGINE OIL PRESSURE MECHANICAL 6. Engine Oil Pressure 7) Start the engine, and then measure the oil pres- sure. A: INSPECTION 1) Disconnect the ground cable from battery. S2M0242 Oil pressure: G6M0095 98 kPa (1.0 kg/cm , 14 psi) or more at 800 rpm 2) Remove the generator from bracket.
Page 906: Fuel Pressure
FUEL PRESSURE MECHANICAL 7. Fuel Pressure 6) Measure the fuel pressure while disconnecting the pressure regulator vacuum hose from intake A: INSPECTION manifold. WARNING: Fuel pressure: Before removing the fuel pressure gauge, re- Standard; 284 — 314 kPa (2.9 — 3.2 kg/cm lease the fuel pressure.
Page 907: Valve Clearance
VALVE CLEARANCE MECHANICAL 8. Valve Clearance 8) When inspecting the #2 and #4 cylinders; (1) Disconnect the spark plug cords from spark A: INSPECTION plugs (LH Side) <Ref. to IG-5, LH SIDE, RE- MOVAL, Spark Plug.> or <Ref. to IG(w/oOBD)- CAUTION: 5, LH SIDE, REMOVAL, Spark Plug.>.
Page 908 VALVE CLEARANCE MECHANICAL 10) Measure the #1 cylinder valve clearance by us- 13) After inspection, install the related parts in the ing thickness gauge. reverse order of removal. CAUTION: Tightening torque: • Insert the thickness gauge (A) in as horizon- Resonator chamber;...
Page 909 VALVE CLEARANCE MECHANICAL B: ADJUSTMENT 2) Adjust the #1 cylinder valve clearance. (1) Loosen the valve rocker nut and screw. CAUTION: (2) Place suitable thickness gauge. Adjustment of the valve clearance should be (3) While noting the valve clearance, tighten the performed while engine is cold.
Page 910 VALVE CLEARANCE MECHANICAL 6) Similar to adjustment procedures used for #1 cylinder, adjust the #2, #3 and #4 cylinder valve clearances. NOTE: • Be sure to set the cylinder pistons to their re- spective top dead centers on compression stroke before adjusting valve clearances.
Page 911: Engine Assembly
ENGINE ASSEMBLY MECHANICAL 9. Engine Assembly 10) Remove the air cleaner case stay. • MT MODEL A: REMOVAL 1) Set the vehicle on lift arms. 2) Open the front hood fully, and then support with the hood stay. 3) Release the fuel pressure. <Ref. to FU-54, RE- LEASING OF FUEL PRESSURE, OPERATION, Fuel.>...
Page 912 ENGINE ASSEMBLY MECHANICAL (3) Engine ground cable (6) Accelerator cable and cruise control cable S2M0731 B2M3415A (4) Engine harness connectors (A) Accelerator cable (B) Cruise control cable (7) Pressure switch EN0360 12) Disconnect the following hoses. (1) Brake booster vacuum hose B2M4292 (5) Generator connector, terminal and A/C compressor connector...
Page 913 ENGINE ASSEMBLY MECHANICAL 13) Remove the power steering pump from brack- (6) Place the power steering pump on right side wheel apron. (1) Remove the resonator chamber. (2) Loosen the lock bolt and slider bolt, and then remove the front side V-belt.<Ref. to ME- 44, FRONT SIDE BELT, REMOVAL, V-belt.>...
Page 914 ENGINE ASSEMBLY MECHANICAL 17) Separate the torque converter clutch from drive 20) Support the engine with a lifting device and plate. (AT model) wire ropes. (1) Lower the vehicle. (2) Remove the service hole plug. (3) Remove the bolts which hold torque con- verter clutch to drive plate.
Page 915 ENGINE ASSEMBLY MECHANICAL 23) Install the ST to torque converter clutch case. B: INSTALLATION (AT model) 1) Install the front cushion rubbers. ST 498277200 STOPPER SET Tightening torque: 34 N·m (3.5 kgf-m, 25.3 ft-lb) 2) Install the engine onto transmission. (1) Position the engine in engine compartment and align it with transmission.
Page 916 ENGINE ASSEMBLY MECHANICAL 6) Install the pitching stopper. 10) Install the power steering pump on bracket. (1) Install the power steering tank on bracket. Tightening torque: T1: 50 N·m (5.1 kgf-m, 37 ft-lb) T2: 58 N·m (5.9 kgf-m, 43 ft-lb) EN0361 (2) Install the power steering pump on bracket, and then tighten the bolts.
Page 917 ENGINE ASSEMBLY MECHANICAL (5) Install the front side V-belt, and adjust it. 13) Install the front and center exhaust pipe. <Ref. to ME-44, FRONT SIDE BELT, INSTAL- <Ref. to EX-8, INSTALLATION, Front Exhaust LATION, V-belt.> Pipe.> and <Ref. to EX(w/oOBD)-10, INSTALLA- TION, Front Exhaust Pipe.>...
Page 918 ENGINE ASSEMBLY MECHANICAL 23) Fill engine coolant. C: INSPECTION <Ref. to CO-26, FILLING OF ENGINE COOLANT, 1) Make sure the pipes and hoses are installed cor- REPLACEMENT, Engine Coolant.> rectly. 24) Check the ATF level and correct if necessary. 2) Make sure the engine coolant and ATF are at (AT model) specified levels.
Page 919: Engine Mounting
ENGINE MOUNTING MECHANICAL 10.Engine Mounting A: REMOVAL 1) Remove the engine assembly. <Ref. to ME-34, 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; 34 N·m (3.5 kgf-m, 25.3 ft-lb) C: INSPECTION Make sure there are no cracks or other damage.
Page 920: Preparation For Overhaul
PREPARATION FOR OVERHAUL MECHANICAL 11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER ST2 498457100 ENGINE STAND ADAPTER ST3 499817100 ENGINE STAND B2M2582A 2) In this section the procedures described under each index are all connected and stated in order.
Page 921: V-Belt
V-BELT MECHANICAL 12.V-belt 3) Remove the A/C belt. 4) Remove the A/C belt tensioner. A: REMOVAL 1. FRONT SIDE BELT NOTE: Perform the following procedures 1) to 4) with the engine installed to body. 1) Remove the V-belt cover. B2M2585 B: INSTALLATION 1.
Page 922 V-BELT MECHANICAL 2. REAR SIDE BELT C: INSPECTION 1) Replace the belts, if cracks, fraying or wear is 1) Install the belt, and tighten the slider bolt (B) so found. as to obtain the specified belt tension. <Ref. to ME- 2) Check the drive belt tension and adjust it if nec- 45, INSPECTION, V-belt.>...
Page 923: Crankshaft Pulley
CRANKSHAFT PULLEY MECHANICAL 13.Crankshaft Pulley (4) Tighten the crankshaft pulley bolts. Tightening torque: A: REMOVAL 127 N·m (13.0 kgf-m, 94.0 ft-lb) 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, V-belt.> 2) Remove the crankshaft pulley bolt. To lock the crankshaft, use ST. ST 499977300 (1600 cc and 2000 cc model) ST 499977100...
Page 924 CRANKSHAFT PULLEY MECHANICAL (4) Tighten the crankshaft pulley bolts. 7) Install the A/C belt. Tightening torque: 177 N·m (18.0 kgf-m, 130.2 ft-lb) B2M2584 C: INSPECTION 1) Make sure the V-belt is not worn or otherwise H2M2393A damaged. 5) Confirm that the tightening angle of crankshaft 2) Check the tension of the belt.
Page 925: Belt Cover
BELT COVER MECHANICAL 14.Belt Cover A: REMOVAL 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME-46, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover (LH). 4) Remove the front belt cover. B2M2587B (A) Belt cover (LH) (B) Front belt cover B: INSTALLATION...
Page 926: Timing Belt Assembly
TIMING BELT ASSEMBLY MECHANICAL 15.Timing Belt Assembly A: REMOVAL 1. TIMING BELT 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME-46, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME-48, RE- MOVAL, Belt Cover.>...
Page 927 TIMING BELT ASSEMBLY MECHANICAL 7) Remove the belt idler No. 2. B: INSTALLATION 1. AUTOMATIC BELT TENSION ADJUST- ER ASSEMBLY AND BELT IDLER 1) Preparation for installation of automatic belt ten- sion adjuster assembly; CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down.
Page 928 TIMING BELT ASSEMBLY MECHANICAL 2) Install the automatic belt tension adjuster as- 2. TIMING BELT sembly. 1) Preparation for the installation of automatic belt Tightening torque: tension adjuster assembly. <Ref. to ME-50, AUTO- MATIC BELT TENSION ADJUSTER ASSEMBLY 25 N·m (2.5 kgf-m, 18.1 ft-lb) AND BELT IDLER, INSTALLATION, Timing Belt Assembly.>...
Page 929 TIMING BELT ASSEMBLY MECHANICAL 4) Install the belt idler (No. 2). (2) Check and adjust the clearance between timing belt and timing belt guide by using thick- Tightening torque: ness gauge. 39 N·m (4.0 kgf-m, 28.9 ft-lb) Clearance: 1.0 ± ± ± ± 0.5 mm (0.039 ± ± ± ± 0.020 in) S2M1008 5) After ensuring that the marks on timing belt and S2M0297...
Page 930 TIMING BELT ASSEMBLY MECHANICAL C: INSPECTION CAUTION: • Always use a vertical type pressing tool to 1. TIMING BELT move the adjuster rod down. • Do not use a lateral type vise. 1) Check the timing belt teeth for breaks, cracks, and wear.
Page 931: Camshaft Sprocket
CAMSHAFT SPROCKET MECHANICAL 16.Camshaft Sprocket B: INSTALLATION 1) Install the camshaft sprocket No. 1. To lock the A: REMOVAL camshaft, use ST. ST 499207400 CAMSHAFT SPROCKET 1. REMOVAL WRENCH 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, Tightening torque: V-belt.> 78 N·m (8.0 kgf-m, 57.9 ft-lb) 2) Remove the crankshaft pulley.
Page 932 CAMSHAFT SPROCKET MECHANICAL 7) Install the V-belt. <Ref. to ME-44, INSTALLA- TION, V-belt.> C: INSPECTION 1) Check the sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between sprock- et and key. 3) Check the camshaft sprocket notch for sensor for damage and contamination of foreign matter.
Page 933: Crankshaft Sprocket
CRANKSHAFT SPROCKET MECHANICAL 17.Crankshaft Sprocket B: INSTALLATION 1) Install the crankshaft sprocket. A: REMOVAL 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME-46, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME-48, RE- MOVAL, Belt Cover.>...
Page 934 VALVE ROCKER ASSEMBLY MECHANICAL 18.Valve Rocker Assembly (3) Tighten the bolts (a) through (d) to specified torque. A: REMOVAL Tightening torque: 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, 25 N·m (2.5 kgf-m, 18.1 ft-lb) V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME-46, REMOVAL, Crankshaft Pulley.>...
Page 935 VALVE ROCKER ASSEMBLY MECHANICAL E: INSPECTION 4) If oil clearance exceeds the limit, replace the rocker shaft support or shaft, whichever shows 1. VALVE ROCKER ARM greater amount of wear. 1) Measure the inside diameter of valve rocker arm Rocker shaft support inside diameter: and outside diameter of valve rocker shaft, and de- 22.005 —...
Page 936: Camshaft
CAMSHAFT MECHANICAL 19.Camshaft (1) Remove the bolts (a) through (b) in alpha- betical sequence. A: REMOVAL 1) Remove the V-belt. <Ref. to ME-44, INSTALLA- TION, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME-46, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME-48, RE- MOVAL, Belt Cover.>...
Page 937 CAMSHAFT MECHANICAL 16) Remove the plug from rear side of camshaft. (3) Install the valve rocker assembly. CAUTION: • Do not remove the oil seal unless necessary. • Do not scratch the journal surface when re- moving oil seal. B: INSTALLATION 1) Apply a coat of engine oil to the camshaft jour- nals, and then install the camshaft.
Page 938 CAMSHAFT MECHANICAL (6) Tighten the bolts (o) through (v) in alphabet- 6) Install the rocker cover and connect PCV hose. ical sequence. 7) Install the oil level gauge guide. (LH side only) 8) Install the camshaft position sensor support. (LH Tightening torque: side only) 10 N·m (1.0 kgf-m, 7.2 ft-lb)
Page 939 CAMSHAFT MECHANICAL C: INSPECTION Model Item Unit: mm (in) 39.485 — 39.585 1. CAMSHAFT (1.5545 — 1.5585) Intake 1) Measure the bend, and repair or replace if nec- Limit 39.385 (1.5506) 2500 cc essary. 39.257 — 39.357 (1.5455 — 1.5495) Exhaust Limit: Limit...
Page 940: Cylinder Head Assembly
CYLINDER HEAD ASSEMBLY MECHANICAL 20.Cylinder Head Assembly 13) Remove the cylinder head gasket. CAUTION: A: REMOVAL Do not scratch the mating surface of cylinder 1) Remove the V-belt. <Ref. to ME-44, REMOVAL, head and cylinder block. V-belt.> 14) Similarly, remove the right side cylinder head. 2) Remove the crankshaft pulley.
Page 941 CYLINDER HEAD ASSEMBLY MECHANICAL 6) Install the intake manifold. <Ref. to FU-19, IN- STALLATION, Intake Manifold.> or <Ref. to FU(w/ oOBD)-20, INSTALLATION, Intake Manifold.> 7) Install the camshaft sprocket. <Ref. to ME-54, INSTALLATION, Camshaft Sprocket.> 8) Install the timing belt assembly. <Ref. to ME-50, INSTALLATION, Timing Belt Assembly.>...
Page 942 CYLINDER HEAD ASSEMBLY MECHANICAL D: ASSEMBLY B2M2629B Valve Retainer (11) Plug Valve guide Retainer key (12) Camshaft cap Valve spring seat Spark plug gasket (13) Valve rocker ASSY Oil seal Camshaft Valve spring (10) Oil seal 1) Installation of valve spring and valve (4) Set the ST on valve spring.
Page 943 CYLINDER HEAD ASSEMBLY MECHANICAL (5) Compress the valve spring, and then fit the 2. INTAKE AND EXHAUST VALVE OIL valve spring retainer key. SEAL Replace the oil seal with new one, if lip is damaged 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 944 CYLINDER HEAD ASSEMBLY MECHANICAL 3) Measure the warping of the cylinder head sur- 2. VALVE SEAT face that mates with crankcase using a straight Inspect the intake and exhaust valve seats, and edge and thickness gauge. then correct the contact surfaces with valve seat If the warping exceeds 0.05 mm (0.0020 in), re- cutter if they are defective or when valve guides are grind the surface with a surface grinder.
Page 945 CYLINDER HEAD ASSEMBLY MECHANICAL 3. VALVE GUIDE (2) Insert the ST2 into valve guide and press it down to remove valve guide. 1) Check the clearance between valve guide and ST1 498267800 CYLINDER HEAD TABLE stem. The clearance can be checked by measuring ST2 499767200 VALVE GUIDE REMOVER the outside diameter of valve stem and the inside...
Page 946 CYLINDER HEAD ASSEMBLY MECHANICAL (5) Put new valve guide, coated with sufficient (7) Ream the inside of valve guide with ST. oil, in the cylinder, and then insert the ST1 into Gently rotate the reamer clockwise while press- valve guide. Press in until the valve guide upper ing it lightly into valve guide, and return it also ro- end is flush with the upper surface of ST2.
Page 947 CYLINDER HEAD ASSEMBLY MECHANICAL 4. INTAKE AND EXHAUST VALVE 1) Inspect the flange and stem of valve, and re- place if damaged, worn, or deformed, or if “H” is less than the specified limit. Intake Standard 1.0 mm (0.039 in) Limit 0.6 mm (0.024 in) Exhaust Standard 1.2 mm (0.047 in)
Page 948: Cylinder Block
CYLINDER BLOCK MECHANICAL 21.Cylinder Block 12) Remove the bolts (a) and (b) to remove cylin- der head. A: REMOVAL NOTE: Before conducting this procedure, drain the engine oil completely if applicable. 1) Remove the intake manifold. <Ref. to FU-17, REMOVAL, Intake Manifold.> or <Ref. to FU(w/ oOBD)-17, REMOVAL, Intake Manifold.>...
Page 949 CYLINDER BLOCK MECHANICAL ST1 498497100 CRANKSHAFT STOPPER 21) Removal of oil pan ST2 499057000 TORX PLUS (1) Turn the cylinder block with #2 and #4 piston sides facing upward. (2) Remove the bolts which secure oil pan to cylinder block. (3) Insert a oil pan cutter blade between cylin- der block-to-oil pan clearance, and then remove the oil pan.
Page 950 CYLINDER BLOCK MECHANICAL S2M1590B Service hole plug Circlip Service hole cover Gasket Piston pin O-ring 27) Remove the service hole cover and service 28) Rotate the crankshaft to bring #1 and #2 pis- hole plugs using hexagon wrench [14 mm (0.55 tons to bottom dead center position, and then re- in)].
Page 951 CYLINDER BLOCK MECHANICAL 29) Draw out the piston pin from #1 and #2 pistons 30) Similarly remove the piston pins from #3 and #4 using ST. pistons. ST 499097700 PISTON PIN REMOVER 31) Remove the bolts which connect cylinder block on the side of #2 and #4 cylinders.
Page 952 CYLINDER BLOCK MECHANICAL 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 T2: 47 (4.8, 34.7) CAUTION: CAUTION: Remove oil in the mating surface of bearing and Do not allow fluid packing to jut into O-ring cylinder block before installation.
Page 953 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 OIL SEAL GUIDE the figure. ST2 499587200 OIL SEAL INSTALLER B2M0088D S2M1827A 4) Tighten the 10 mm cylinder block connecting...
Page 954 CYLINDER BLOCK MECHANICAL • 2500 cc MODEL 10) Position the lower rail gap at (D) in the figure. • 1600 cc MODEL 180˚ B5SH B2M4618A EN1379 9) Position the expander gap at (C) in the figure. • 1600 cc MODEL •...
Page 955 CYLINDER BLOCK MECHANICAL 11) Position the upper rail gap at (G) in the figure. 12) Install circlip. • 1600 cc MODEL Install circlips in the piston holes located opposite service holes in cylinder block, when positioning all pistons in the corresponding cylinders. NOTE: Use new circlips.
Page 956 CYLINDER BLOCK MECHANICAL • 2500 cc MODEL B5SH B2M4626A (A) Front mark B2M1322J Piston Gasket Tightening torque: N·m (kgf-m, ft-lb) Piston pin Service hole plug T: 69 (7.0, 50.6) Circlip 13) Installing piston ST2 498747300 PISTON GUIDE (2500 cc model) (1) Turn the cylinder block so that #1 and #2 cyl- inders face upward.
Page 957 CYLINDER BLOCK MECHANICAL 14) Installing piston pin (5) Install the service hole plug and gasket. (1) Insert the ST3 into service hole to align pis- NOTE: ton pin hole with connecting rod small end. Use a new gasket. CAUTION: Apply a coat of engine oil to the ST3 before in- sertion.
Page 958 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 the matching surfaces, inders face upward.
Page 959 CYLINDER BLOCK MECHANICAL 20) Apply fluid packing to the matching surfaces, ST1 498497100 CRANKSHAFT STOPPER and then install the oil separator cover. ST2 499057000 TORX PLUS Fluid packing: THREE BOND 1215 or equivalent B2M3347A 22) Install the housing cover. 23) Installation of oil pump S2M1834A (1) Discard the front oil seal after removal.
Page 960 CYLINDER BLOCK MECHANICAL 26) Install the oil filter using ST. ST 498547000 OIL FILTER WRENCH S2M0118B (4) Install the oil pump on cylinder block. Be B2M2611A careful not to damage the oil seal during instal- lation. 27) Tighten the cylinder head bolts. (1) Apply a coat of engine oil to the washers and Tightening torque: bolt threads.
Page 961 CYLINDER BLOCK MECHANICAL 32) Install the timing belt assembly. <Ref. to ME- 50, INSTALLATION, Timing Belt Assembly.> 33) Install the belt cover. <Ref. to ME-48, INSTAL- LATION, Belt Cover.> 34) Install the crankshaft pulley. <Ref. to ME-46, INSTALLATION, Crankshaft Pulley.> 35) Install the generator and A/C compressor brackets on cylinder head.
Page 962 CYLINDER BLOCK MECHANICAL C: DISASSEMBLY B2M1320I 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 the removed connecting rod, connect- ing rod cap and bearing in order to prevent con- fusion.
Page 963 CYLINDER BLOCK MECHANICAL D: ASSEMBLY B2M1320J Connecting rod bearing Second ring Tightening torque: N·m (kgf-m, ft-lb) Connecting rod Top ring T: 44.6 (4.55, 32.9) Connecting rod cap Circlip Oil ring 1) Install the connecting rod bearings on connect- E: INSPECTION ing rods and connecting rod caps.
Page 964 CYLINDER BLOCK MECHANICAL Standard diameter: 2) How to measure the inner diameter of each cyl- inder 1600 cc MODEL Measure the inner diameter of each cylinder in both A: 87.905 — 87.915 mm (3.4608 — 3.4612 the thrust and piston pin directions at the heights shown in the figure, using a cylinder bore gauge.
Page 965 CYLINDER BLOCK MECHANICAL 4) How to measure the outer diameter of each pis- Measure the outer diameter of each piston at the height shown in the figure. (Thrust direction) CAUTION: Measurement should be performed at a temper- ature of 20° ° ° ° C (68° ° ° ° F). Piston grade point H: 1600 cc and 2000 cc MODEL 40.0 mm (1.575 in)
Page 966 CYLINDER BLOCK MECHANICAL 3. PISTON AND PISTON PIN 5) Check the piston pin circlip for distortion, cracks and wear. 1) Check the pistons and piston pins for damage, cracks, and wear and the piston ring grooves for 4. PISTON RING wear and damage.
Page 967 CYLINDER BLOCK MECHANICAL 2) Squarely place the piston ring and oil ring in cyl- 5. CONNECTING ROD inder, and then measure the piston ring gap with a 1) Replace the connecting rod, if the large or small thickness gauge. end thrust surface is damaged. 2) Check for bend or twist using a connecting rod Unit: mm (in) aligner.
Page 968 CYLINDER BLOCK MECHANICAL 4) Inspect the connecting rod bearing for scar, Connecting rod oil clearance: peeling, seizure, melting, wear, etc. • 2500 cc MODEL 5) Measure the oil clearance on individual connect- Standard ing rod bearings by means of plastigauge. If any oil 0.012 —...
Page 969 CYLINDER BLOCK MECHANICAL 7) Replacement procedure is as follows. (1) Remove the bushing from connecting rod with ST and press. (2) Press the bushing with ST after applying oil on the periphery of bushing. ST 499037100 CONNECTING ROD BUSH- ING REMOVER AND IN- STALLER G2M0177 (3) Make two 3 mm (0.12 in) holes in bushing.
Page 970 CYLINDER BLOCK MECHANICAL 6. CRANKSHAFT AND CRANKSHAFT 3) Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace the BEARING bearing with a suitable (undersize) one, and then 1) Clean the crankshaft completely and check for replace or recondition the crankshaft as necessary.
Page 971 CYLINDER BLOCK MECHANICAL 4) Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bearing. Crankshaft thrust clearance: Standard 0.030 — 0.115 mm (0.0012 — 0.0045 in) Limit 0.25 mm (0.0098 in) EN0341 5) Inspect the individual crankshaft bearings for signs of flaking, seizure, melting, and wear.
Page 972: Engine Trouble In General
ENGINE TROUBLE IN GENERAL MECHANICAL 22.Engine Trouble in General A: INSPECTION NOTE: “RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”) A — Very often B — Sometimes C — Rarely TROUBLE PROBLEM PARTS, ETC.
Page 973 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 3) Initial combustion occur. • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Defective intake manifold gasket •...
Page 974 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 2. Rough idle and engine • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ stall oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Loosened or cracked intake duct •...
Page 975 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 3. Low output, hesitation and • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ poor acceleration oOBD)-2, Basic Diagnostic Procedure.> • Intake system •...
Page 976 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 5. Engine does not return to • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ idle. oOBD)-2, Basic Diagnostic Procedure.> • Intake system •...
Page 977 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 10. Excessive fuel consump- • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ tion oOBD)-2, Basic Diagnostic Procedure.> • Intake system • Dirty air cleaner element •...
Page 978: Engine Noise
ENGINE NOISE MECHANICAL 23.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 979 ENGINE NOISE MECHANICAL ME-102...
Page 980 EXHAUST Page General Description ..................2 Front Exhaust Pipe..................7 Center Exhaust Pipe .................10 Rear Exhaust Pipe ..................11 Muffler .......................12...
Page 981 GENERAL DESCRIPTION EXHAUST 1. General Description A: COMPONENT 1. 1600 CC (16) (15) (13) (14) (16) (11) (10) (12) (16) (27) (26) (17) (28) (22) (18) (25) (24) (23) (31) (30) (19) (29) (21) (20) (31) EN1372 EX-2...
Page 982 GENERAL DESCRIPTION EXHAUST Upper front exhaust pipe cover (13) Gasket (27) Rear oxygen sensor (14) Self-locking nut (28) Upper rear catalytic converter Lower front exhaust pipe cover (15) Muffler cover (16) Cushion rubber (29) Lower rear catalytic converter Clamp (17) Lower clamp cover Upper front exhaust pipe cover LH...
Page 983 GENERAL DESCRIPTION EXHAUST 2. 2000 CC AND 2500 CC (16) (15) (13) (14) (16) (11) (10) (17) (16) (12) (28) (27) (18) (29) (23) (19) (26) (25) (24) (32) (31) (20) (30) (22) (21) (32) EN1373 EX-4...
Page 984 GENERAL DESCRIPTION EXHAUST Upper front exhaust pipe cover (14) Self-locking nut (29) Upper rear catalytic converter (15) Muffler cover Lower front exhaust pipe cover (16) Cushion rubber (30) Lower rear catalytic converter cover (17) Rear exhaust pipe Clamp (18) Lower clamp (31) Rear catalytic converter Upper front exhaust pipe cover LH...
Page 985 GENERAL DESCRIPTION EXHAUST B: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 986 FRONT EXHAUST PIPE EXHAUST 2. Front Exhaust Pipe 5) Separate the front and center exhaust pipe as- sembly from rear exhaust pipe. A: REMOVAL WARNING: 1) Disconnect the ground cable from battery. Be careful, the exhaust pipe is hot. G6M0095 B2M3109 2) Disconnect the front oxygen (A/F) sensor con- 6) Remove the under cover.
Page 987 FRONT EXHAUST PIPE EXHAUST 9) Remove the front and center exhaust pipe as- 4) Temporarily tighten the bolt which installs front sembly from vehicle. and center exhaust pipe assembly to hanger brack- CAUTION: • Be careful not to let the front and center ex- haust pipe assembly fall off when removing as it is quite heavy.
Page 988 FRONT EXHAUST PIPE EXHAUST 8) Tighten the bolt which holds front and center ex- C: INSPECTION haust pipe assembly to hanger bracket. 1) Make sure there are no exhaust leaks from con- nections and welds. Tightening torque: 2) Make sure there are no holes or rusting. 35 N·m (3.6 kgf-m, 26.0 ft-lb) B2M3111 9) Lower the vehicle.
Page 989 CENTER EXHAUST PIPE EXHAUST 3. Center Exhaust Pipe A: REMOVAL After removing the center and front exhaust pipes as one unit, separate them. Refer to the procedure for removing the front exhaust pipe. <Ref. to EX-7, REMOVAL, Front Exhaust Pipe.> B: INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit.
Page 990 Tightening torque: G2M0382 18 N·m (1.8 kgf-m, 13.0 ft-lb) 3) Apply a coat of SUBARU CRC to mating area of the cushion rubbers in advance. SUBARU CRC (Part No. 004301003) 4) Remove the rear exhaust pipe bracket from the cushion rubber.
Page 991 Be careful, the exhaust pipe is hot. 48 N·m (4.9 kgf-m, 35.4 ft-lb) G2M0382 G2M0382 2) Apply a coat of SUBARU CRC to mating area of C: INSPECTION the cushion rubbers in advance. 1) Make sure there are no exhaust leaks from con- SUBARU CRC (Part No.
Page 992 COOLING Page General Description ..................2 Radiator Main Fan System................10 Radiator Sub Fan System .................18 Engine Coolant..................26 Water Pump ....................28 Thermostat ....................37 Radiator.....................39 Radiator Cap .....................47 Radiator Main Fan and Fan Motor ............48 Radiator Sub Fan and Fan Motor..............50 Reservoir Tank..................52 Coolant Filler Tank ..................53 Engine Cooling System Trouble in General ..........54...
Page 993 GENERAL DESCRIPTION COOLING 1. General Description A: SPECIFICATIONS Model Non-turbo Turbo Cooling system Electric fan + Forced engine coolant circulation system 1.6 L AT: Approx. 7.3 (7.71, 6.42) 1.6 L MT: Approx. 7.4 AT: Approx. 7.6 (7.82, 6.51) (8.03, 6.69) 2 (US qt, Imp qt) Total engine coolant capacity 2.0 and 2.5 L AT: Approx.
Page 994 GENERAL DESCRIPTION COOLING B: COMPONENT 1. WATER PUMP • NON-TURBO MODEL H2M2354A Water pump ASSY Gasket Tightening torque: N·m (kgf-m, ft-lb) Gasket Thermostat cover T1: First 12 (1.2, 8.7) Second 12 (1.2, 8.7) Heater by-pass hose Thermostat T2: 6.4 (0.65, 4.7) CO-3...
Page 995 GENERAL DESCRIPTION COOLING • TURBO MODEL H2M1785B Thermostat cover Heater by-pass hose Tightening torque: N·m (kgf-m, ft-lb) Gasket Coolant filler tank by-pass hose T1: First 12 (1.2, 8.7) Second 12 (1.2, 8.7) Thermostat Water by-pass pipe Water pump ASSY T2: 6.4 (0.65, 4.7) Gasket CO-4...
Page 996 GENERAL DESCRIPTION COOLING 2. RADIATOR AND RADIATOR FAN • NON-TURBO MODEL (12) (10) (15) (11) (13) (24) (16) (17) (16) (14) (18) (21) (16) (16) (16) (23) (19) (20) (16) (22) EN0068 Radiator lower cushion (14) Radiator main fan (22) Radiator outlet hose Radiator (15)
Page 997 GENERAL DESCRIPTION COOLING • TURBO MODEL (21) (20) (19) (11) (10) (13) (16) (12) (14) (18) (15) (17) (22) EN0069 Radiator lower cushion (10) Over flow pipe (19) Engine coolant filler tank Radiator (11) Radiator sub fan shroud (20) Engine coolant filler tank cap Radiator upper cushion (12) Radiator sub fan...
Page 998 GENERAL DESCRIPTION COOLING C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
Page 999 GENERAL DESCRIPTION COOLING D: PREPARATION TOOL 1. NON-TURBO MODEL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977100 CRANK PULLEY Used for stopping crankshaft pulley when WRENCH loosening and tightening crankshaft pulley bolts. (2500 cc model) B2M3870 499977300 CRANK PULLEY Used for stopping crankshaft pulley when WRENCH loosening and tightening crankshaft pulley bolts.
Page 1000 GENERAL DESCRIPTION COOLING 2. TURBO MODEL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977300 CRANK PULLEY Used for stopping crankshaft pulley when WRENCH loosening and tightening crankshaft pulley bolts. B2M4157 18231AA010 CAMSHAFT Used for removing and installing camshaft (Newly adopted SPROCKET sprocket. (Intake) tool) WRENCH B2M3859...
Page 1001 RADIATOR MAIN FAN SYSTEM COOLING 2. Radiator Main Fan System A: SCHEMATIC 1. NON-TURBO MODEL BATTERY SBF-1 IGNITION SWITCH SBF-4 No.17 No.18 AIR CONDITIONING AIR CONDITIONING RELAY HOLDER RELAY HOLDER F27 20A F27 20A MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR LHD :2...
Page 1002 RADIATOR MAIN FAN SYSTEM COOLING 2. TURBO MODEL BATTERY SBF-1 IGNITION SWITCH SBF-4 No.18 LHD : 2 No.17 RHD : 7 LHD : 12 RHD : 17 B137 ECM SUB FAN SUB FAN MAIN FAN MAIN FAN RELAY2 RELAY1 RELAY2 RELAY1 SUB FAN MAIN FAN...
Page 1003 RADIATOR MAIN FAN SYSTEM COOLING B: INSPECTION 1. NON-TURBO MODEL DETECTING CONDITION: • Engine coolant temperature is above 95°C (203°F). • Vehicle speed is below 19 km/h (12 MPH). TROUBLE SYMPTOM: • Radiator main fan does not rotate under the above conditions. Step Check CHECK POWER SUPPLY TO MAIN FAN MO-...
Page 1004 Contact with your Check poor contact in connector between main nector between main fan motor contact connector. Subaru distributor fan and ECM. and ECM? service. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-13...
Page 1005 RADIATOR MAIN FAN SYSTEM COOLING 2. TURBO MODEL DETECTING CONDITION: • Engine coolant temperature is above 96°C (205°F). • A/C compressor is rotated. • Vehicle speed is below 19 km/h (12 MPH). TROUBLE SYMPTOM: • Radiator main fan does not rotate under the above conditions. •...
Page 1006 RADIATOR MAIN FAN SYSTEM COOLING Step Check CHECK POWER SUPPLY TO MAIN FAN Is the voltage more than 10 V? Go to step 8. Go to step 9. RELAY1. 1)Turn the ignition switch to OFF. 2)Remove the main fan relay1 from A/C relay holder.
Page 1007 Repair the poor Contact with your Check poor contact in connector between main nector between main fan motor contact connector. Subaru distributor fan and ECM. and ECM? service. CHECK POWER SUPPLY TO MAIN FAN MO- Is the voltage more than 10 V? Go to step 18.
Page 1008 Contact with your Check poor contact in connector between main nector between main fan motor contact connector. Subaru distributor fan and ECM. and ECM? service. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. CO-17...
Page 1009 RADIATOR SUB FAN SYSTEM COOLING 3. Radiator Sub Fan System A: SCHEMATIC 1. NON-TURBO MODEL BATTERY SBF-1 IGNITION SWITCH SBF-4 No.17 No.18 AIR CONDITIONING AIR CONDITIONING RELAY HOLDER RELAY HOLDER F27 20A F27 20A MAIN RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR LHD :2...
Page 1010 RADIATOR SUB FAN SYSTEM COOLING 2. TURBO MODEL BATTERY SBF-1 IGNITION SWITCH SBF-4 No.18 LHD : 2 No.17 RHD : 7 LHD : 12 RHD : 17 B137 ECM SUB FAN SUB FAN MAIN FAN MAIN FAN RELAY2 RELAY1 RELAY2 RELAY1 SUB FAN MAIN FAN...

Subaru Impreza 2002 Service Manual

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