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Subaru IMPREZA 1993 Service Manual

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1993 IMPREZA SERVICE MANUAL

REPAIR SECTION

FOREWORD

This portion of the service manual has been prepared

to provide SUBARU service personnel with the neces-

sary information and data for the correct maintenance

and repair of SUBARU vehicles.

This manual includes the procedures for maintenance

disassembling, reassembling, inspection and adjust-

ment of components and diagnostics for guidance of

both the fully qualified and the less-experienced

mechanics.

Please peruse and utilize this manual fully to ensure

complete repair work for satisfying our customers by

keeping their vehicle in optimum condition. When

replacement of parts during repair work is needed, be

sure to use SUBARU genuine parts.

All information, illustration and specifications con-

tained in this manual are based on the latest product

information available at the time of publication

approval.

FUJI HEAVY INDUSTRIES LTD.

QUICK REFERENCE INDEX

ENGINE SECTION

TRANSMISSION AND

DIFFERENTIAL SECTION

MECHANICAL COMPONENTS

SECTION

BODY SECTION

ELECTRICAL SECTION

G170ABE

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Summary of Contents for Subaru IMPREZA 1993

Page 1 MECHANICAL COMPONENTS SECTION BODY SECTION This portion of the service manual has been prepared to provide SUBARU service personnel with the neces- ELECTRICAL SECTION sary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance...
Page 2 Providing appropriate service and repair is a matter of great importance in the serviceman’s safety maintenance and safe operation, function and performance which the SUBARU vehicle possesses. ¼ In case the replacement of parts or replenishment of consumables is required, genuine SUBARU parts whose parts numbers are designated or their equivalents must be utilized. ¼...
Page 3 How to use this manual ¼ This Service Manual is divided into four volumes by section so that it can be used with ease at work. Refer to the Table of Contents, select and use the necessary section. ¼ GENERAL INFORMATION SECTION ¼...
Page 4 ¼ The Title Index No. is indicated on the top left (or right) side of the page as the book is opened. This is useful for retrieving the necessary portion. (Example of usage) Refer to 4 - 1 [ W 1 A 0 ] Small title (Sub-section) Medium title (Section) Large title (Heading)
Page 5 ¼ In this manual, the following symbols are used. : Selective part : Replacement part : Should be lubricated with oil. : Should be lubricated with grease. : Sealing point : Tightening torque ¼ WARNING, CAUTION, NOTE ¼ WARNING: Indicates the item which must be observed precisely during performance of maintenance ser- vices in order to avoid injury to the mechanics and other persons.
Page 6: Table Of Contents
TABLE OF CONTENTS On-Car Services Engine Engine Lubrication System Engine Cooling System ENGINE SECTION Fuel Injection System Fuel System Exhaust System 2-10 Clutch 2-11 Engine and Transmission Mounting System Manual Transmission and Differential Automatic Transmission and Differential TRANSMISSION AND DIFFEREN- TIAL SECTION Transmission Control System AWD System...
Page 7: On-Car Services
ON-CAR SERVICES Page 1. Foreword....................2 2. Ignition Timing................... 2 3. Engine Idle Speed ..................3 4. Engine Compression ................4 5. Intake Manifold Vacuum ................5 6. Engine Oil Pressure.................. 6...
Page 8: Foreword
ON-CAR SERVICES 1. Foreword - 2. Ignition Timing 1. Foreword This chapter describes major inspection and service pro- cedures for the engine mounted on the body. For proce- dures not found in this chapter, refer to the service proce- dure section in the applicable chapter. 2.
Page 9: Engine Idle Speed
ON-CAR SERVICES 3. Engine Idle Speed 3. Engine Idle Speed A: INSPECTION 1) Before checking idle speed, check the following: (1) Ensure that air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that hoses are connected properly. (2) Ensure that malfunction indicator lamp is OFF.
Page 10: Engine Compression
ON-CAR SERVICES 4. Engine Compression 4. Engine Compression A: MEASUREMENT 1) After warming-up the engine, turn ignition switch to OFF. 2) Make sure that the battery is fully charged. 3) Remove all the spark plugs. 4) Disconnect connectors from fuel injectors. 5) Fully open throttle valve.
Page 11: Intake Manifold Vacuum
ON-CAR SERVICES 5. Intake Manifold Vacuum 5. Intake Manifold Vacuum A: MEASUREMENT 1) Warm-up the engine. 2) Disconnect the vacuum hose and install the vacuum gauge to the hose fitting on the manifold. 3) Keep the engine at the idle speed and read the vacuum gauge indication.
Page 12: Engine Oil Pressure
ON-CAR SERVICES 6. Engine Oil Pressure 6. Engine Oil Pressure A: MEASUREMENT 1) Remove generator from bracket. (1) Disconnect connector and terminal from generator. G2M0088 (2) Remove V-belt cover. (3) Loosen lock bolt and slider bolt, and remove front side V-belt. G2M0089 (4) Remove lock bolt.
Page 13 ON-CAR SERVICES 6. Engine Oil Pressure 4) Connect oil pressure gauge hose. 5) Start the engine, and measure oil pressure. Oil pressure: 98 kPa (1.0 kg/cm ,14 psi) or more at 600 rpm 294 kPa (3.0 kg/cm , 43 psi) or more at 5,000 rpm CAUTION: ¼...
Page 14 ENGINE Page S SPECIFICATIONS AND SERVICE DATA........... 2 1. Specifications ................... 2 2. Service Data .................... 3 C COMPONENT PARTS ..................8 1. Timing Belt ....................8 2. Cylinder Head and Camshaft ..............9 3. Cylinder Head and Valve Assembly ............10 4. Cylinder Block ..................11 5.
Page 15 SPECIFICATIONS AND SERVICE DATA 1. Specifications 1. Specifications Horizontally opposed, liquid cooled, Type 4-cylinder, 4-stroke gasoline engine Belt driven, single over-head Valve arrangement camshaft, 4-valve/cylinder Bore x Stroke mm (in) 87.9 x 75 (3.461 x 2.95) Piston displacement (cu in) 1,820 (111.06) Compression ratio Compression pressure...
Page 16: S Specifications And Service Data
SPECIFICATIONS AND SERVICE DATA 2. Service Data 2. Service Data Belt tension Protrusion of adjuster rod 15.4 — 16.4 mm (0.606 — 0.646 in) adjuster Spacer O.D. 16 mm (0.63 in) Tensioner bush I.D. 16.16 mm (0.6362 in) 0.117 — 0.180 mm (0.0046 —...
Page 17 SPECIFICATIONS AND SERVICE DATA 2. Service Data Free length 46.16 mm (1.8173 in) Squareness 2.5°, 2.0 mm (0.079 in) Valve 190.3 — 219.7 N spring (19.4 — 22.4 kg, 42.8 — 49.4 lb)/37.0 mm (1.457 in) Tension/spring height 401.1 — 461.9 N (40.9 —...
Page 18 SPECIFICATIONS AND SERVICE DATA 2. Service Data 0.015 — 0.045 mm (0.0006 — 0.0018 in) Oil clearance Limit 0.05 mm (0.0020 in) 1.492 — 1.501 mm (0.0587 — 0.0591 in) 0.03 mm (0.0012 1.510 — 1.513 mm (0.0594 — 0.0596 in) Connect- in) US ing rod...
Page 19 SPECIFICATIONS AND SERVICE DATA 2. Service Data Bend limit 0.035 mm (0.0014 in) Out-of-roundness 0.030 mm (0.0012 in) or less Crankpin and crank journal Grinding limit 0.250 mm (0.0098 in) 51.984 — 52.000 mm (2.0466 — 2.0472 in) 0.03 mm (0.0012 in) 51.954 —...
Page 20 SPECIFICATIONS AND SERVICE DATA 2. Service Data 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) 0.05 mm #1, #5 (0.0020 in) 2.027 — 2.030 mm (0.0798 — 0.0799 in) 0.25 mm (0.0098 in) 2.127 —...
Page 21: C Component Parts
COMPONENT PARTS 1. Timing Belt 1. Timing Belt G2M0101 Crankshaft sprocket Right-hand belt cover Right-hand belt cover No. 2 Front belt cover Left-hand belt cover No. 2 Left-hand belt cover Right-hand camshaft sprocket Crankshaft pulley Belt idler Tightening torque: N⋅m (kg-m, ft-lb) Tensioner bracket T1: 5 (0.5, 3.6) Belt idler...
Page 22: Cylinder Head And Camshaft
COMPONENT PARTS 2. Cylinder Head and Camshaft 2. Cylinder Head and Camshaft H2M1295A Rocker cover (RH) Oil seal Rocker cover gasket Oil filler cap Camshaft support (RH) Gasket O-ring Oil filler pipe Camshaft (RH) O-ring Intake valve guide Rocker gasket Exhaust valve guide Rocker cover (LH) Oil seal...
Page 23: Cylinder Head And Valve Assembly
COMPONENT PARTS 3. Cylinder Head and Valve Assembly 3. Cylinder Head and Valve Assembly H2M1296A Exhaust valve Rocker shaft Intake valve Hydraulic lash adjuster Intake valve oil seal Intake valve rocker arm Valve spring Exhaust valve rocker arm Retainer Spring Retainer key Tightening torque: N⋅m (kg-m, ft-lb) Exhaust valve oil seal...
Page 24: Cylinder Block
COMPONENT PARTS 4. Cylinder Block 4. Cylinder Block G2M0104 Oil pressure switch Gasket Cylinder block (RH) Oil pan Service hole plug Oil drain plug Gasket Gasket Oil separator cover Oil filler pipe Water pipe Tightening torque: N⋅m (kg-m, ft-lb) Oil pump T1: 5 (0.5, 3.6) Front oil seal T2: 6.4 (0.65, 4.7)
Page 25: Crankshaft And Piston
COMPONENT PARTS 5. Crankshaft and Piston 5. Crankshaft and Piston H2M1297A Drive plate Connecting rod bearing Reinforcement Connecting rod cap Flywheel Crankshaft Bell bearing Woodruff key Top ring Crankshaft bearing #1, #5 Second ring Crankshaft bearing #2, #4 Oil ring Crankshaft bearing #3 Piston Tightening torque: N⋅m (kg-m, ft-lb)
Page 26: General Precautions
SERVICE PROCEDURE 1. General Precautions 1. General Precautions 1) Before disassembling engine, place it on ST3. 498457000 ENGINE STAND ADAPTER RH 498457100 ENGINE STAND ADAPTER LH 499817000 ENGINE STAND G2M0106 2) All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pistons and bearings. 3) Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.
Page 27: Hydraulic Lash Adjuster
SERVICE PROCEDURE 2. Hydraulic Lash Adjuster 2. Hydraulic Lash Adjuster A: INSPECTION 1) Disconnect blow-by hose. 2) Remove plug cap. 3) Disconnect connectors from fuel injectors. G2M0197 4) Remove left and right rocker covers. CAUTION: Before removing left rocker cover, disconnect engine harness connector, battery cables and alternator cable.
Page 28 SERVICE PROCEDURE 2. Hydraulic Lash Adjuster B: AIR BLEEDING 1) Remove valve rocker assembly. (1) Remove bolts k through k in numerical sequence. CAUTION: Leave two or three threads of bolt k engaged to retain valve rocker assembly. (2) Equally loosen bolts k through k all the way, being careful that knock pin is not gouged.
Page 29 SERVICE PROCEDURE 2. Hydraulic Lash Adjuster 4) Using ST; (1) Insert lash adjuster into ST, and fill ST with engine oil. Using a 2 mm (0.08 in) diameter rod, push check ball in. 499597000 OIL SEAL GUIDE (2) With check ball pushed in, push plunger at an inter- val of one second.
Page 30 SERVICE PROCEDURE 2. Hydraulic Lash Adjuster 7) Temporarily and equally tighten bolts k through k . Do not allow knock pin to catch valve rocker assembly. 8) Tighten bolts k through k to specified torque. 9) Tighten bolts k through k to specified torque.
Page 31: Timing Belt
SERVICE PROCEDURE 3. Timing Belt 3. Timing Belt A: REMOVAL 1. CRANKSHAFT PULLEY AND BELT COVER G2M0107 1) Remove V-belt and A/C belt tensioner. 2) Remove pulley bolt. To lock crankshaft use ST. 499977000 CRANKSHAFT PULLEY WRENCH 3) Remove crankshaft pulley. 4) Remove left-hand belt cover.
Page 32 SERVICE PROCEDURE 3. Timing Belt 2. TIMING BELT G2M0109 1) If alignment mark k and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing timing belt as follows: G2M0110 (1) Turn crankshaft, and align alignment marks k crankshaft sprocket, and left and right camshaft sprock- ets with notches k of belt cover and cylinder block.
Page 33 SERVICE PROCEDURE 3. Timing Belt (2) Using white paint, put alignment and/or arrow marks on timing belts in relation to the sprockets. : 44 tooth length : 40.5 tooth length G2M0111 2) Loosen tensioner adjuster mounting bolts. 3) Remove belt idler. 4) Remove belt idler No.
Page 34 SERVICE PROCEDURE 3. Timing Belt 3. BELT TENSIONER AND IDLER G2M0112 1) Remove belt idler. 2) Remove belt tensioner and spacer. 3) Remove belt tension adjuster.
Page 35 SERVICE PROCEDURE 3. Timing Belt 4. SPROCKET G2M0113 1) Remove left-hand camshaft sprocket. 2) Remove right-hand camshaft sprocket. To lock cam- shaft use ST. 499207100 CAMSHAFT SPROCKET WRENCH G2M0114 3) Remove crankshaft sprocket. 4) Remove left-hand belt cover No. 2. 5) Remove right-hand belt cover No.
Page 36 SERVICE PROCEDURE 3. Timing Belt B: INSPECTION 1. TIMING BELT 1) Check timing belt teeth for breaks, cracks, and wear. If any fault is found, replace belt. 2) Check the condition of back side of belt; if any crack is found, replace belt.
Page 37 SERVICE PROCEDURE 3. Timing Belt 3) Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one. Rod extension: H 15.4 — 16.4 mm (0.606 — 0.646 in) G2M0116 3. BELT TENSIONER 1) Check mating surfaces of timing belt and contact point of tension adjuster rod for abnormal wear or scratches.
Page 38 SERVICE PROCEDURE 3. Timing Belt C: INSTALLATION 1. SPROCKET G2M0117 Tightening torque: N⋅m (kg-m, ft-lb) T1: 5 (0.5, 3.6) T2: 23 — 26 (2.3 — 2.7, 17 — 20) T3: 64 — 74 (6.5 — 7.5, 47 — 54) 1) Install right-hand belt cover No. 2. 2) Install tensioner bracket.
Page 39 SERVICE PROCEDURE 3. Timing Belt 2. BELT TENSIONER AND IDLER G2M0118 Tightening torque: N⋅m (kg-m, ft-lb) T1: 23 — 26 (2.3 — 2.7, 17 — 20) T2: 35 — 43 (3.6 — 4.4, 26 — 32) 1) Installation of belt tension adjuster Insert stopper pin 1.5 mm (0.059 in) diameter into place while pushing tension adjuster rod into body using a press.
Page 40 SERVICE PROCEDURE 3. Timing Belt 2) Install belt tensioner and spacer. 3) Install belt idler. (1) Temporarily tighten bolts while belt tension adjuster is pushed all the way to the right. G2M0120...
Page 41 SERVICE PROCEDURE 3. Timing Belt 3. TIMING BELT G2M0121 Tightening torque: N⋅m (kg-m, ft-lb) T: 35 — 43 (3.6 — 4.4, 26 — 32) 1) Installation of timing belt. (1) Using ST, turn left and right camshaft sprockets so that their alignment marks come to top positions. 499207100 CAMSHAFT SPROCKET WRENCH G2M0122...
Page 42 SERVICE PROCEDURE 3. Timing Belt 2) Install belt idler No. 2. 3) Install belt idler. 4) Loosen belt tension adjuster attaching bolts and move adjuster all the way to the left. Tighten the bolts. G2M0124 5) After ensuring that the marks on timing belt and cam- shaft sprockets are aligned, remove stopper pin from belt tension adjuster.
Page 43 SERVICE PROCEDURE 3. Timing Belt 4. CRANKSHAFT PULLEY AND BELT COVER G2M0126 Tightening torque: N⋅m (kg-m, ft-lb) T1: 5 (0.5, 3.6) T2: 93 — 103 (9.5 — 10.5, 69 — 76) 1) Install front belt cover. 2) Install right-hand belt cover. 3) Install left-hand belt cover.
Page 44: Valve Rocker Assembly
SERVICE PROCEDURE 4. Valve Rocker Assembly 4. Valve Rocker Assembly A: REMOVAL G2M0127 1) Disconnect PCV hose and remove rocker cover. 2) Removal of valve rocker assembly (1) Remove bolts k through k in numerical sequence. CAUTION: Leave two or three threads of bolt k engaged to retain valve rocker assembly.
Page 45 SERVICE PROCEDURE 4. Valve Rocker Assembly B: DISASSEMBLY H2M1298A 1) Remove bolts which secure rocker shaft. 2) Extract rocker shaft. Remove valve rocker arms, springs and shaft supports from rocker shaft. CAUTION: ¼ Arrange all removed parts in order so that they can be installed in their original positions.
Page 46 SERVICE PROCEDURE 4. Valve Rocker Assembly C: INSPECTION 1. HYDRAULIC LASH ADJUSTER 1) Bleed air from hydraulic lash adjuster as described below: (1) While dipping hydraulic lash adjuster in engine oil, as shown in Figure, push check ball in using a 2 mm (0.08 in) dia.
Page 47 SERVICE PROCEDURE 4. Valve Rocker Assembly 2. VALVE ROCKER ARM 1) Measure inside diameter of valve rocker arm and out- side diameter of valve rocker shaft, and determine the dif- ference between the two (= oil clearance). Clearance between arm and shaft: Standard 0.020 —...
Page 48 SERVICE PROCEDURE 4. Valve Rocker Assembly D: ASSEMBLY H2M1299A Tightening torque: N⋅m (kg-m, ft-lb) T: 5 (0.5, 3.6) 1) After bleeding air from hydraulic lash adjuster, position hydraulic lash adjuster in valve rocker arm while dipping in engine oil. <Ref. to 2-3 [W4C1].> CAUTION: ¼...
Page 49 SERVICE PROCEDURE 4. Valve Rocker Assembly E: INSTALLATION G2M0133 Tightening torque: N⋅m (kg-m, ft-lb) T1: 5 (0.5, 3.6) T2: 12 (1.2, 9) 1) Installation of valve rocker assembly (1) Temporarily tighten bolts k through k equally as shown in Figure. CAUTION: Do not allow valve rocker assembly to gouge knock pins.
Page 50: Camshaft
SERVICE PROCEDURE 5. Camshaft 5. Camshaft A: REMOVAL 1. RELATED PARTS 1) Remove timing belt, camshaft sprockets and related parts. <Ref. to 2-3 [W3A0].> 2) Remove valve rocker Assembly. <Ref. to 2-3 [W4A0].> 2. CAMSHAFT LH G2M0135 1) Remove camshaft position sensor. 2) Remove oil level gauge guide attaching bolt.
Page 51 SERVICE PROCEDURE 5. Camshaft 3. CAMSHAFT RH G2M0136 1) Remove camshaft support RH. 2) Remove O-ring. 3) Remove camshaft. 4) Remove oil seal. CAUTION: ¼ Do not remove oil seal unless necessary. ¼ Do not scratch journal surface when removing oil seal.
Page 52 SERVICE PROCEDURE 5. Camshaft B: INSPECTION 1. CAMSHAFT 1) Measure the bend, and repair or replace if necessary. Limit: 0.025 mm (0.0010 in) G2M0137 2) Check journal for damage and wear. Replace if faulty. 3) Measure outside diameter of camshaft journal and inside diameter of cylinder head journal, and determine the difference between the two (= oil clearance).
Page 53 SERVICE PROCEDURE 5. Camshaft 2. CAMSHAFT SUPPORT Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the limit, replace camshaft sup- port. Standard: 0.030 — 0.260 mm (0.0012 — 0.0102 in) Limit: 0.35 mm (0.0138 in) G2M0139...
Page 54 SERVICE PROCEDURE 5. Camshaft C: INSTALLATION 1. CAMSHAFT LH G2M0140 Tightening torque: N⋅m (kg-m, ft-lb) T1: 5 (0.5, 3.6) T2: 10 (1.0, 7) T3: 16 (1.6, 12) 1) Apply a coat of engine oil to camshaft journals and install camshaft LH. 2) Apply a coat of engine oil or grease to O-ring.
Page 55 SERVICE PROCEDURE 5. Camshaft 2. CAMSHAFT RH G2M0142 Tightening torque: N⋅m (kg-m, ft-lb) T: 16 (1.6, 1.2) 1) Apply a coat of engine oil to camshaft journals and install camshaft RH. 2) Apply a coat of engine oil or grease to O-ring. 3) Install O-ring to camshaft support.
Page 56 SERVICE PROCEDURE 5. Camshaft 3. RELATED PARTS 1) Install valve rocker assembly. <Ref. to 2-3 [W4E0].> G2M0133 Tightening torque: N⋅m (kg-m, ft-lb) T1: 5 (0.5, 3.6) T2: 12 (1.2, 9) 2) Install timing belt, camshaft sprockets and related parts. <Ref. to 2-3 [W3C0].> G2M0121 Tightening torque: N⋅m (kg-m, ft-lb) T: 35 —...
Page 57: Cylinder Head
SERVICE PROCEDURE 6. Cylinder Head 6. Cylinder Head A: REMOVAL 1. INTAKE MANIFOLD 1) Release fuel pressure. 2) Drain engine coolant. 3) Remove V-belt. 4) Remove alternator and bracket. 5) Disconnect spark plug caps. 6) Remove Connector bracket attaching bolt. 7) Remove crankshaft position sensor and camshaft posi- tion sensor.
Page 58 SERVICE PROCEDURE 6. Cylinder Head 2. CYLINDER HEAD H2M1300A 1) Remove timing belt, camshaft sprocket and related parts. <Ref. to 2-3 [W3A0].> 2) Remove oil level gauge guide attaching bolt (left hand only) and oil level gauge guide. 3) Remove cylinder head bolts in numerical sequence shown in Figure.
Page 59 SERVICE PROCEDURE 6. Cylinder Head B: DISASSEMBLY G2M0146 1) Remove rocker cover. 2) Remove valve rocker assembly. <Ref. to 2-3 [W4A0].> 3) Remove camshaft and support. <Ref. to 2-3 [W5A0].> 4) Place cylinder head on ST. 498267200 CYLINDER HEAD TABLE...
Page 60 SERVICE PROCEDURE 6. Cylinder Head 5) Set ST on valve spring. Compress valve spring and remove the valve spring retainer key. Remove each valve and valve spring. 499718000 VALVE SPRING REMOVER CAUTION: ¼ Mark each valve to prevent confusion. ¼ Use extreme care not to damage the lips of the intake valve oil seals and exhaust valve oil seals.
Page 61 SERVICE PROCEDURE 6. Cylinder Head 2. VALVE SEAT Inspect intake and exhaust valve seats, and correct the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced. Valve seat width: W Intake Standard 0.7 mm (0.028 in) Limit 1.4 mm (0.055 in) G2M0149...
Page 62 SERVICE PROCEDURE 6. Cylinder Head (3) Turn cylinder head upside down and place ST as shown in the Figure. 499767000 VALVE GUIDE ADJUSTER G2M0151 (4) Before installing new oversize valve guide, make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head.
Page 63 SERVICE PROCEDURE 6. Cylinder Head (8) Recheck the contact condition between valve and valve seat after replacing valve guide. 4. INTAKE AND EXHAUST VALVE 1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if “H” is less than the specified limit.
Page 64 SERVICE PROCEDURE 6. Cylinder Head 5. VALVE SPRINGS 1) Check valve springs for damage, free length, and ten- sion. Replace valve spring if it is not to the specifications presented below. 2) To measure the squareness of the valve spring, stand the spring on a surface plate and measure its deflection at the top using a try square.
Page 65 SERVICE PROCEDURE 6. Cylinder Head D: ASSEMBLY G2M0156 Tightening torque: N⋅m (kg-m, ft-lb) T1: 5 (0.5, 3.6) T2: 10 (1.0, 7) T3: 12 (1.2, 9) T4: 16 (1.6, 12) 1) Install plug (cylinder head LH) by using ST. 499587100 OIL SEAL INSTALLER 2) Installation of valve spring and valve.
Page 66 SERVICE PROCEDURE 6. Cylinder Head (3) Install valve spring and retainer. CAUTION: Be sure to install the valve springs with their close- coiled end facing the seat on the cylinder head. (4) Set ST on valve spring. 499718000 VALVE SPRING REMOVER (5) Compress valve spring and fit valve spring retainer key.
Page 67 SERVICE PROCEDURE 6. Cylinder Head E: INSTALLATION 1. CYLINDER HEAD H2M1301A 1) Install cylinder head and gaskets on cylinder block. CAUTION: Use new cylinder head gaskets. 2) Tighten cylinder head bolts. (1) Apply a coat of engine oil to washers and bolt threads.
Page 68 SERVICE PROCEDURE 6. Cylinder Head (7) Further tighten all bolts by 80 to 90° in numerical sequence. CAUTION: Ensure that the total “re-tightening angle” [steps (6) and (7) above] do not exceed 180°. 3) Install oil level gauge guide attaching bolt (left hand only).
Page 69: Cylinder Block
SERVICE PROCEDURE 7. Cylinder Block 7. Cylinder Block A: REMOVAL 1. RELATED PARTS 1) Remove timing belt, camshaft sprocket and related parts. <Ref. to 2-3 [W3A0].> G2M0109 2) Remove intake manifold and cylinder head. <Ref. to 2-3 [W6A0].>...
Page 70 SERVICE PROCEDURE 7. Cylinder Block 2. OIL PUMP AND WATER PUMP G2M0160...
Page 71 SERVICE PROCEDURE 7. Cylinder Block 1) Remove housing cover. 2) Remove flywheel or drive plate. To lock crankshaft use ST. 498497100 CRANKSHAFT STOPPER G2M0161 3) Remove oil separator cover. 4) Remove water pipes. 5) Remove water pump. 6) Remove oil pump from cylinder block. Use a flat-bladed screwdriver as shown in Figure when removing oil pump.
Page 72 SERVICE PROCEDURE 7. Cylinder Block 7) Removal of oil pan. (1) Turn cylinder block with #2 and #4 piston sides facing upward. (2) Remove bolts which secure oil pan to cylinder block. (3) Insert a oil pan cutter blade between cylinder block- to-oil pan clearance and remove oil pan.
Page 73 SERVICE PROCEDURE 7. Cylinder Block B: DISASSEMBLY 1. PISTON PIN AND CYLINDER BLOCK CONNECTING BOLT G2M0164 1) Remove service hole cover and service hole plugs using hexagon wrench (14 mm). 2) Rotate crankshaft to bring #1 and #2 pistons to BDC position, then remove piston circlip through service hole of #1 and #2 cylinders.
Page 74 SERVICE PROCEDURE 7. Cylinder Block 3) Draw out piston pin from #1 and #2 pistons by using ST. 499097500 PISTON PIN REMOVER CAUTION: Be careful not to confuse original combination of piston, piston pin and cylinder. 4) Similarly remove piston pins from #3 and #4 pistons by using ST.
Page 75 SERVICE PROCEDURE 7. Cylinder Block 2. CYLINDER BLOCK 1) Set up cylinder block so that #1 and #3 cylinders are on the upper side, then remove cylinder block connecting bolts. 2) Separate left-hand and right-hand cylinder blocks. CAUTION: When separating cylinder block, do not allow the con- necting rod to fall and damage the cylinder block.
Page 76 SERVICE PROCEDURE 7. Cylinder Block 3. CRANKSHAFT AND PISTON G2M0168 1) Remove connecting rod cap. 2) Remove connecting rod bearing. CAUTION: Arrange removed connecting rod, connecting rod cap and bearing in order to prevent confusion. 3) Remove piston rings using the piston ring expander. 4) Remove the oil ring by hand.
Page 77 SERVICE PROCEDURE 7. Cylinder Block C: INSPECTION 1. CYLINDER BLOCK 1) Check for cracks and damage visually. Especially, inspect important parts by means of red check. 2) Check the oil passages for clogging. 3) Inspect crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary.
Page 78 SERVICE PROCEDURE 7. Cylinder Block 2) How to measure the inner diameter of each cylinder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the Figure, using a cylinder bore gauge. CAUTION: Measurement should be performed at a temperature 20°C (68°F).
Page 79 SERVICE PROCEDURE 7. Cylinder Block 6) Boring and honing (1) If the value of taper, out-of-roundness, or cylinder- to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use...
Page 80 SERVICE PROCEDURE 7. Cylinder Block 3. PISTON AND PISTON PIN 1) Check pistons and piston pins for damage, cracks, and wear and the piston ring grooves for wear and damage. Replace if defective. 2) Measure the piston-to-cylinder clearance at each cylin- der as instructed in 2.
Page 81 SERVICE PROCEDURE 7. Cylinder Block 4. PISTON RING 1) If piston ring is broken, damaged, or worn, or if its ten- sion is insufficient, or when the piston is replaced, replace piston ring with a new one of the same size as the piston. CAUTION: ¼...
Page 82 SERVICE PROCEDURE 7. Cylinder Block 5. CONNECTING ROD 1) Replace connecting rod, if the large or small end thrust surface is damaged. 2) Check for bend or twist using a connecting rod aligner. Replace connecting rod if the bend or twist exceeds the limit.
Page 83 SERVICE PROCEDURE 7. Cylinder Block 5) Measure the oil clearance on individual connecting 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. (See the table below.) Connecting rod oil clearance: Standard...
Page 84 SERVICE PROCEDURE 7. Cylinder Block (4) After completion of reaming, clean bushing to remove chips. 6. CRANKSHAFT AND CRANKSHAFT BEARING 1) Clean crankshaft completely and check for cracks by means of red check etc., and replace if defective. 2) Measure the crankshaft bend, and correct or replace if it exceeds the limit.
Page 85 SERVICE PROCEDURE 7. Cylinder Block 3) Inspect the crank journal and crankpin for wear. If not to specifications, replace bearing with an undersize one, and replace or recondition crankshaft as necessary. When grinding crank journal or crankpin, finish them to the speci- fied dimensions according to the undersize bearing to be used.
Page 86 SERVICE PROCEDURE 7. Cylinder Block 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) G2M0180 5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear.
Page 87 SERVICE PROCEDURE 7. Cylinder Block D: ASSEMBLY 1. CRANKSHAFT AND PISTON H2M1302A Tightening torque: N⋅m (kg-m, ft-lb) T: 43 — 46 (4.4 — 4.7, 32 — 34) 1) Install connecting rod bearings on connecting rods and connecting rod caps. CAUTION: Apply oil to the surfaces of the connecting rod bear- ings.
Page 88 SERVICE PROCEDURE 7. Cylinder Block 4) Installation of piston rings and oil ring (1) Install oil ring spacer, upper rail and lower rail in this order by hand. Then install second ring and top ring with a piston ring expander. (2) Position the top ring gap at A or B in the Figure.
Page 89 SERVICE PROCEDURE 7. Cylinder Block 2. CYLINDER BLOCK 1) Install ST to cylinder block, then install crankshaft bear- ings. 499817000 ENGINE STAND CAUTION: Remove oil the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.
Page 90 SERVICE PROCEDURE 7. Cylinder Block 3) Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block. Fluid packing: THREE BOND 1215 or equivalent CAUTION: Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.
Page 91 SERVICE PROCEDURE 7. Cylinder Block 3. PISTON AND PISTON PIN (#1 AND #2) G2M0187 Tightening torque: N⋅m (kg-m, ft-lb) T: 62 — 76 (6.3 — 7.7, 46 — 56) 1) Installing piston (1) Turn cylinder block so that #1 and #2 cylinders face upward.
Page 92 SERVICE PROCEDURE 7. Cylinder Block (3) Install circlip. CAUTION: Use new circlips. G2M0190 (4) Install service hole plug and gasket. CAUTION: Use a new gasket and apply a coat of fluid packing to it before installation. Fluid packing: THREE BOND 1105...
Page 93 SERVICE PROCEDURE 7. Cylinder Block 4. PISTON AND PISTON PIN (#3 AND #4) G2M0191 Tightening torque: N⋅m (kg-m, ft-lb) T1: 6.4 (0.65, 4.7) T2: 62 — 76 (6.3 — 7.7, 46 — 56) Turn cylinder block so that #3 and #4 cylinders face upward.
Page 94 SERVICE PROCEDURE 7. Cylinder Block E: INSTALLATION 1. OIL PUMP AND WATER PUMP G2M0192 Tightening torque: N⋅m (kg-m, ft-lb) T1: 5 (0.5, 3.6) T2: 6.4 (0.65, 4.7) T3: 10 (1.0, 7) T4: 69 — 75 (7.0 — 7.6, 51 — 55) T5: First 10 —...
Page 95 SERVICE PROCEDURE 7. Cylinder Block 1) Install baffle plate. 2) Install oil strainer and O-ring 3) Install oil strainer stay. 4) Apply fluid packing to matching surfaces and install oil pan. Fluid packing: THREE BOND 1207C or equivalent G2M0084 5) Apply fluid packing to matching surfaces and install oil separator cover.
Page 96 SERVICE PROCEDURE 7. Cylinder Block (2) Apply fluid packing to matching surface of oil pump. Fluid packing: THREE BOND 1215 or equivalent (3) Install oil pump on cylinder block. Be careful not to damage oil seal during installation. CAUTION: ¼ Do not forget to install O-ring and seal when install- ing oil pump.
Page 97: T Diagnostics
DIAGNOSTICS 1. Engine Trouble in General 1. Engine Trouble in General Numbers shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”) 1 — Very often 2 — Sometimes 3 — Rarely TROUBLE Engine will not start.
Page 98 DIAGNOSTICS 1. Engine Trouble in General TROUBLE Engine will not start. INTAKE SYSTEM ¼ Improper idle adjustment. ¼ Loosened or cracked intake duct. ¼ Loosened or cracked blow-by hose. ¼ Loosened or cracked vacuum hose. ¼ Defective air cleaner gasket. ¼...
Page 99 DIAGNOSTICS 1. Engine Trouble in General TROUBLE Engine will not start. LUBRICATION SYSTEM ¼ Incorrect oil pressure. ¼ Loosened oil pump attaching bolts and defective gasket. ¼ Defective oil filter seal. ¼ Defective crankshaft oil seal. ¼ Defective rocker cover gasket. ¼...
Page 100: Engine Noise
DIAGNOSTICS 2. Engine Noise 2. Engine Noise Valve lash adjusters may make clicking noise once engine starts. It is normal if clicking noise ceases after a few min- utes. If clicking noise continues after a few minutes, check engine oil level and add oil if necessary. Then, do as follows to cease clicking noise.
Page 101: Engine
DIAGNOSTICS 2. Engine Noise Type of sound Condition Possible cause Valve mechanism is defective ¼ Broken lash adjuster. ¼ Worn valve rocker. Sound increases as engine Regular clicking sound. ¼ Worn camshaft. speed increases. ¼ Broken valve spring. ¼ Worn valve lifter hole. ¼...
Page 102: Engine Lubrication System
ENGINE LUBRICATION SYSTEM Page S SPECIFICATIONS AND SERVICE DATA............ 2 1. Specifications ................... 2 C COMPONENT PARTS.................. 3 1. Lubrication System .................. 3 W SERVICE PROCEDURE ................4 1. Oil Pump ....................4 2. Oil Pan and Oil Strainer................8 3.
Page 103: S Specifications And Service Data
SPECIFICATIONS AND SERVICE DATA 1. Specifications 1. Specifications Lubrication method Forced lubrication Pump type Trochoid type Inner rotor Number of teeth Outer rotor Outer rotor diameter x thickness 78 x 9 mm (3.07 x 0.35 in) STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in) Tip clearance between inner and outer rotor LIMIT 0.18 mm (0.0071 in)
Page 104: C Component Parts
COMPONENT PARTS 1. Lubrication System 1. Lubrication System G2M0065 Plug Baffle plate Washer Oil strainer stay Relief valve spring O-ring Relief valve Oil strainer Oil seal Oil level gauge guide Oil pump case Oil pan Inner rotor Oil level gauge Outer rotor Tightening torque: N⋅m (kg-m, ft-lb) Oil pump cover...
Page 105: Oil Pump
SERVICE PROCEDURE 1. Oil Pump 1. Oil Pump A: REMOVAL 1) Drain engine oil. Set container under the vehicle, and remove drain plug from oil pan. G2M0066 2) Drain coolant. Set container under the vehicle, and remove drain cock from radiator. G2M0067 3) Remove belt covers, timing belt and related parts.
Page 106 SERVICE PROCEDURE 1. Oil Pump 7) Remove oil pump by using flat-bladed screwdriver. CAUTION: Be careful not to scratch mating surfaces of cylinder block and oil pump. G2M0071 B: DISASSEMBLY Remove screws which secure oil pump cover and disas- semble oil pump. Inscribe alignment marks on inner and outer rotors so that they can be replaced in their original positions during reas- sembly.
Page 107 SERVICE PROCEDURE 1. Oil Pump 3. SIDE CLEARANCE Measure clearance between oil pump inner rotor and pump cover. If the clearance exceeds the limit, replace rotor or pump body. Side clearance: Standard 0.02 — 0.07 mm (0.0008 — 0.0028 in) Limit 0.15 mm (0.0059 in) G2M0075...
Page 108 SERVICE PROCEDURE 1. Oil Pump 2) Install inner and outer rotors in their original positions. 3) Install oil relief valve and relief spring. 4) Install oil pump cover. Tightening torque: T1: 5 — 6 N⋅m (0.5 — 0.6 kg-m, 3.6 — 4.3 ft-lb) T2: 40.7 —...
Page 109: Oil Pan And Oil Strainer
SERVICE PROCEDURE 2. Oil Pan and Oil Strainer 2. Oil Pan and Oil Strainer A: REMOVAL 1) Remove front wheels. 2) Remove air intake duct. 3) Disconnect connector from oxygen sensor. G2M0544 4) Remove pitching stopper. G2M0295 5) Remove radiator upper brackets. G2M0218 6) Support engine with a lifting device and wire ropes.
Page 110 SERVICE PROCEDURE 2. Oil Pan and Oil Strainer 9) Remove front exhaust pipe. (1) Separate front catalytic converter from center exhaust pipe. (2) Remove front exhaust pipe from engine. (3) Remove bolt which installs front exhaust pipe on bracket. G2M0290 10) Remove nuts which install front cushion rubber onto front crossmember.
Page 111 SERVICE PROCEDURE 2. Oil Pan and Oil Strainer 15) Remove baffle plate and oil strainer stay. G2M0377 B: INSPECTION By visual check make sure oil pan, oil strainer, oil strainer stay and baffle plate are not damaged. C: INSTALLATION CAUTION: Before installing oil pan, clean sealant from oil and engine block.
Page 112 SERVICE PROCEDURE 2. Oil Pan and Oil Strainer 4) Apply fluid packing to mating surfaces and install oil pan. Fluid packing: THREE BOND 1207C G2M0084 5) Tighten bolts which install oil pan onto engine block. Tightening torque: 9.8 N⋅m (1.0 kg-m, 7 ft-lb) G2M0081 6) Lower engine onto front crossmember.
Page 113 SERVICE PROCEDURE 2. Oil Pan and Oil Strainer (4) Tighten bolt which installs front exhaust pipe on bracket. Tightening torque: 21 — 26 N⋅m (2.1 — 2.7 kg-m, 15 — 20 ft-lb) G2M0379 9) Lower the vehicle. CAUTION: At this time, lower lifting device and release steel cables.
Page 114: Oil Pressure Switch
SERVICE PROCEDURE 2. Oil Pan and Oil Strainer - 3. Oil Pressure Switch 14) Install air intake duct. G2M0205 3. Oil Pressure Switch A: REMOVAL 1) Remove alternator from bracket. (1) Disconnect connector and terminal from generator. G2M0088 (2) Remove V-belt cover. (3) Loosen lock bolt and slider bolt, and remove front side V-belt.
Page 115 SERVICE PROCEDURE 3. Oil Pressure Switch B: INSTALLATION 1) Install oil pressure switch onto engine block. Tightening torque: 25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb) 2) Connect terminal of oil pressure switch. G2M0091 3) Install generator on bracket and temporary tighten installing bolts.
Page 116: T Diagnostics
DIAGNOSTICS 1. Engine Lubrication System 1. Engine Lubrication System Before troubleshooting, make sure that the engine oil level is correct and no oil leakage exists. Trouble Possible cause Corrective action Cracked diaphragm or oil leakage within switch Replace. 1) Oil pressure switch failure Broken spring or seized contacts Replace.
Page 117: Engine Cooling System
ENGINE COOLING SYSTEM Page S SPECIFICATIONS AND SERVICE DATA............2 1. Specifications .....................2 2. Service Data ....................2 C COMPONENT PARTS..................3 1. Engine Coolant Pump................3 2. Radiator and Radiator Fan ................4 3. Engine Coolant Pipe ..................5 W SERVICE PROCEDURE ................6 1. Engine Coolant Pump................6 2.
Page 118: S Specifications And Service Data
SPECIFICATIONS AND SERVICE DATA 1. Specifications - 2. Service Data 1. Specifications Electric fan + Forced engine coolant circulation Cooling system system MT model 6.4 (6.8, 5.6) Total engine coolant capacity (US qt, Imp qt) AT model 6.35 (6.7, 5.6) Type Centrifugal impeller type Discharge...
Page 119: C Component Parts
COMPONENT PARTS 1. Engine Coolant Pump 1. Engine Coolant Pump G2M0201 Engine coolant pump ASSY Tightening torque: N⋅m (kg-m, ft-lb) Gasket T1: First 10 — 14 (1.0 — 1.4, 7 — 10) Heater hose Second 10 — 14 (1.0 — 1.4, 7 — 10) Thermostat T2: 6 —...
Page 120: Radiator And Radiator Fan
COMPONENT PARTS 2. Radiator and Radiator Fan 2. Radiator and Radiator Fan G2M0202 Radiator lower cushion Radiator outlet hose Radiator ATF hose clamp Radiator cap ATF inlet hose A Radiator upper cushion ATF outlet hose A Radiator upper bracket ATF pipe Clamp ATF outlet hose B Radiator inlet hose...
Page 121: Engine Coolant Pipe
COMPONENT PARTS 3. Engine Coolant Pipe 3. Engine Coolant Pipe G2M0203 Engine coolant temperature sensor Tightening torque: N⋅m (kg-m, ft-lb) Engine coolant temperature gauge 6 — 7 (0.6 — 0.7, 4.3 — 5.1) Engine coolant pipe O-ring By-pass hose...
Page 122: Engine Coolant Pump
SERVICE PROCEDURE 1. Engine Coolant Pump 1. Engine Coolant Pump A: REMOVAL 1) Open front hood. 2) Disconnect ground cable from the battery. 3) Drain engine coolant completely. Set container under the vehicle, and remove drain cock from radiator. G2M0067 4) Disconnect radiator outlet hose from engine coolant pump.
Page 123 SERVICE PROCEDURE 1. Engine Coolant Pump 7) Remove timing belt. <Ref. to 1-5 [02A0].> G2M0068 8) Remove belt tension adjuster. G2M0069 9) Remove camshaft position sensor. G2M0417 10) Remove left side camshaft pulley by using ST. 499207100 CAMSHAFT SPROCKET WRENCH G2M0207 11) Remove left side rear timing belt cover.
Page 124 SERVICE PROCEDURE 1. Engine Coolant Pump 12) Remove tensioner bracket. 13) Disconnect heater hose from engine coolant pump. 14) Remove engine coolant pump. EQA0019 B: INSPECTION 1) Check engine coolant pump bearing for smooth rota- tion. 2) Check engine coolant pump pulley for abnormalities. 3) Using a dial gauge, measure impeller runout in thrust direction while rotating the pulley.
Page 125: Thermostat
SERVICE PROCEDURE 1. Engine Coolant Pump - 2. Thermostat C: INSTALLATION Installation is in the reverse order of removal. CAUTION: ¼ Replace gasket with a new one. ¼ When installing engine coolant pump, tighten bolts in two stages in numerical sequence as shown in fig- ure.
Page 126: Radiator
SERVICE PROCEDURE 3. Radiator 3. Radiator A: ON-CAR SERVICE 1) Remove radiator cap, top off radiator, and attach tester to radiator in place of cap. 2) Apply a pressure of 157 kPa (1.6 kg/cm , 23 psi) to radiator to check if: (1) Engine coolant leaks at/around radiator.
Page 127 SERVICE PROCEDURE 3. Radiator 6) Disconnect inlet hose from radiator. G2M0267 7) Disconnect connectors of radiator main fan and sub fan motor. G2M0263 8) Remove radiator upper brackets. NOTE: Place left upper radiator bracket between grille and body. G2M0218 9) While slightly lifting radiator, slide it to left. 10) Lift radiator up and away from vehicle.
Page 128 SERVICE PROCEDURE 3. Radiator C: INSTALLATION 1) Attach radiator mounting cushions to pins on the lower side of radiator. G2M0221 2) Fit cushions on lower side of radiator, into holes on body side and install radiator. G2M0220 3) Install radiator brackets and tighten bolts. 4) Connect radiator main fan motor and sub fan motor connectors.
Page 129: Radiator Cap
SERVICE PROCEDURE 3. Radiator - 4. Radiator Cap 8) Pour engine coolant. (1) Pour engine coolant into radiator up to filler neck position. (2) Pour engine coolant into reservoir tank up to upper level. (3) Attach radiator cap and reservoir tank cap properly. (4) Warm-up engine completely for more than five min- utes at 2,000 to 3,000 rpm.
Page 130: Radiator Fan And Fan Motor
SERVICE PROCEDURE 5. Radiator Fan and Fan Motor 5. Radiator Fan and Fan Motor A: REMOVAL 1) Disconnect ground cable from battery terminal. 2) Disconnect connector from fan motor. G2M0263 3) Remove reservoir tank. G2M0224 4) Remove two bolts holding shroud to radiator upper side. G2M0225 5) Remove radiator fan motor assembly.
Page 131: T Diagnostics
DIAGNOSTICS 1. Engine Cooling System 1. Engine Cooling System Trouble Possible cause Corrective action Replenish engine coolant, inspect for leakage, and a. Insufficient engine coolant. repair. b. Loose timing belt. Repair or replace timing belt tensioner. c. Oil on drive belt. Replace.
Page 132: Fuel Injection System
FUEL INJECTION SYSTEM Page C COMPONENT PARTS..................2 1. Collector Chamber and Intake Manifold ............2 2. Air Intake System..................4 3. Air Cleaner ....................5 S SERVICE PROCEDURE ................6 1. Air Cleaner and Air Intake Duct..............6 2. Mass Air Flow Sensor................7 3. Throttle Body....................8 4.
Page 133: C Component Parts
COMPONENT PARTS 1. Collector Chamber and Intake Manifold 1. Collector Chamber and Intake Manifold G2M0441...
Page 134 COMPONENT PARTS 1. Collector Chamber and Intake Manifold Gasket Fuel injector pipe insulator Hole lid EGR pipe cover Air suction pipe EGR pipe Air suction valve bracket Collector chamber gasket RH Air suction valve Intake manifold RH Air suction hose A Intake manifold gasket RH Air suction valve holder EGR solenoid valve...
Page 135: Air Intake System
COMPONENT PARTS 2. Air Intake System 2. Air Intake System G2M0387 Gasket By-pass hose Throttle position sensor Throttle body O-ring Tightening torque: N⋅m (kg-m, ft-lb) Gasket T1: 2.0 — 2.4 (0.20 — 0.24, 1.5 — 1.8) Idle air control solenoid valve T2: 5.2 —...
Page 136: Air Cleaner
COMPONENT PARTS 3. Air Cleaner 3. Air Cleaner G2M0388 Mass air flow sensor bracket Cushion rubber Mass air flow sensor ASSY Resonator chamber ASSY Air cleaner upper cover Clip Air cleaner element Tightening torque: N⋅m (kg-m, ft-lb) Spacer T1: 5.5 — 9.5 (0.56 — 0.97, 4.1 — 7.0) Bush T2: 23 —...
Page 137: Air Cleaner And Air Intake Duct
SERVICE PROCEDURE 1. Air Cleaner and Air Intake Duct 1. Air Cleaner and Air Intake Duct A: REMOVAL AND INSTALLATION 1) Loosen clamp which connect air intake duct to throttle body and mass air flow sensor. 2) Remove air intake duct. G2M0266 3) Disconnect connector from mass air flow sensor.
Page 138: Mass Air Flow Sensor
SERVICE PROCEDURE 2. Mass Air Flow Sensor 2. Mass Air Flow Sensor A: REMOVAL AND INSTALLATION 1) Remove air intake duct. G2M0266 2) Disconnect connector from mass air flow sensor. G2M0305 3) Remove air cleaner upper cover. G2M0390 4) Remove mass air flow sensor from air cleaner upper cover.
Page 139: Throttle Body
SERVICE PROCEDURE 3. Throttle Body 3. Throttle Body A: REMOVAL AND INSTALLATION 1) Remove air intake duct. G2M0266 2) Disconnect accelerator cable k 3) Disconnect cruise control cable k . (With cruise control) G2M0280 4) Disconnect connectors from idle air control solenoid valve and throttle position sensor.
Page 140: Collector Chamber And Intake Manifold
SERVICE PROCEDURE 3. Throttle Body - 4. Collector Chamber and Intake Manifold 7) Installation is in the reverse order of removal. CAUTION: Always use a new gasket. Tightening torque: 14 — 24 N⋅m (1.4 — 2.4 kg-m, 10 — 18 ft-lb) G2M0397 4.
Page 141 SERVICE PROCEDURE 4. Collector Chamber and Intake Manifold 7) Disconnect spark plug cords from ignition coil. 8) Disconnect connector from ignition coil. G6M0092 9) Disconnect water hose from throttle body. G2M0396 10) Disconnect brake booster hose k 11) Disconnect cruise control vacuum hose k .
Page 142 SERVICE PROCEDURE 4. Collector Chamber and Intake Manifold 15) Disconnect hose from air suction valve. (California only) G2M0401 16) Disconnect canister hose from pipe. G2M0370 17) Disconnect fuel hoses from pipes. WARNING: Catch fuel from hoses in a container. G2M0296 18) Remove bolts which hold power steering pipe bracket onto intake manifold.
Page 143 SERVICE PROCEDURE 4. Collector Chamber and Intake Manifold B: DISASSEMBLY 1) Remove throttle body from collector chamber. G2M0397 2) Remove intake manifold from collector chamber. G2M0405 C: ASSEMBLY 1) Assemble intake manifold from collector chamber. CAUTION: Replace gaskets with new ones. Tightening torque: 9 —...
Page 144 SERVICE PROCEDURE 4. Collector Chamber and Intake Manifold 2) Install intake manifold and collector chamber onto cyl- inder heads. CAUTION: Always use new gaskets. Tightening torque: 20 — 34 N⋅m (2.0 — 3.5 kg-m, 15 — 25 ft-lb) G2M0402 3) Install power steering pipe bracket onto intake manifold. G2M0287 4) Connect fuel hoses.
Page 145 SERVICE PROCEDURE 4. Collector Chamber and Intake Manifold 8) Connect air by-pass hose to FICD solenoid valve. (With A/C) 9) Connect emission hose to PCV valve. FICD solenoid valve PCV valve G2M0399 10) Connect engine coolant hoses to throttle body. G2M0396 11) Connect pipe to EGR valve, and install cover.
Page 146: Engine Coolant Temperature Sensor
SERVICE PROCEDURE 4. Collector Chamber and Intake Manifold - 5. Engine Coolant Temperature Sensor 14) Connect spark plug cords to ignition coil. 15) Connect connector to ignition coil. G6M0092 16) Connect connectors to throttle position sensor and idle air control solenoid valve. Idle air control solenoid valve Throttle position sensor G2M0395...
Page 147: Crankshaft Position Sensor
SERVICE PROCEDURE 5. Engine Coolant Temperature Sensor - 6. Crankshaft Position Sensor 2) Disconnect connector from engine coolant temperature sensor. 3) Remove engine coolant temperature sensor. G2M0407 4) Installation is in the reverse order of removal. Tightening torque: 22 — 27 N⋅m (2.2 — 2.8 kg-m, 16 — 20 ft-lb) G2M0407 6.
Page 148: Oxygen Sensor
2) Disconnect connector from oxygen sensor. G2M0544 3) Lift up the vehicle. 4) Apply SUBARU CRC or its equivalent to threaded por- tion of oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove oxygen sensor.
Page 149: Throttle Position Sensor
SERVICE PROCEDURE 7. Oxygen Sensor - 8. Throttle Position Sensor B: INSTALLATION 1) Before installing oxygen sensor, apply anti-seize com- pound only to threaded portion of oxygen sensor to make the next removal easier. Anti-seize compound: SS-30 by JET LUBE CAUTION: Never apply anti-seize compound to protector of oxy- gen sensor.
Page 150: Camshaft Position Sensor
SERVICE PROCEDURE 8. Throttle Position Sensor - 9. Camshaft Position Sensor 3) When using voltage meter; (1) Take out ECM. (2) Turn ignition switch to ON. (3) Adjust throttle position sensor to specified voltage between ECM connector terminal Connector & Terminal / Specified voltage (B121) No.
Page 151: Idle Air Control Solenoid Valve
SERVICE PROCEDURE 10. Idle Air Control Solenoid Valve - 11. Purge Control Solenoid Valve 10. Idle Air Control Solenoid Valve A: REMOVAL AND INSTALLATION 1) Disconnect connector from idle air control solenoid valve. G2M0418 2) Remove idle air control solenoid valve from throttle body.
Page 152: Egr Valve
SERVICE PROCEDURE 11. Purge Control Solenoid Valve - 12. EGR Valve 3) Take out purge control solenoid valve with bracket through the bottom of the collector chamber. 4) Disconnect connector and hoses from purge control solenoid valve. B: INSTALLATION 1) Connect hoses and connector to purge control solenoid valve.
Page 153: Egr Solenoid Valve
A: REMOVAL AND INSTALLATION 1) Disconnect connectors from recirculation gas tempera- ture sensor. G2M0426 2) Apply SUBARU CRC or its equivalent to threaded por- tion of recirculation gas temperature sensor and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 3) Remove recirculation gas temperature sensor from col- lector chamber.
Page 154: Air Suction Valve (California Model)
SERVICE PROCEDURE 15. Air Suction Valve (California Model) - 16. Air Suction Solenoid Valve (California Model) 15. Air Suction Valve (California Model) A: REMOVAL 1) Remove air intake duct. G2M0266 2) Remove hose from air suction valve. 3) Remove air suction valve. Silencer Air suction valve G2M0428...
Page 155: Fuel Injector
SERVICE PROCEDURE 16. Air Suction Solenoid Valve (California Model) - 17. Fuel Injector 3) Installation is in the reverse order of removal. Tightening torque: 14 — 24 N⋅m (1.4 — 2.4 kg-m, 10 — 18 ft-lb) G2M0420 17. Fuel Injector A: REMOVAL AND INSTALLATION 1) Release fuel pressure.
Page 156: Main Relay And Fuel Pump Relay
SERVICE PROCEDURE 19. Main Relay and Fuel Pump Relay 2) Detach floor mat of front passenger seat. 3) Remove protect cover. G2M0434 4) Remove nuts which install ECM onto body. G2M0435 5) Take out ECM and disconnect connector from it. 6) Installation is in the reverse order of removal.
Page 157 SERVICE PROCEDURE 19. Main Relay and Fuel Pump Relay 2) Remove screw which installs bracket of main relay k and fuel pump relay k G2M0438 3) Disconnect connectors from main relay and fuel pump relay. 4) Installation is in the reverse order of removal. Main relay Fuel pump relay G2M0438...
Page 158: Fuel System
FUEL SYSTEM Page S SPECIFICATIONS AND SERVICE DATA........... 2 1. Specifications ................... 2 C COMPONENT PARTS ................3 1. Fuel Tank ....................3 2. Fuel Line ....................5 W SERVICE PROCEDURE ................6 1. Precautions ....................6 2. On-Car Services ..................7 3.
Page 159: Specifications
SPECIFICATIONS AND SERVICE DATA 1. Specifications 1. Specifications Capacity (15.9 US gal, 13.2 Imp gal) Fuel tank Location Under rear seat Type Impeller Discharge pressure 250.1 kPa (2.55 kg/cm , 36.3 psi) Fuel pump More than 80 (21.1 US gal, 17.6 Imp gal)/h Discharge flow [12V at 250.1 kPa (2.55 kg/cm , 36.3 psi)]...
Page 160: C Component Parts
COMPONENT PARTS 1. Fuel Tank 1. Fuel Tank 1. AWD MODEL G2M0350 Heat sealed cover Fuel pipe ASSY Fuel delivery hose B Fuel tank band Fuel return hose B Protector Evaporation hose E Fuel tank Evaporation hose F Fuel pump gasket Roll cover valve bracket Fuel pump ASSY Roll over valve...
Page 161 COMPONENT PARTS 1. Fuel Tank 2. FWD MODEL H2M1303A Heat seated cover Tightening torque: N⋅m (kg-m, ft-lb) Fuel tank band T1: 3 — 6 (0.3 — 0.6, 2.2 — 4.4) Protector T2: 5 — 8 (0.5 — 0.8, 3.7 — 5.9) T3: 5.5 —...
Page 162: Fuel Line
COMPONENT PARTS 2. Fuel Line 2. Fuel Line G2M0339 Clamp Fuel return hose Fuel delivery hose A Air vent hose Fuel filter bracket Canister Fuel filter holder Canister hose A Fuel filter cup Two-way valve Fuel filter Canister hose B Evaporation hose Canister hose C Clip...
Page 163: Precautions
SERVICE PROCEDURE 1. Precautions 1. Precautions WARNING: ¼ Place “No fire” signs near the working area. ¼ Disconnect ground terminal from battery. ¼ Be careful not to spill fuel on the floor. A: RELEASING OF FUEL PRESSURE 1) Remove rear seat, and turn up floor mat. 2) Disconnect connector from fuel tank.
Page 164: On-Car Services
SERVICE PROCEDURE 1.Precautions - 2. On-Car Services 7) Take off fuel pump from fuel tank. G2M0344 8) Drain fuel from fuel tank by using a hand pump. WARNING: Do not use a motor pump when draining fuel. G2M0345 9) After draining fuel, reinstall fuel pump. Tighten nuts in numerical sequence shown in Figure to specified torque.
Page 165: Fuel Tank
(2) Separate rear exhaust pipe from front catalyst con- verter. (3) Separate rear exhaust pipe from muffler. (4) Remove hook from rubber cushion, and remove exhaust pipe. NOTE: To facilitate the removal of parts, apply a coat of SUBARU G2M0382 CRC5-56 (004301003) <Ref. to 2-9 [W2A0].>...
Page 166 SERVICE PROCEDURE 3. Fuel Tank 4) Remove muffler assembly. NOTE: To facilitate the removal of parts, apply a coat of SUBARU CRC5-56 (004301003) <Ref. to 2-9 [W3A0].> G2M0384 5) Remove rear differential assembly. (AWD model) (1) Remove rear axle shafts from rear differential assembly.
Page 167 SERVICE PROCEDURE 3. Fuel Tank 10) While holding fuel tank, remove bolts from bands and dismount fuel tank. WARNING: A helper is required to perform step 10). G2M0356 B: INSTALLATION Installation is in the reverse order of removal. Observe the following: 1) When installing fuel tank, have a helper hold fuel tank while installing bands.
Page 168 SERVICE PROCEDURE 3. Fuel Tank 4) Tighten band mounting bolts. Tightening torque: 23 — 24 N⋅m (2.3 — 4.3 kg-m, 17 — 31 ft-lb) G2M0359 5) Install rear crossmember. <Ref. to 4-1 [W11C0].> G4M0545 6) Install rear differential assembly. <Ref. to 3-4 [W2G0].> G3M0059 7) Install muffler assembly.
Page 169: Fuel Filler Pipe
SERVICE PROCEDURE 3. Fuel Tank - 4. Fuel Filler Pipe 10) Lower the vehicle, and connect connector to fuel pump. 11) Install access hole lid. 12) Install rear seat back and rear seat. G2M0341 4. Fuel Filler Pipe A: REMOVAL 1) Release fuel pressure.
Page 170 SERVICE PROCEDURE 4. Fuel Filler Pipe B: INSTALLATION 1) Hold fuel filler flap open. 2) Set fuel saucer k with rubber packing k , and insert fuel filler pipe into hole from the inner side of apron. 3) Align holes in fuel filler pipe neck and set cup k , and tighten screws.
Page 171: Fuel Filter
SERVICE PROCEDURE 5. Fuel Filter 5. Fuel Filter A: REMOVAL 1) Release fuel pressure. <Ref. to 2-8 [W1A0].> 2) Disconnect fuel hoses from fuel filter. 3) Remove filter from holder. G2M0347 B: INSPECTION 1) Check the inside of fuel filter for dirt and water sedi- ment.
Page 172: Fuel Pump
SERVICE PROCEDURE 6. Fuel Pump 6. Fuel Pump A: REMOVAL 1) Release fuel pressure. <Ref. to 2-8 [W1A0].> 2) Disconnect fuel delivery hose k and return hose k G2M0342 3) Remove nuts which install fuel pump onto fuel tank. G2M0343 4) Take off fuel pump from fuel tank.
Page 173: Fuel Meter Unit
SERVICE PROCEDURE 6. Fuel Pump - 7. Fuel Meter Unit C: INSTALLATION Installation is in the reverse order of removal. Observe the following: (1) Always use new gaskets. (2) Ensure sealing portion is free from fuel or foreign particles before installation. (3) Tighten nuts in numerical sequence shown in Fig- ure to specified torque.
Page 174: Fuel Delivery, Return And Evaporation Lines
SERVICE PROCEDURE 8. Fuel Delivery, Return and Evaporation Lines 8. Fuel Delivery, Return and Evaporation Lines A: REMOVAL 1) Release fuel pressure. <Ref. to 2-8 [W1A0].> 2) Remove inner trim, insulator and rear seat. <Ref. to 5-3 [W2A0].> 3) Remove fuel delivery pipes and hoses, fuel return pipes and hoses, and evaporation pipes and hoses.
Page 175 SERVICE PROCEDURE 8. Fuel Delivery, Return and Evaporation Lines 4) In engine compartment, detach fuel delivery hoses, return hoses and evaporation hose. G2M0296 5) In engine compartment, detach canister hoses from canister. G2M0370 B: INSTALLATION Installation is in the reverse order of removal. 1) Connect fuel delivery hose to pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in).
Page 176: Roll Over Valve
SERVICE PROCEDURE 9. Roll Over Valve - 10. Canister 9. Roll Over Valve A: REMOVAL 1) Lift up the vehicle. 2) Remove with bracket roll over valve. 3) Disconnect hoses from roll over valve, and remove it from bracket. G2M0373 B: INSPECTION 1) Connect hoses to roll over valve as shown in Figure.
Page 177: Fuel System
DIAGNOSTICS 1. Fuel System 1. Fuel System Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and tighten k Defective terminal contact. securely. k Trouble in electromagnetic or electronic circuit parts. Replace fuel pump.
Page 178: Exhaust System
EXHAUST SYSTEM Page C COMPONENT PARTS..................2 1. Exhaust System ..................2 W SERVICE PROCEDURE ................3 1. Front Exhaust Pipe and Front Catalytic Converter ........3 2. Rear Exhaust Pipe..................5 3. Muffler ......................6...
Page 179: C Component Parts
COMPONENT PARTS 1. Exhaust System 1. Exhaust System G2M0378 Upper front exhaust pipe cover CTR Muffler Front catalytic converter Lower front exhaust pipe cover CTR Cushion rubber Lower front catalytic converter cover Clamp Upper clamp Upper front catalytic converter cover Upper front exhaust pipe cover LH Lower clamp Tightening torque: N⋅m (kg-m, ft-lb)
Page 180: Front Exhaust Pipe And Front Catalytic Converter
SERVICE PROCEDURE 1. Front Exhaust Pipe and Front Catalytic Converter 1. Front Exhaust Pipe and Front Catalytic Converter A: REMOVAL 1) Disconnect connector from oxygen sensor. G2M0544 2) Lift up the vehicle. 3) Separate front catalytic converter from rear exhaust pipe.
Page 181 SERVICE PROCEDURE 1. Front Exhaust Pipe and Front Catalytic Converter B: INSTALLATION CAUTION: Replace gaskets with new ones. 1) Install front catalytic converter to front exhaust pipe. Tightening torque: 25 — 35 N⋅m (2.6 — 3.6 kg-m, 18 — 26 ft-lb) G2M0380 2) Install front exhaust pipe with front catalytic converter.
Page 182: Rear Exhaust Pipe
Be careful not to pull down front exhaust pipe and front catalytic converter. G2M0382 3) Remove rear exhaust pipe bracket from rubber cushion. NOTE: To facilitate removal, apply a coat of SUBARU CRC to pipe bracket in advance. SUBARU CRC (Part No. 004301003) G2M0315 B: INSTALLATION CAUTION: Replace gaskets with new ones.
Page 183: Muffler
CAUTION: Be careful not to pull down front exhaust pipe and front catalytic converter. NOTE: To facilitate removal, apply a coat of SUBARU CRC to mating area of rubber cushions in advance. SUBARU CRC (Part No. 004301003) G2M0384 3) Remove front rubber cushion, and detach muffler assembly.
Page 184 2-10 CLUTCH Page S SPECIFICATIONS AND SERVICE DATA........... 2 1. Clutch System..................2 C COMPONENT PARTS ................3 1. Clutch System..................3 W SERVICE PROCEDURE ................4 1. General ....................4 2. On-Car Service ..................4 3. Release Bearing and Lever ..............5 4.
Page 185: Clutch System
2-10 SPECIFICATIONS AND SERVICE DATA 1. Clutch System 1. Clutch System A: SPECIFICATIONS Type Push type Clutch cover Diaphragm set load kg (lb) 400 (882) 440 (970) Facing material Woven (Non asbestos) Clutch disc O.D. x I.D. x thickness mm (in) 200 x 130 x 3.5 (7.87 x 5.12 x 0.138) 215 x 150 x 3.5 (8.46 x 5.91 x 0.138) Spline O.D.
Page 186: C Component Parts
2-10 COMPONENT PARTS 1. Clutch System 1. Clutch System H2M1304A Clutch cable bracket Clutch release lever sealing Retainer spring Pivot Clutch release lever Clip Clutch release bearing Clutch cover Clutch disc Tightening torque: N⋅m (kg-m, ft-lb) T: 14.2 — 17.2 (1.45 — 1.75, 10.5 — 12.7)
Page 187: General
2-10 SERVICE PROCEDURE 1. General - 2. On-Car Service 1. General A: PRECAUTION When servicing clutch system, pay attention to the follow- ing items. 1. MECHANICAL APPLICATION TYPE 1) Check the routing of clutch cable for smoothness. 2) Excessive tightness or looseness of clutch cable have a bad influence upon the cable durability.
Page 188: Release Bearing And Lever
2-10 SERVICE PROCEDURE 3. Release Bearing and Lever 3. Release Bearing and Lever A: REMOVAL 1. MECHANICAL APPLICATION TYPE 1) Remove the two clips k from clutch release lever k and remove release bearing k CAUTION: Be careful not to deform clips. 2) Remove release lever seal k G2M0237 3) Remove release lever retainer spring from release lever...
Page 189 2-10 SERVICE PROCEDURE 3. Release Bearing and Lever 2. RELEASE LEVER Check lever pivot portion and the point of contact with release bearing case for wear. G2M0241 C: INSTALLATION CAUTION: Before or during assembling, lubricate the following points with a light coat of grease. ¼...
Page 190: Clutch Disc And Cover
2-10 SERVICE PROCEDURE 4. Clutch Disc and Cover 4. Clutch Disc and Cover A: REMOVAL 1) Install ST on flywheel. 498497100 CRANKSHAFT STOPPER 2) Remove clutch cover and clutch disc. CAUTION: ¼ Take care not to allow oil on the clutch disc facing. ¼...
Page 191 2-10 SERVICE PROCEDURE 4. Clutch Disc and Cover 4) Deflection on facing If deflection exceeds the specified value at the outer cir- cumference of facing, repair or replace. Limit for deflection: FWD model: 1.0 mm (0.039 in) at R = 95 mm (3.74 in) AWD model: 1.0 mm (0.039 in) at R = 102 mm (4.02 in)
Page 192 2-10 SERVICE PROCEDURE 4. Clutch Disc and Cover 2) Smoothness of rotation Rotate ball bearing applying pressure in thrust direction. If noise or excessive play is noted, replace ball bearing as follows: (1) Drive out ball bearing from flywheel. (2) Press bearing into flywheel until bearing end sur- face is flush with clutch disc contact surface of flywheel.
Page 193 2-10 SERVICE PROCEDURE 4. Clutch Disc and Cover 4) Install clutch cover on flywheel and tighten bolts to the specified torque. NOTE: ¼ When installing the clutch cover on the flywheel, position the clutch cover so that there is a gap of 120° or more between “0”...
Page 194: Clutch System
2-10 DIAGNOSTICS 1. Clutch System 1. Clutch System Condition Possible cause and testing Corrective action 1. Clutch slip- It is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms. page (a) Engine revs up when shifting. (b) High speed driving is impossible;...
Page 195: Clutch
2-10 DIAGNOSTICS 1. Clutch System 4. Noisy Examine whether the noise is generated when the clutch is disengaged, engaged, or partially engaged. clutch (a) Broken, worn or unlubricated release bearing Replace release bearing. (b) Insufficient lubrication of pilot bearing Apply grease. (c) Loose clutch disc hub Replace clutch disc.
Page 196 2-10 DIAGNOSTICS 1. Clutch System 1. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG Test (1) Disengage the clutch and shift quickly from neutral to reverse in idling condition. Gear noise Sufficient disengagement of clutch Test (2) Shift to reverse after 0.5 to 1.0 sec of clutch disengagement. Gear noise Defective transmission or excessive clutch drag torque...
Page 197: Engine And Transmission Mounting System
ENGINE AND TRANSMISSION 2-11 MOUNTING SYSTEM Page C COMPONENT PARTS .................. 2 1. Engine Mounting ..................2 2. Transmission Mounting ................3 W SERVICE PROCEDURE ................5 1. General Precaution .................. 5 2. Engine ...................... 6 3. Transmission ....................24...
Page 198: C Component Parts
2-11 COMPONENT PARTS 1. Engine Mounting 1. Engine Mounting G2M0258 Front cushion rubber Front engine mounting bracket Tightening torque: N⋅m (kg-m, ft-lb) T1: 20 — 33 (2.0 — 3.4, 14 — 25) T2: 31 — 51 (3.2 — 5.2, 23 — 38) T3: 54 —...
Page 199: Transmission Mounting
2-11 COMPONENT PARTS 2. Transmission Mounting 2. Transmission Mounting 1. MT MODEL G2M0259 Pitching stopper Rear cushion rubber (FWD) Rear cushion rubber (AWD) Rear crossmember Rubber cushion Tightening torque: N⋅m (kg-m, ft-lb) T1: 23 — 36 (2.3 — 3.7, 17 — 27) T2: 28 —...
Page 200 2-11 COMPONENT PARTS 2. Transmission Mounting 2. AT MODEL G2M0260 Pitching stopper Rear cushion rubber (FWD) Rear cushion rubber RH (AWD) Rear cushion rubber LH (AWD) Crossmember Tightening torque: N⋅m (kg-m, ft-lb) T1: 13 — 23 (1.3 — 2.3, 9 — 17) T2: 18 —...
Page 201: General Precaution
2-11 SERVICE PROCEDURE 1. General Precaution 1. General Precaution 1) Remove or install engine and transmission in an area where chain hoists, lifting devices, etc. are available for ready use. 2) Be sure not to damage coated surfaces of body panels with tools or stain seats and windows with coolant or oil.
Page 202: Engine
2-11 SERVICE PROCEDURE 2. Engine 2. Engine A: REMOVAL 1. Set the vehicle on lift arms. 2. Open front hood and support with a stay. 3. Release fuel pressure. 4. Disconnect battery cable and remove battery from vehicle. 5. Drain coolant. 6.
Page 203 2-11 SERVICE PROCEDURE 2. Engine 1) Set the vehicle on lift arms. 2) Open front hood fully and support with stay. 3) Release fuel pressure. (1) Disconnect fuel pump connector. (2) Start the engine, and run until it stalls. (3) After the engine stalls, crank it for five seconds more.
Page 204 2-11 SERVICE PROCEDURE 2. Engine (2) Disconnect radiator outlet hose from thermostat cover. (3) Disconnect ATF cooler hoses from pipes. (AT model) G2M0217 (4) Remove V-belt cover. G2M0089 (5) Disconnect radiator inlet hose from radiator. G2M0267 (6) Remove radiator upper bracket, and remove radia- tor assembly from vehicle.
Page 205 2-11 SERVICE PROCEDURE 2. Engine (3) Disconnect A/C pressure hoses from A/C compres- sor. G2M0270 8) Remove air intake system. (1) Disconnect connector from mass air flow sensor. (2) Remove air intake duct with air cleaner upper cover, and remove air cleaner element. G2M0271 9) Remove canister and bracket.
Page 206 2-11 SERVICE PROCEDURE 2. Engine 10) Disconnect connectors, cables and hoses. (1) Disconnect the following connectors. FICD solenoid valve (With A/C) Engine harness connectors Oxygen sensor connector Engine ground terminal Alternator connector and terminal A/C compressor connectors (With A/C) G2M0278 G2M0275 G2M0277 G2M0273...
Page 207 2-11 SERVICE PROCEDURE 2. Engine (2) Disconnect the following cables. Accelerator cable Cruise control cable Clutch release spring (MT model) Clutch cable (MT model) Hill holder cable (MT model) CAUTION: Disconnect hill-holder cable at connection on clutch release fork side and transfer it to PHV side. G2M0282 G2M0280 G2M0279...
Page 208 2-11 SERVICE PROCEDURE 2. Engine (3) Disconnect the following hoses. Cruise control vacuum hose (With cruise control) Brake booster vacuum hose Heater inlet and outlet hoses G2M0285 G2M0283 G2M0284...
Page 209 2-11 SERVICE PROCEDURE 2. Engine 11) Remove power steering pump from bracket. (1) Loosen lock bolt and slider bolt, and remove front side V-belt. G2M0286 (2) Remove pipe with bracket from intake manifold. G2M0287 (3) Remove bolts which install power steering pump from bracket.
Page 210 2-11 SERVICE PROCEDURE 2. Engine (3) Separate center exhaust pipe from rear exhaust pipe. G2M0291 (4) Remove bolt which installs center exhaust pipe on hunger bracket. CAUTION: Exhaust pipe will drop when all bolts are removed. So, hold it when removing the last bolt. G2M0379 13) Remove nuts which hold lower side of transmission to engine.
Page 211 2-11 SERVICE PROCEDURE 2. Engine 16) Remove pitching stopper. G2M0295 17) Disconnect fuel delivery hose, return hose and evapo- ration hose. CAUTION: Catch fuel from hose into container. G2M0296 18) Support engine with a lifting device and wire ropes. G2M0297 19) Support transmission with a garage jack.
Page 212 2-11 SERVICE PROCEDURE 2. Engine 21) Remove engine from vehicle. (1) Slightly raise engine. (2) Raise transmission with garage jack. (3) Move engine horizontally until mainshaft is with- drawn from clutch cover. (4) Slowly move engine away from engine compart- ment.
Page 213 2-11 SERVICE PROCEDURE 2. Engine B: INSTALLATION 1. Install engine to transmission. 2. Tighten bolts which hold upper side of transmission to engine. 3. Remove lifting device and wire rope. 4. Remove garage jack. 5. Install pitching stopper. AT model 6.
Page 214 2-11 SERVICE PROCEDURE 2. Engine 1) Install engine onto transmission. (1) Position engine in engine compartment and align it with transmission. CAUTION: Be careful not to damage adjacent parts or body pan- els with crank pulley, oil pressure gauge, etc. G2M0301 (2) Apply a small amount of grease to splines of main- shaft.
Page 215 2-11 SERVICE PROCEDURE 2. Engine 5) Install pitching stopper. Tightening torque: T1: 44 — 54 N⋅m (4.5 — 5.5 kg-m, 33 — 40 ft-lb) T2: 47 — 67 N⋅m (4.8 — 6.8 kg-m, 35 — 49 ft-lb) G2M0302 6) Install torque converter onto drive plate. (AT model) (1) Tighten bolts which hold torque converter to drive plate.
Page 216 2-11 SERVICE PROCEDURE 2. Engine (2) Install power steering pipe bracket on right side intake manifold, and install spark plug codes. G2M0287 (3) Install front side V-belt, and adjust it. <Ref. to 1-5 [W1A0].> G2M0286 9) Tighten nuts which hold lower side of transmission to engine.
Page 217 2-11 SERVICE PROCEDURE 2. Engine 11) Install front exhaust pipe and center exhaust pipe. 12) Connect hoses, connectors and cables. (1) Connect the following hoses. ¼ Fuel delivery hose, return hose and evaporation hose ¼ Heater inlet and outlet hoses ¼...
Page 218 2-11 SERVICE PROCEDURE 2. Engine 14) Install A/C flexible hoses. (With A/C) <Ref. to 4-7 [W16B0].> CAUTION: Use new O-rings. Tightening torque: 18 — 31 N⋅m (1.8 — 3.2 kg-m, 13 — 23 ft-lb) G2M0270 15) Install cooling system. (1) Attach radiator mounting cushions to pins on lower side of radiator.
Page 219 2-11 SERVICE PROCEDURE 2. Engine (5) Connect radiator inlet hose. G2M0267 (6) Connect radiator outlet hose. (7) Connect ATF cooler hoses. (AT model) G2M0217 (8) Install V-belt cover. G2M0089 16) Install battery in the vehicle, and connect cables. 17) Fill coolant. <Ref.
Page 220: Transmission
2-11 SERVICE PROCEDURE 3. Transmission 3. Transmission A: REMOVAL 1. Open front hood fully, and support it with stay. 2. Disconnect battery ground terminal. 3. Remove air intake duct. 4. Disconnect connectors and cables. 5. Remove starter. 6. Remove pitching stopper and bracket. AT model 7.
Page 221 2-11 SERVICE PROCEDURE 3. Transmission 16. Remove gear shift rod and stay from transmission. AT model 17. Remove gear selector cable. 18. Remove bolts which install stabilizer clamp onto crossmember. 19. Remove front drive shaft from transmission. 20. Remove nuts which hold lower side of transmission to engine.
Page 222 2-11 SERVICE PROCEDURE 3. Transmission 1) Open front hood fully, and support with stay. 2) Disconnect battery ground terminal. 3) Remove air intake duct. G2M0266 4) Disconnect connectors and cables. (1) Disconnect the following connectors. ¼ Oxygen sensor G2M0544 ¼ Transmission harness connector ¼...
Page 223 2-11 SERVICE PROCEDURE 3. Transmission ¼ Speedometer cable G2M0308 5) Remove starter. (1) Disconnect connectors and terminal from starter. (2) Remove bolt which installs upper side of starter. (3) Remove nut which installs lower side of starter, and remove starter from transmission. G2M0309 6) Remove pitching stopper.
Page 224 2-11 SERVICE PROCEDURE 3. Transmission 9) Remove transmission connector holder bracket. G2M0312 10) Set special tool. 41099AA000 ENGINE SUPPORT ASSY NOTE: Also available is Part No. 927670000. G2M0313 11) Remove bolt which holds right upper side of transmis- sion to engine. G2M0299 12) Remove exhaust system.
Page 225 2-11 SERVICE PROCEDURE 3. Transmission (4) Remove bolt which installs center exhaust pipe to hunger bracket. G2M0379 (5) Remove rear exhaust pipe. (AWD model) CAUTION: When removing exhaust pipes, be careful each exhaust pipe does not drop out. G2M0315 13) Drain ATF to remove drain plug. (AT model) Front differential oil drain plug ATF drain plug G2M0316...
Page 226 2-11 SERVICE PROCEDURE 3. Transmission (3) Remove bolts which hold center bearing onto body. CAUTION: Be careful not to drop propeller shaft. (4) Remove propeller shaft from transmission. G3M0024 CAUTION: ¼ Be sure to use an empty container to catch oil flow- ing out when removing propeller shaft.
Page 227 2-11 SERVICE PROCEDURE 3. Transmission 19) Remove front drive shaft from transmission. (1) Remove transverse link from housing. (2) Lower transverse link. G2M0324 (3) Remove spring pin and separate front drive shaft from each side of the transmission. CAUTION: Discard removing spring pin. Replace with a new one. G2M0325 20) Remove nuts which hold lower side of transmission to engine.
Page 228 2-11 SERVICE PROCEDURE 3. Transmission ¼ AT model G2M0329 23) Remove transmission. CAUTION: ¼ Move transmission jack toward rear until mainshaft is withdrawn from clutch cover. (MT model) ¼ Move transmission and torque converter as a unit away from engine. (AT model)
Page 229 2-11 SERVICE PROCEDURE 3. Transmission B: INSTALLATION 1. Install transmission to engine. 2. Install transmission rear crossmember. 3. Take off transmission jack. 4. Tighten nuts which hold lower side of transmission to engine. 5. Tighten bolt which holds right upper side of transmission to engine.
Page 230 2-11 SERVICE PROCEDURE 3. Transmission AT model 12. Install gear selector cable to gear selector lever. 13. Install ATF supply pipe, and connect ATF cooler hose to pipe. AWD model 14. Install propeller shaft. 15. Install exhaust system. ¼ Rear exhaust pipe [AWD] ¼...
Page 231 2-11 SERVICE PROCEDURE 3. Transmission 1) Install transmission onto engine. (1) Gradually raise transmission with transmission jack. (2) Engage them at splines. CAUTION: Be careful not to strike mainshaft against clutch cover. (MT model) 2) Install transmission rear crossmember. ¼ MT model Tightening torque: T1: 23 —...
Page 232 2-11 SERVICE PROCEDURE 3. Transmission 6) Install torque converter to drive plate. (AT model) (1) Tighten bolts which hold torque converter to drive plate. (2) Tighten other bolts while rotating the engine by using ST. 499977000 CRANK PULLEY WRENCH CAUTION: Be careful not to drop bolts into torque converter housing.
Page 233 2-11 SERVICE PROCEDURE 3. Transmission 9) Install front drive shaft into transmission. (1) Lift up the vehicle. (2) Install front drive shaft into transmission. (3) Drive spring pin into chamfered hole of drive shaft. CAUTION: Always use a new spring pin. G2M0325 (4) Install ball joint of lower arm into knuckle arm of housing, and tighten installing bolt.
Page 234 2-11 SERVICE PROCEDURE 3. Transmission 13) Install ATF supply pipe, and ATF cooler hose onto pipe. (AT model) G2M0317 14) Install propeller shaft. (AWD model) (1) Install propeller shaft into transmission. (2) Tighten bolts which install propeller shaft onto com- panion flange of rear differential.
Page 235 2-11 SERVICE PROCEDURE 3. Transmission (3) Install center exhaust pipe to rear exhaust pipe. Tightening torque: 13 — 23 N⋅m (1.3 — 2.3 kg-m, 9 — 17 ft-lb) G2M0291 (4) Tighten bolt which installs center exhaust pipe to hunger bracket. Tightening torque: 25 —...
Page 236 2-11 SERVICE PROCEDURE 3. Transmission (2) Connect the following cables. ¼ Speedometer cable ¼ Cruise control cable ¼ Clutch cable ¼ Hill holder cable 19) Install starter. (1) Install starter onto transmission case, and connect connectors and terminals. (2) Tighten bolt and nut which install starter onto trans- mission.
Page 237: Manual Transmission And Differential
MANUAL TRANSMISSION AND DIFFERENTIAL Page S SPECIFICATIONS AND SERVICE DATA............2 1. Manual Transmission and Differential ............2 C COMPONENT PARTS ..................7 1. Transfer Case and Extension ..............7 2. Rear Case (FWD Model)................8 3. Transmission Case .................9 4. Shifter Fork and Shifter Rod..............10 5.
Page 238: Manual Transmission And Differential
SPECIFICATIONS AND SERVICE DATA 1. Manual Transmission and Differential 1. Manual Transmission and Differential A: SPECIFICATIONS Model Item 1800cc 1800cc Type 5-forward speeds with synchromesh and 1-reverse 3.636 3.545 1.950 1.947 1.344 1.366 Transmission gear ratio 0.971 0.972 0.783 0.780 Reverse 3.583 3.416...
Page 239 SPECIFICATIONS AND SERVICE DATA 1. Manual Transmission and Differential B: SERVICE DATA Reverse accent shaft (FWD Model) 1. EXTENSION (AWD Model) Part No. Mark Remarks Snap ring (Inner-72) to ball bearing side clearance: Neutral position is closer to 0 — 0.15 mm (0 — 0.0059 in) 32188AA040 1st gear.
Page 240 SPECIFICATIONS AND SERVICE DATA 1. Manual Transmission and Differential 5. REVERSE IDLER GEAR (FWD Model) 5th shifter fork Adjustment of reverse idler gear position Reverse idler gear to transmission case (LH) wall clearance Part No. Mark Remarks 1.5 — 3.0 mm (0.059 — 0.118 in) Approach to 5th gear by 32812AA060 0.2 mm (0.008 in)
Page 241 SPECIFICATIONS AND SERVICE DATA 1. Manual Transmission and Differential 8. TRANSMISSION CASE ASSEMBLY (AWD 10. DRIVE PINION ASSEMBLY (AWD Model) Model) Preload adjustment of thrust bearing: Starting torque Drive pinion shim adjustment 0.3 — 0.8 N⋅m (3 — 8 kg-cm, 2.6 — 6.9 in-lb) Drive pinion shim Adjusting washer No.
Page 242 SPECIFICATIONS AND SERVICE DATA 1. Manual Transmission and Differential 11. CENTER DIFFERENTIAL 13. FRONT DIFFERENTIAL (FWD Model) Snap ring (Inner-110) to center differential case clearance: Bevel gear to pinion backlash 0 — 0.15 mm (0 — 0.0059 in) 0.13 — 0.18 mm (0.0051 — 0.0071 in) Snap ring (Inner-110) Washer (35.1 x 45 x t) Part No.
Page 243: Transfer Case And Extension
COMPONENT PARTS 1. Transfer Case and Extension 1. Transfer Case and Extension 1. AWD MODEL B3M0326A Transfer cover Reverse checking spring Snap ring (Outer-30) Cover gasket Reverse return spring Gasket Oil seal Reverse checking cam Ball bearing Gasket Reverse accent shaft Snap ring (Inner-72) Neutral switch O-ring...
Page 244: Rear Case (Fwd Model)
COMPONENT PARTS 2. Rear Case (FWD Model) 2. Rear Case (FWD Model) G3M0265 Rear case O-ring Case gasket Oil seal Back-up light switch Tightening torque: N⋅m (kg-m, ft-lb) Neutral switch T1: 6 — 7 (0.6 — 0.7, 4.3 — 5.1) Reverse check sleeve ASSY T2: 23 —...
Page 245: Transmission Case
COMPONENT PARTS 3. Transmission Case 3. Transmission Case G3M0266 Transmission case ASSY Tightening torque: N⋅m (kg-m, ft-lb) Gasket T: 41 — 47 (4.2 — 4.8, 30 — 35) Drain plug Snap ring (Outer) Speedometer driven gear Size All models Torque Washer 23 —...
Page 246: Shifter Fork And Shifter Rod
COMPONENT PARTS 4. Shifter Fork and Shifter Rod 4. Shifter Fork and Shifter Rod 1. AWD MODEL G3M0508 Plug Selector arm 3rd-4th fork rod Gasket Shifter arm 1st-2nd fork rod Reverse accent spring Reverse shifter lever Ball Ball Reverse fork rod arm Checking ball spring Snap ring (Inner) Snap ring (Outer)
Page 247 COMPONENT PARTS 4. Shifter Fork and Shifter Rod 2. FWD MODEL G3M0509 Plug Shifter arm Interlock plunger Gasket Reverse shifter lever Ball Reverse accent spring Reverse fork rod arm Spring Ball Snap ring Gasket Snap ring (Inner) Spring Plug Reverse check plate Ball Tightening torque: N⋅m (kg-m, ft-lb) Reverse check spring...
Page 248: Drive Pinion Assembly
COMPONENT PARTS 5. Drive Pinion Assembly 5. Drive Pinion Assembly 1. AWD MODEL G3M0510 Drive pinion shaft Baulk ring Washer Roller bearing Spring Differential bevel gear sleeve Washer 1st-2nd synchronizer hub Washer Thrust bearing Insert Lock washer Needle bearing Reverse driven gear Lock nut 2nd driven gear Tightening torque: N⋅m (kg-m, ft-lb)
Page 249 COMPONENT PARTS 5. Drive Pinion Assembly 2. FWD MODEL G3M0511 Drive pinion shaft Reverse driven gear Shifting insert 2nd driven gear Coupling sleeve Roller bearing 3rd-4th driven gear Insert guide 1st gear thrust washer Drive pinion shim Insert stopper plate Needle bearing Ball bearing Lock washer...
Page 250: Main Shaft Assembly
COMPONENT PARTS 6. Main Shaft Assembly 6. Main Shaft Assembly 1. AWD MODEL G3M0841 Oil seal Shifting insert Lock nut Needle bearing 4th drive gear Reverse idler gear shaft Transmission main shaft 4th gear thrust washer Straight pin 4th needle bearing race Ball bearing Reverse idler gear Needle bearing...
Page 251 COMPONENT PARTS 6. Main Shaft Assembly 2. FWD MODEL G3M0513 Oil seal Ball bearing Needle bearing Main shaft rear plate Transmission main shaft 5th drive gear Woodruff key Lock washer 5th needle bearing race Lock nut Needle bearing Washer 3rd drive gear Reverse idler gear Baulk ring Straight pin...
Page 252: Center Differential
COMPONENT PARTS 7. Center Differential 7. Center Differential G3M0514 Ball bearing Differential bevel pinion Snap ring (Inner-110) Retainer Center differential cover Differential bevel gear Needle bearing Washer Adjusting washer Center differential case Viscous coupling Snap ring Pinion shaft Roller bearing...
Page 253: Front Differential
COMPONENT PARTS 8. Front Differential 8. Front Differential G3M0515 Drive pinion shaft Oil seal Hypoid driven gear Differential side retainer Pinion shaft O-ring Straight pin Axle drive shaft Washer Retainer lock plate Differential bevel gear Tightening torque: N⋅m (kg-m, ft-lb) Differential bevel pinion T1: 22 —...
Page 254: General
SERVICE PROCEDURE 1. General 1. General A: APPLICATION Model Large title General Transfer Case and Extension (AWD Model) Rear Case (FWD Model) Transmission Case (AWD Model) Transmission Case (FWD Model) Drive Pinion Assembly (AWD Model) Drive Pinion Assembly (FWD Model) Main Shaft Assembly (AWD Model) Main Shaft Assembly (FWD Model) Center Differential (AWD Model)
Page 255 SERVICE PROCEDURE 1. General C: INSPECTION Disassembled parts should be washed clean first and then inspected carefully. 1) Bearings Replace bearings in the following cases: ¼ Bearings whose balls, outer races and inner races are broken or rusty. ¼ Worn bearings. ¼...
Page 256 SERVICE PROCEDURE 1. General 5) Insert (shifting) Replace the insert if deformed, excessively worn, or defec- tive in any way. G3M0520 6) Oil seal Replace the oil seal if the lip is deformed, hardened, damaged, worn, or defective in any way. 7) O-ring Replace the O-ring if the sealing face is deformed, hardened, damaged, worn, or defective in any way.
Page 257 SERVICE PROCEDURE 2. Transfer Case and Extension (AWD Model) 2. Transfer Case and Extension (AWD Model) A: REMOVAL G3M0789 1) Remove transfer cover k 2) Remove shifter fork screw k which secures selector arm to shifter arm. 3) Remove transfer case k with extension assembly.
Page 258 SERVICE PROCEDURE 2. Transfer Case and Extension (AWD Model) 2. TRANSFER CASE 1) Remove neutral switch k NOTE: Before removing shifter arm, disconnect neutral switch. 2) Draw out shifter arm k and remove selector arm k 3) Remove plug k , spring k and reverse check ball k Tightening torque:...
Page 259 SERVICE PROCEDURE 2. Transfer Case and Extension (AWD Model) 3. EXTENSION G3M0526 1) Remove extension cover k and shift bracket k 2) Remove snap ring (Outer-30) k 3) Remove transfer drive shaft k CAUTION: Do not remove ball bearing unless replacing. 4) Remove snap ring (Inner-72) k 5) Removal of ball bearing k CAUTION:...
Page 260 SERVICE PROCEDURE 2. Transfer Case and Extension (AWD Model) C: ASSEMBLY 1. EXTENSION G3M0953 Tightening torque: N⋅m (kg-m, ft-lb) T: 23 — 26 (2.3 — 2.7, 17 — 20) 1) Installation of ball bearing k and selection of snap ring (Inner-72) k (1) Attach ball bearing k (30 x 72 x 17) to extension...
Page 261 SERVICE PROCEDURE 2. Transfer Case and Extension (AWD Model) 2) Installation of transfer drive shaft. Press transfer drive shaft into inner race of ball bearing. G3M0529 3) Selection of snap ring (Outer-30). (1) Install snap ring on transfer drive shaft. (2) Measure clearance between snap ring and inner race of ball bearing.
Page 262 SERVICE PROCEDURE 2. Transfer Case and Extension (AWD Model) 2. TRANSFER CASE Assembly of transfer case is in the reverse order of disas- sembly. Observe the following: 1) Assembly of reverse checking sleeve. (1) Install reverse accent shaft, checking cam, return spring and checking spring onto reverse checking sleeve.
Page 263 SERVICE PROCEDURE 2. Transfer Case and Extension (AWD Model) 2) Installation of shifter arm k and selector arm k Install shifter arm into the partition from the front while inserting selector arm into the opening in reverse checking sleeve. Pass shaft through hole in selector arm until its end comes out of the rear of transfer case.
Page 264 SERVICE PROCEDURE 2. Transfer Case and Extension (AWD Model) (2) Measure depth “X” as shown in figure. (3) Calculate space “Y” using the following equation: Y = X − W + 0.24 mm (0.0094 in) [Thickness of gasket] (4) Select suitable washer in the following table. G3M0535 ¼...
Page 265 SERVICE PROCEDURE 2. Transfer Case and Extension (AWD Model) D: INSTALLATION G3M0792 Tightening torque: N⋅m (kg-m, ft-lb) T1: 14.2 — 17.2 (1.45 — 1.75, 10.5 — 12.7) T2: 18.1 — 21.1 (1.85 — 2.15, 13.4 — 15.6) T3: 23 — 26 (2.3 — 2.7, 17 — 20) 1) Install transfer case with extension assembly k 2) Secure selector arm to shifter arm with shifter fork screw k...
Page 266 SERVICE PROCEDURE 2. Transfer Case and Extension (AWD Model) ¼ When shim is removed, the neutral position will move closer to reverse; when shim is added, the neutral position will move closer to 1st gear. ¼ If shims alone cannot adjust the clearance, replace reverse accent shaft and re-adjust.
Page 267: Rear Case (Fwd Model)
SERVICE PROCEDURE 3. Rear Case (FWD Model) 3. Rear Case (FWD Model) A: DISASSEMBLY G3M0952 Tightening torque: N⋅m (kg-m, ft-lb) T1: 6 — 7 (0.6 — 0.7, 4.3 — 5.1) T2: 9 — 11 (0.9 — 1.1, 6.5 — 8.0) T3: 23 —...
Page 268 SERVICE PROCEDURE 3. Rear Case (FWD Model) 6) Remove back-up light switch. 7) Removal of oil seal. CAUTION: Do not reuse oil seal. G3M0541 B: ASSEMBLY Assembly of rear case is in the reverse order of disassem- bly. Observe the following: 1) Assembly of reverse checking sleeve.
Page 269 SERVICE PROCEDURE 3. Rear Case (FWD Model) G3M0952 Tightening torque: N⋅m (kg-m, ft-lb) T1: 6 — 7 (0.6 — 0.7, 4.3 — 5.1) T2: 9 — 11 (0.9 — 1.1, 6.5 — 8.0) T3: 23 — 26 (2.3 — 2.7, 17 — 20) 2) Installation of shifter arm k Install shifter arm into the partition from the front while inserting selector arm into the opening in reverse checking...
Page 270 SERVICE PROCEDURE 3. Rear Case (FWD Model) ¼ Adjustment shim Part No. Thickness mm (in) 32190AA000 0.15 (0.0059) 32190AA010 0.30 (0.0118) NOTE: ¼ When shim is removed, the neutral position will move closer to reverse; when shim is added, the neutral position will move closer to 1st gear.
Page 271: Transmission Case (Awd Model)
SERVICE PROCEDURE 4. Transmission Case (AWD Model) 4. Transmission Case (AWD Model) A: DISASSEMBLY 1. SEPARATION OF TRANSMISSION G3M0542 1) Remove clutch release lever k and bearing k . <Ref. to 2-10 [W3A1].> G3M0596 2) Remove bearing mounting bolts. G3M0597...
Page 272 SERVICE PROCEDURE 4. Transmission Case (AWD Model) 3) Remove main shaft rear plate k G3M0598 4) Separating transmission case. (1) Put vinyl tape around splines of right and left axle drive shafts to prevent damage to oil seals. G3M0543 (2) Separate transmission case into right and left cases by loosening seventeen coupling bolts and nuts.
Page 273 SERVICE PROCEDURE 4. Transmission Case (AWD Model) 2. TRANSMISSION CASE G3M0545 1) Drive out straight pin k with ST, and remove 5th shifter fork k 398791700 STRAIGHT PIN REMOVER G3M0600 2) Remove plugs k , springs k and checking balls k...
Page 274 SERVICE PROCEDURE 4. Transmission Case (AWD Model) 3) Drive out straight pin k , and pull out 3-4 fork rod k shifter fork k NOTE: When removing rod, keep other rods in neutral. Also, when pulling out straight pin, remove it toward inside of case so that it may not hit against case.
Page 275 SERVICE PROCEDURE 4. Transmission Case (AWD Model) B: ASSEMBLY 1. TRANSMISSION CASE G3M0548 Tightening torque: N⋅m (kg-m, ft-lb) T: 18.1 — 21.1 (1.85 — 2.15, 13.4 — 15.6) 1) Position interlock plungers (5.56 x 19.6), one plunger in hole between 1-2 and 3-4 fork rod holes, and one plunger in hole between 3-4 and reverse fork rod holes.
Page 276 SERVICE PROCEDURE 4. Transmission Case (AWD Model) 3) Install reverse arm fork spring, ball and interlock plunger (5.56 x 19.6) to reverse fork rod arm k . Insert reverse fork rod k into hole in reverse fork rod arm k , and hold it with outer snap ring k using ST.
Page 277 SERVICE PROCEDURE 4. Transmission Case (AWD Model) (2) After installing a suitable reverse shifter lever, shift into Neutral. Adjust clearance between reverse idler gear and transmission case wall, using washer(s). Clearance: 0 — 0.5 mm (0 — 0.020 in) G3M0550 ¼...
Page 278 SERVICE PROCEDURE 4. Transmission Case (AWD Model) 9) Position balls (7.1438 mm dia.) k , checking ball springs and gaskets k into 3-4 and 1-2 rod holes, and install plugs k CAUTION: Replace gasket with a new one. G3M0552 10) Installation of speedometer driven gear k (1) Install washer and speedometer shaft, and press fit oil seal with ST.
Page 279 SERVICE PROCEDURE 4. Transmission Case (AWD Model) 2. COMBINATION OF TRANSMISSION CASE G3M0553 Tightening torque: N⋅m (kg-m, ft-lb) T1: 25 (2.5, 18) T2: 26 — 32 (2.7 — 3.3, 20 — 24) 1) Alignment marks/figures on hypoid gear set k The upper figure on driven pinion is the match number for combining it with hypoid driven gear.
Page 280 SERVICE PROCEDURE 4. Transmission Case (AWD Model) 2) Adjustment of drive pinion shim k (1) Place drive pinion shaft assembly on right hand transmission main case without shim and tighten bear- ing mounting bolts. (2) Inspection and adjustment of ST. NOTE: ¼...
Page 281 SERVICE PROCEDURE 4. Transmission Case (AWD Model) 3) Install differential assembly k on left hand transmission case. CAUTION: Be careful not to fold the sealing lip of oil seal. NOTE: Wrap the left and right splined sections of axle shaft with vinyl tape to prevent scratches.
Page 282 SERVICE PROCEDURE 4. Transmission Case (AWD Model) 6) Selection of suitable 1st-2nd, 3rd-4th and 5th shifter forks. Set transmission main shaft assembly and drive pinion shaft assembly in position (so there is no clearance between the two when moved all the way to the front). Select suitable 1st-2nd, 3rd-4th and 5th shifter forks so that coupling sleeve and reverse driven gear are positioned in the center of their synchronizing mechanisms.
Page 283 SERVICE PROCEDURE 4. Transmission Case (AWD Model) 8) Combination of transmission case. (1) Wipe off grease, oil and dust on the mating sur- faces of transmission cases with white gasoline, and apply liquid gasket, and then put case right side and left side together.
Page 284 SERVICE PROCEDURE 4. Transmission Case (AWD Model) (1) Place the transmission with case left side facing downward and put ST1 on bearing cup. (2) Screw retainer assembly into left case from the bot- tom with ST2. Fit ST3 on the transmission main shaft. Shift gear into 4th or 5th and turn the shaft several times.
Page 285 SERVICE PROCEDURE 4. Transmission Case (AWD Model) (8) Set ST1 and ST2. Insert the needle through trans- mission oil drain plug hole so that the needle comes in contact with the tooth surface at a right angle and check the backlash. 498247001 MAGNET BASE 498247100...
Page 286 SERVICE PROCEDURE 4. Transmission Case (AWD Model) ¼ The drive pinion shim selected before is too thick. Reduce its thickness. G3M0571 ¼ The drive pinion shim selected before is too thin. Increase its thickness. G3M0572 11) After checking the tooth contact of hypoid gears, remove the lock plate k .
Page 287 SERVICE PROCEDURE 4. Transmission Case (AWD Model) 12) Selecting of main shaft rear plate. Using ST, measure the amount (A) of ball bearing protru- sion from transmission main case surface and select the proper plate in the following table. 498147000 DEPTH GAUGE Dimension A Part No.
Page 288: Transmission Case (Fwd Model)
SERVICE PROCEDURE 5. Transmission Case (FWD Model) 5. Transmission Case (FWD Model) A: DISASSEMBLY 1. SEPARATION OF TRANSMISSION G3M0576 1) Remove clutch release lever k and bearing k . <Ref. to 2-10 [W3A1].> G3M0596 2) Remove bearing mounting bolts k 3) Remove main shaft rear plate k...
Page 289 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 4) Separating transmission case. (1) Put vinyl tape around splines of right and left axle drive shafts to prevent damage to oil seals. G3M0543 (2) Separate transmission case into right and left cases by loosening seventeen coupling bolts and nuts. G3M0574 5) Remove drive pinion shaft assembly k from left side...
Page 290 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 2. TRANSMISSION CASE 1) Drive out straight pin k with ST, and remove 5th shifter fork k 398791700 STRAIGHT PIN REMOVER 2 2) Remove three plugs k , springs k and checking balls 3) Drive out straight pin k from 1-2 shifter fork k with ST,...
Page 291 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 8) Removing speedometer driven gear Remove outer snap ring k and pull out speedometer driven gear k . Next, remove speedometer shaft and washer from main case. G3M0547 B: ASSEMBLY 1. TRANSMISSION CASE 1) Assembly of differential side retainer Press-fit oil seal to differential side retainer using ST.
Page 292 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 5) For reverse shifter rail, install ball, spring and gasket into case and tighten plug. Tightening torque: 18.1 — 21.1 N⋅m (1.85 — 2.15 kg-m, 13.4 — 15.6 ft-lb) G3M0585 6) Adjustment of reverse idler gear position. 7) Shift reverse fork rod to reverse side, and adjust reverse shifter lever position so that the specified clear- ance is obtained between idler gear and left side case wall.
Page 293 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 9) Installation of plunger (5.56 x 10.1) Fit plunger into left side transmission case and reverse shifter rod arm. CAUTION: Be sure to insert the correct plunger. G3M0581 10) Installation of 5th shifter fork Install 5th shifter fork to reverse fork rod, and drive in straight pin with ST.
Page 294 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 12) Installation of 3rd-4th rod plug Fit the following parts into 3rd-4th rod plug hole of trans- mission case, and tighten plug. (1) Ball (7.1438) (2) Checking ball spring (3) Aluminium gasket (Use new part.) Tightening torque: 18.1 —...
Page 295 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 2. COMBINATION OF TRANSMISSION CASE 1) Alignment marks/figures on hypoid gear set The upper figure on driven pinion is the match number for combining it with hypoid driven gear. The lower figure is for shim adjustment.
Page 296 SERVICE PROCEDURE 5. Transmission Case (FWD Model) (3) Position the ST by inserting the knock pin of ST into the knock hole in the transmission case. (4) Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion.
Page 297 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 4) Transmission main shaft assembly Install needle bearing and oil seal onto the front of trans- mission main shaft assembly, and position in left side trans- mission case. CAUTION: ¼ Wrap clutch splined section with vinyl tape to pre- vent damage to oil seal.
Page 298 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 6) Selection of suitable 1st-2nd, 3rd-4th and 5th shifter forks. Set transmission main shaft assembly and drive pinion shaft assembly in position (so there is no clearance between the two when moved all the way to the front). Select suitable 1st-2nd, 3rd-4th and 5th shifter forks so that coupling sleeve and reverse driven gear are positioned in the center of their synchronizing mechanisms.
Page 299 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 8) Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline, and apply liquid gasket, and then put right and left side cases together. Liquid gasket: Three-bond 1215 or equivalent 9) Tighten 17 bolts with bracket, clip, etc.
Page 300 SERVICE PROCEDURE 5. Transmission Case (FWD Model) (3) Remove weight and screw in retainer without O-ring on the upper side and stop at the point where slight resistance is felt. NOTE: At this point, the backlash between the hypoid gear and drive pinion shaft is zero.
Page 301 SERVICE PROCEDURE 5. Transmission Case (FWD Model) (2) Backlash is excessive. To reduce backlash, loosen holder on the upper side (case right side) and turn in the holder on the lower side (case left side) by the same amount. G3M0569 (3) Backlash is insufficient.
Page 302 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 13) After checking the tooth contact of hypoid gears, remove the lock plate k . Then loosen retainer until the O-ring groove appears. Fit O-ring into the groove and tighten retainer into the position where retainer has been tightened in.
Page 303 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 16) Neutral position adjustment (1) Shift gear into 3rd gear position. (2) Shifter arm turns lightly toward the 1st/2nd gear side but heavily toward the reverse gear side because of the function of the return spring, until arm contacts the stopper.
Page 304 SERVICE PROCEDURE 5. Transmission Case (FWD Model) 17) Reverse check plate adjustment. Shift shifter arm complete to “5th” and then to reverse to see if reverse check mechanism operates properly. Also check to see if arm returns to Neutral when released from the reverse position.
Page 305: Drive Pinion Assembly (Awd Model)
SERVICE PROCEDURE 6. Drive Pinion Assembly (AWD Model) 6. Drive Pinion Assembly (AWD Model) A: DISASSEMBLY 1. DRIVE PINION SHAFT 1) Straighten lock nut at staked portion. Remove the lock nut using ST1, ST2 and ST3. 899884100 HOLDER 498427100 STOPPER 899988608 SOCKET WRENCH G3M0595...
Page 306 SERVICE PROCEDURE 6. Drive Pinion Assembly (AWD Model) 3) Remove woodruff key. 4) Remove roller bearing (42 x 74 x 40), 3rd and 4th driven gear using ST1 and ST2. 499757002 SNAP RING PRESS 899714110 REMOVER G3M0610 5) Remove the key. 6) Remove 2nd driven gear assembly.
Page 307 SERVICE PROCEDURE 6. Drive Pinion Assembly (AWD Model) 2. DRIVEN GEAR ASSEMBLY Assemble a driven shaft and 1st driven gear that select for adjustment the proper radial clearance. Driven shaft 1st driven gear Diameter k Part No. mm (in) Part No. 49.959 —...
Page 308 SERVICE PROCEDURE 6. Drive Pinion Assembly (AWD Model) 4) Install a set of roller bearings (42 x 74 x 40) onto the driven shaft using ST and press. 499277200 INSTALLER G3M0616 5) Position woodruff key in groove on the rear of driven shaft.
Page 309 SERVICE PROCEDURE 6. Drive Pinion Assembly (AWD Model) NOTE: When installing roller bearing, note its directions (front and rear) because knock pin hole in outer race is offset. G3M0621 2) Install thrust bearing (33 x 50 x 3) and needle bearing (30 x 37 x 23).
Page 310 SERVICE PROCEDURE 6. Drive Pinion Assembly (AWD Model) 2) Using ST1, ST2 and ST3, tighten lock nut to the speci- fied torque. 899884100 HOLDER 498427100 STOPPER 899988608 SOCKET WRENCH (27) Tightening torque: 118±8 N⋅m (12±0.8 kg-m, 86.8±5.8 ft-lb) G3M0626 3) After removing ST1, measure starting torque. 899884100 HOLDER 498427100...
Page 311: Drive Pinion Assembly (Fwd Model)
SERVICE PROCEDURE 6. Drive Pinion Assembly (AWD Model) - 7. Drive Pinion Assembly (FWD Model) 5) If specified starting torque range cannot be obtained when a No. 1 k adjusting washer is used, then select a suitable No. 2 k adjusting washer from those listed in the following table.
Page 312 SERVICE PROCEDURE 7. Drive Pinion Assembly (FWD Model) 3) Using ST1, ST2, and a press, remove: ¼ k 5th needle bearing race ¼ k 5th gear thrust washer ¼ k Ball bearing ¼ k 3rd and 4th driven gear 899714110 REMOVER 899864100 REMOVER...
Page 313 SERVICE PROCEDURE 7. Drive Pinion Assembly (FWD Model) 3) Fit roller bearing in drive pinion shaft. Install 1st driven gear thrust washer k 499877000 RACE 4-5 INSTALLER 499277100 BUSH 1-2 INSTALLER G3M0635 4) Install needle bearing inner race k 499877000 RACE 4-5 INSTALLER 499277100 BUSH 1-2 INSTALLER...
Page 314 SERVICE PROCEDURE 7. Drive Pinion Assembly (FWD Model) 9) Install ball bearing with ST. 899874100 INSTALLER NOTE: Some ball bearings may be installed in the drive pinion shaft without press tightness, but it causes no problem in practical operation. G3M0640 10) Install 5th driven gear thrust washer and then, install 5th needle bearing inner race k 899874100...
Page 315: Main Shaft Assembly (Awd Model)
SERVICE PROCEDURE 8. Main Shaft Assembly (AWD Model) 8. Main Shaft Assembly (AWD Model) A: DISASSEMBLY 1) Put vinyl tape around main shaft splines to protect oil seal from damage. Then pull out oil seal and needle bear- ing by hand. 2) Remove lock nut with ST1 and ST2.
Page 316 SERVICE PROCEDURE 8. Main Shaft Assembly (AWD Model) B: ASSEMBLY 1) Assemble sleeve and hub assembly for 3rd-4th, 5th and high-low synchronizing. NOTE: Position open ends of spring 120° apart. G3M0646 G3M0647 2) Install 3rd drive gear, balk ring, sleeve and hub assem- bly for 3rd-4th needle bearing (32 x 36 x 25.7) on transmis- sion main shaft.
Page 317 SERVICE PROCEDURE 8. Main Shaft Assembly (AWD Model) 5) Drive ball bearing k onto the rear section of transmis- sion main shaft using ST1, ST2 and a press. 899714110 REMOVER 499877000 INSTALLER G3M0650 6) Using the same tools as in step 5) above, install the following parts onto the rear section of transmission main shaft.
Page 318: Main Shaft Assembly (Fwd Model)
SERVICE PROCEDURE 9. Main Shaft Assembly (FWD Model) 9. Main Shaft Assembly (FWD Model) A: DISASSEMBLY 1) Put vinyl tape around main shaft splines to protect oil seal from damage. Then pull out oil seal and needle bear- ing by hand. 2) Removing lock nut Remove lock nut using ST1 and ST2.
Page 319 SERVICE PROCEDURE 9. Main Shaft Assembly (FWD Model) B: ASSEMBLY 1) Assemble sleeve and hub assembly. NOTE: ¼ Make sure bent sections of springs on both sides are kept 180° apart and hooked at hub’s holes. ¼ Before assembling main shaft, apply transmission oil to needle bearing, ball bearing and bushings sufficiently.
Page 320 SERVICE PROCEDURE 9. Main Shaft Assembly (FWD Model) 7) Assemble woodruff key and then 5th drive gear using ST1 and ST2. 899714110 REMOVER 899754112 PRESS NOTE: When assembling key, pay attention to the groove. G3M0659 8) Tighten lock nut using ST1 and ST2. 898938600 HOLDER 899988608...
Page 321: Center Differential (Awd Model)
SERVICE PROCEDURE 10. Center Differential (AWD Model) 10. Center Differential (AWD Model) A: DISASSEMBLY G3M0661 1) Remove snap ring (Inner-110) k using flat bladed screw driver. 2) Remove center differential cover k 3) Remove viscous coupling k 4) Remove needle bearings k 5) Remove adjusting washer (45 x 62 x t) k 6) Remove pinion shaft k , bevel pinions k...
Page 322 SERVICE PROCEDURE 10. Center Differential (AWD Model) B: ASSEMBLY Assembly is in the reverse order of disassembly. Observe the following; ¼ Install thrust washer with chamfered side of inner perim- eter facing the side gear. ¼ Install adjusting washer with chamfered side of inner perimeter facing the viscous coupling.
Page 323: Front Differential
SERVICE PROCEDURE 11. Front Differential 11. Front Differential A: DISASSEMBLY 1) Remove right and left snap rings k from differential, and then remove two axle drive shafts k NOTE: During reassembly, reinstall each axle drive shaft in the same place from which it was removed. 2) Loosen twelve bolts k and remove hypoid driven gear G3M0666...
Page 324 SERVICE PROCEDURE 11. Front Differential 5) Remove roller bearing. 899524100 PULLER SET (FWD) 399527700 PULLER SET (AWD) G3M0668 B: ASSEMBLY 1) Install bevel gear and bevel pinion together with washers, and insert pinion shaft. NOTE: Face the chamfered side of washer toward gear. G3M0669 2) Measure backlash between bevel gear and pinion.
Page 325 SERVICE PROCEDURE 11. Front Differential 3) Align pinion shaft and differential case at their holes, and drive straight pin k into holes from the hypoid driven gear side, using ST. 899904100 REMOVER NOTE: Lock straight pin after installing. G3M0666 4) Install roller bearing (40 x 80 x 19.75) to differential case.
Page 326 SERVICE PROCEDURE 11. Front Differential 5) Install hypoid driven gear k to differential case k using twelve bolts k Tightening torque: 57 — 67 N⋅m (5.8 — 6.8 kg-m, 42 — 49 ft-lb) G3M0666 6) Position drive axle shaft in differential case and hold it with outer snap ring (28).
Page 327: Manual Transmission And Differential
DIAGNOSTICS 1. Manual Transmission and Differential 1. Manual Transmission and Differential Symptom and possible cause Remedy 1. Gears are difficult to intermesh. The cause for difficulty in shifting gears can be classified into two kinds: one is malfunction of the gear shift system and the other is malfunction of the transmission.
Page 328 DIAGNOSTICS 1. Manual Transmission and Differential Symptom and possible cause Remedy 4. Broken differential (case, gear, bearing, etc.) Abnormal noise will develop and finally it will become impossible to continue to run due to broken pieces obstructing the gear revolution. (a) Insufficient or improper oil.
Page 329: Automatic Transmission And Differential
AUTOMATIC TRANSMISSION AND DIFFERENTIAL Page S SPECIFICATIONS AND SERVICE DATA..........1. Automatic Transmission and Differential ..........C COMPONENT PARTS................10 1. Torque Converter Clutch and Case ............10 2. Differential Case..................11 3. Oil Pump....................12 4. Transmission Case, Transmission Cover and Control Device ....13 5.
Page 330: S Specifications And Service Data
SPECIFICATIONS AND SERVICE DATA 1. Automatic Transmission and Differential 1. Automatic Transmission and Differential A: SPECIFICATIONS Symmetric, 3-element, single stage, 2 phase torque converter Type clutch coupling Torque Stall torque ratio 2.2 — 2.4 converter Nominal diameter 236 mm (9.29 in) clutch Stall speed (at sea level) 2,200 —...
Page 331 SPECIFICATIONS AND SERVICE DATA 1. Automatic Transmission and Differential Type Variable-capacity type vane pump Oil pump Driving method Driven by engine Number of vanes 9 pieces Electronic/hydraulic control Type [Four forward speed changes by electrical signals of car speed and accelerator (throttle) opening] Hydraulic control Automatic transmission fluid (ATF)
Page 332 SPECIFICATIONS AND SERVICE DATA 1. Automatic Transmission and Differential B: ADJUSTING PARTS G3M0774...
Page 333 SPECIFICATIONS AND SERVICE DATA 1. Automatic Transmission and Differential Part Name Part Number Dimension mm (in) Application Adjusting side — 0.030 —0.0012 — 0.023 —0.0009 13.5 (0.5315 ), 13.5 (0.5315 — 0.037 —0.0015 —0.030 —0.0012 CONTROL PISTON 31235AA040 — 070 clearance of oil —0.016 —0.0006...
Page 334 SPECIFICATIONS AND SERVICE DATA 1. Automatic Transmission and Differential C: LOCATION AND INSTALLING DIRECTION OF THRUST NEEDLE BEARING G3M0775...
Page 335 SPECIFICATIONS AND SERVICE DATA 1. Automatic Transmission and Differential Unit: mm (in) Part Name Part Number Inside diameter Outside diameter Dimension Application Thrust needle A place of high 806530020 30 (1.18) 47 (1.85) 3.3 (0.130) bearing clutch drum Thrust needle A place of high 806536020 36 (1.42)
Page 336 SPECIFICATIONS AND SERVICE DATA 1. Automatic Transmission and Differential D: FLUID PASSAGES G3M0776...
Page 337 SPECIFICATIONS AND SERVICE DATA 1. Automatic Transmission and Differential G3M0777...
Page 338: Torque Converter Clutch And Case
COMPONENT PARTS 1. Torque Converter Clutch and Case 1. Torque Converter Clutch and Case G3M0845 Pitching stopper bracket Oil seal Oil level gauge Air breather hose clip O-ring Torque converter clutch case Oil seal Torque converter clutch Snap ring O-ring Washer Input shaft Speedometer shaft...
Page 339: Differential Case
COMPONENT PARTS 2. Differential Case 2. Differential Case G3M0846 Crown gear Tightening torque: N⋅m (kg-m, ft-lb) Straight pin T1: 25±2 (2.5±0.2, 18.1±1.4) Pinion shaft T2: 62±3 (6.3±0.3, 45.6±2.2) Differential case (RH) Differential case (LH) Taper roller bearing Oil seal (LH) O-ring Differential side retainer Circlip...
Page 340: Oil Pump
COMPONENT PARTS 3. Oil Pump 3. Oil Pump G3M0847 Retainer Oil pump housing Tightening torque: N⋅m (kg-m, ft-lb) Return spring T1: 7±1 (0.7±0.1, 5.1±0.7) Side seal T2: 13±1 (1.3±0.1, 9.4±0.7) T3: 18±5 (1.8±0.5, 13.0±3.6) Friction ring Control piston T4: 25±2 (2.5±0.2, 18.1±1.4) O-ring Plane seal T5: 39±3 (4.0±0.3, 28.9±2.2)
Page 341: Transmission Case, Transmission Cover And Control Device
COMPONENT PARTS 4. Transmission Case, Transmission Cover and Control Device 4. Transmission Case, Transmission Cover and Control Device G3M0848...
Page 342 COMPONENT PARTS 4. Transmission Case, Transmission Cover and Control Device Air breather hose Oil pan Oil level gauge Detention spring Oil charger pipe Pipe (AWD model) Inhibitor switch Transmission cover (FWD model) Range select lever Gasket Manual shaft Shim Manual plate Clip Manual lever Ball...
Page 343: Control Valve And Harness Routing
COMPONENT PARTS 5. Control Valve and Harness Routing 5. Control Valve and Harness Routing G3M0849 Stay Bracket Oil strainer Bracket Transmission harness O-ring O-ring Vehicle speed sensor 1 (FWD only) Duty sol. A (Line pressure) Separator plate Sol. ASSY Tightening torque: N⋅m (kg-m, ft-lb) Upper valve body T1: 7±1 (0.7±0.1, 5.1±0.7) Ball...
Page 344: Reverse Clutch And Band Brake
COMPONENT PARTS 6. Reverse Clutch and Band Brake 6. Reverse Clutch and Band Brake G3M0850 Brake band Lock nut Lathe cut seal ring Reverse clutch drum Brake band adjusting screw Band servo piston (3-4) Lip seal Strut O-ring Piston Band servo piston stem O.D.
Page 345: High Clutch And Planetary Gear
COMPONENT PARTS 7. High Clutch and Planetary Gear 7. High Clutch and Planetary Gear G3M0277 High clutch drum Rear planetary carrier Thrust needle bearing Lathe cut seal ring Rear internal gear Piston Thrust washer Lathe cut seal ring Snap ring Spring retainer One-way clutch (3-4) Snap ring...
Page 346: Forward Clutch And Low & Reverse Brake
COMPONENT PARTS 8. Forward Clutch and Low & Reverse Brake 8. Forward Clutch and Low & Reverse Brake G3M0851 Snap ring Overrunning piston Thrust needle bearing Retaining plate Lathe cut seal ring Needle bearing Driven plate (Thinner) Forward piston Seal ring Drive plate Lip seal Thrust needle bearing...
Page 347: Reduction Gear
COMPONENT PARTS 9. Reduction Gear 9. Reduction Gear G3M0852 Seal ring Reduction driven gear Reduction drive shaft Washer Plug Lock nut Ball bearing Tightening torque: N⋅m (kg-m, ft-lb) Reduction drive gear T: 98±5 (10.0±0.5, 72.3±3.6) Snap ring Drive pinion shaft Washer...
Page 348: Transfer And Extension
COMPONENT PARTS 10. Transfer and Extension 10. Transfer and Extension G3M0853 Snap ring Seal ring O-ring Test plug Pressure plate Vehicle speed sensor 1 (AWD only) O-ring Drive plate Pilot valve pipe Clip Driven plate Duty sol. C (transfer clutch) Transfer valve body Thrust needle bearing Gasket...
Page 349: Precaution
SERVICE PROCEDURE 1. Precaution 1. Precaution When disassembling assembling automatic transmission, observe the following instructions. 1) Workshop Provide a place that is clean and free from dust. Principally the conventional workshop is suitable except for a dusty place. In a workshop where grinding work, etc. which pro- duces fine particles is done, make independent place divided by the vinyl curtain or the equivalent.
Page 350 SERVICE PROCEDURE 1. Precaution (7) Apply the automatic transmission fluid (ATF) onto the parts immediately prior to assembly, and the speci- fied tightening torque should be observed carefully. (8) Use vaseline if it is necessary to hold parts in the position when assembling.
Page 351: On-Car Service
SERVICE PROCEDURE 2. On-Car Service 2. On-Car Service A: INSPECTION 1. ATF LEVEL 1) Raise ATF temperature to 60 to 80°C (140 to 176°F) from 40 to 60°C (104 to 140°F) (when cold) by driving a distance of 5 to 10 km (3 to 6 miles). NOTE: The level of ATF varies with fluid temperature.
Page 352 SERVICE PROCEDURE 2. On-Car Service 2. DIFFERENTIAL GEAR OIL LEVEL 1) Ensure the vehicle NOTE: Do not check the oil level nor add oil to the case with the front end of the vehicle jacked up; this will result in an incorrect reading of the oil level.
Page 353 SERVICE PROCEDURE 2. On-Car Service Oil pump housing ¼ Oil pump housing (Defective casting) ¼ O-ring on the test plugs ¼ Checking blind plugs ¼ Differential gear breather G3M0856 Automatic transmission case ¼ Transmission case (Defective casting) ¼ Mating surface of oil pan ¼...
Page 354 SERVICE PROCEDURE 2. On-Car Service Transmission cover ¼ Transmission cover (Defective casting) The point listed above should be checked for fluid leak. Checking method is as follows: (1) Place the vehicle in the pit, and check whether the leaking oil is ATF or not. The ATF is wine red in color, and can be discriminated easily from engine oil and gear oil.
Page 355 SERVICE PROCEDURE 2. On-Car Service ¼ Adjustment of the adjusting screw 1) Using a ST, immobilize the end of the 10 mm screw projecting on the left side of the transmission case, and loosen the nut with a double-end wrench. In the case of occurrence of problems 1) and 2) mentioned previously, perform the adjustment by loosening or tighten- ing the nut within a range of 3/4 turn from this state.
Page 356 SERVICE PROCEDURE 2. On-Car Service 2. INHIBITOR SWITCH The inhibitor switch allows the back-up lights to turn on when the select lever is in the R range and the starter motor to start when the lever is in the N or P range. It also monitors the input signal electronically controlled for each range and turns on the corresponding range light on the instrument panel.
Page 357 SERVICE PROCEDURE 2. On-Car Service (4) Check if there is continuity at equal points when the select lever is turned 1.5° in both directions from the N range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch.
Page 358 SERVICE PROCEDURE 2. On-Car Service 4. STANDARD VALUES Part name Terminal Resistance (Ω) Vehicle speed sensor 1 9 — 16 450 — 650 ATF temperature sensor 5 — 12 100 — 6,000 [2,000/20°C (68°F)] Duty solenoid A 7 — 4, 8 2.0 —...
Page 359 SERVICE PROCEDURE 2. On-Car Service C: REMOVAL AND INSTALLATION 1. SHIFT SOLENOID, DUTY SOLENOID AND VALVE BODY 1) Removal (1) Clean transmission exterior. (2) Drain ATF completely. NOTE: Tighten ATF drain plug after draining ATF. Tightening torque: G3M0297 23 — 26 N⋅m (2.3 — 2.7 kg-m, 17 — 20 ft-lb) (3) Remove oil pan and gasket.
Page 360 SERVICE PROCEDURE 2. On-Car Service (6) Remove control valve body and two brackets. Remove 6 long bolts (Black) and 11 short bolts (Yellow). NOTE: ¼ Be careful because oil flows from valve body. ¼ Be careful not to damage accumulator spring at rear of control valve.
Page 361 SERVICE PROCEDURE 2. On-Car Service (3) Install valve body and two brackets. Tightening torque: 7 — 9 N⋅m (0.7 — 0.9 kg-m, 5.1 — 6.5 ft-lb) NOTE: ¼ Secure accumulator springs using vaseline. ¼ Align manual valve connections. G3M0950 (4) Install oil strainer. Also install oil pipe and harness connector bracket.
Page 362 SERVICE PROCEDURE 2. On-Car Service 2. DUTY SOLENOID C AND TRANSFER VALVE BODY 1) Removal (1) Remove pitching stopper. G3M0304 (2) Raise car and drain ATF. G3M0297 (3) Remove front exhaust pipe. Disconnect oxygen sensor connector, and remove exhaust pipe. G3M0305 (4) Remove propeller shaft.
Page 363 SERVICE PROCEDURE 2. On-Car Service (6) Remove vehicle speed sensor 1. G3M0307 (7) Remove extension and gasket. ¼ Remove gear select cable nut. ¼ Move gear select cable so that extension bolts can be removed. G3M0308 ¼ Remove bolts. ¼ Remove extension and disconnect duty solenoid C connector.
Page 364 SERVICE PROCEDURE 2. On-Car Service 2) Installation (1) Install duty solenoid C and transfer valve body. ¼ Install duty solenoid C and transfer valve body. ¼ Install pipe and clamp. Tightening torque: 7 — 9 N⋅m (0.7 — 0.9 kg-m, 5.1 — 6.5 ft-lb) ¼...
Page 365 SERVICE PROCEDURE 2. On-Car Service (5) Install propeller shaft. Tightening torque: At rear differential 18 — 27 N⋅m (1.8 — 2.8 kg-m, 13 — 20 ft-lb) At center bearing 34 — 44 N⋅m (3.5 — 4.5 kg-m, 25 — 33 ft-lb) NOTE: Align matching marks on propeller shaft and rear differen- tial coupling.
Page 366: Performance Test
SERVICE PROCEDURE 3. Performance Test 3. Performance Test A: STALL TEST 1. GENERAL The stall test is of extreme importance in diagnosing the condition of the automatic transmission and the engine. It should be conducted to measure the engine stall speeds in all shift ranges except the P and N ranges.
Page 367 SERVICE PROCEDURE 3. Performance Test 5) When the engine speed is stabilized, read that speed quickly and release the accelerator pedal. 6) Shift the select lever to Neutral, and cool down the engine by idling it for more than one minute. 7) Record the stall speed.
Page 368 SERVICE PROCEDURE 3. Performance Test B: TIME LAG TEST 1. GENERAL If the shift lever is shifted while the engine is idling, there will be a certain time elapse or lag before the shock can be felt. This is used for checking the condition of the forward clutch, reverse clutch, low &...
Page 369 SERVICE PROCEDURE 3. Performance Test C: LINE PRESSURE TEST 1. GENERAL If the clutch or the brake band shows a sign of slippage or shifting sensation is not correct, the line pressure should be checked. ¼ Excessive shocks during upshifting or shifting takes place at a higher point than under normal circumstances, may be due to the line pressure being too high.
Page 370 SERVICE PROCEDURE 3. Performance Test 2. TEST METHODS 1) Temporarily attach the ST to a suitable place in the driver’s compartment, remove the blind plug located in front of the toe board and pass the hose of the ST to the engine compartment.
Page 371 SERVICE PROCEDURE 3. Performance Test 9) Check line pressure in accordance with the following chart. 3. EVALUATION NOTE: ¼ Under no load: “P”, “N”, “R”, and “2” (manual switch ON) ¼ Under full load: “R”, and “2” (manual switch ON) (With engine running at stall speed) <Standard line pressure>...
Page 372 SERVICE PROCEDURE 3. Performance Test If oil pressure is not produced or if it does not change in the AWD mode, the duty solenoid C or transfer valve assem- bly may be malfunctioning. If oil pressure is produced in the FWD mode, the problem is similar to that in the AWD mode.
Page 373 SERVICE PROCEDURE 3. Performance Test 5. AUTOMATIC SHIFT CHARACTERISTICS G3M0319 G3M0320...
Page 374 SERVICE PROCEDURE 3. Performance Test G3M0321 G3M0322...
Page 375: Overall Transmission
SERVICE PROCEDURE 4. Overall Transmission 4. Overall Transmission 1. SECTIONS THAT CAN BE DETACHED/ASSEMBLED G3M0323...
Page 376 SERVICE PROCEDURE 4. Overall Transmission A: DISASSEMBLY 1. EXTERNAL PARTS 1) Place the transmission unit on a work bench, with the oil pan facing down. CAUTION: Be careful not to bend or damage external parts. G3M0871 2) Remove the drain plug, and drain differential oil. Tighten the plug temporarily after draining.
Page 377 SERVICE PROCEDURE 4. Overall Transmission 6) Disconnect the air breather hose from the pitching stop- per bracket. G3M0329 7) Remove the pitching stopper bracket. G3M0330 8) Disconnect the air breather hose. G3M0872 9) Remove the oil charger pipe, and remove the O-ring from the flange face.
Page 378 SERVICE PROCEDURE 4. Overall Transmission 11) Remove harnesses from bracket. G3M0334 2. SEPARATION OF EACH SECTION 1) Separation of torque converter clutch case and trans- mission case sections CAUTION: ¼ Be careful not to damage the oil seal and bushing inside the torque converter clutch case by the oil pump cover.
Page 379 SERVICE PROCEDURE 4. Overall Transmission 2) Remove the reduction driven gear: ¼ Straighten the staked portion, and remove the lock nut. NOTE: Set the range selector lever to “P”. G3M0339 ¼ Using the ST, extract the reduction driven gear. 899524100 PULLER SET NOTE: Drill two holes in the puller.
Page 380 SERVICE PROCEDURE 4. Overall Transmission 6) Remove the oil pan and gasket. NOTE: Tap the corners of the oil pan when removing. G3M0344 7) Remove the oil cooler outlet pipe. CAUTION: Be careful not to twist the pipe. G3M0345 8) Disconnect the harness connectors for the solenoids and duty solenoids and the ground cord.
Page 381 SERVICE PROCEDURE 4. Overall Transmission 10) Remove the control valve body and the two brackets. G3M0863 11) Remove three accumulator springs. G3M0346 12) Loosen the reverse clutch drum lightly by turning the adjusting screw. Then remove the oil pump housing. CAUTION: Be careful not to lose the total end play adjusting thrust washer.
Page 382 SERVICE PROCEDURE 4. Overall Transmission 14) Remove the brake band and reverse clutch. NOTE: Contract the brake band with a clip. G3M0349 15) Take out the high clutch. CAUTION: Thrust needle bearing, bearing race are removed together with high clutch. Be careful not to lose it. G3M0350 16) Take out the high clutch hub and thrust bearing.
Page 383 SERVICE PROCEDURE 4. Overall Transmission 19) Take out the rear planetary carrier with rear sun gear and the thrust bearing. G3M0878 20) Take out the rear internal gear and the thrust bearing. G3M0879 21) Take out the one-way clutch outer race and the thrust washer.
Page 384 SERVICE PROCEDURE 4. Overall Transmission 24) Take out the low & reverse brake section. ¼ Remove the snap ring. Then remove the retaining plate, drive plates, driven plates, and dish plates as a unit. G3M0359 ¼ Turning the case upside down, take out the one-way clutch inner race and spring retainer.
Page 385 SERVICE PROCEDURE 4. Overall Transmission 27) Remove the range select lever. 28) Remove the detention spring. G3M0364 29) Remove the parking rod together with the manual lever. Then remove the manual shaft by pulling off the straight pin. CAUTION: Be careful not to damage the lips of the press-fitted oil seal in the case.
Page 386 SERVICE PROCEDURE 4. Overall Transmission 3) Extract the axle shaft with ST1 and ST2. 499095500 REMOVER 499247300 INSTALLER CAUTION: Do not reuse the circlip. G3M0369 4) Remove the differential case assembly. CAUTION: ¼ Remove the seal pipe if it is attached. (Reusing is not allowed.) ¼...
Page 387 SERVICE PROCEDURE 4. Overall Transmission 2) Remove duty solenoid C and the transfer valve body and the transfer pipe. CAUTION: ¼ Take out the inlet filter. ¼ Do not damage the O-ring. ¼ Be careful not to bend the pipe. G3M0867 3) Take out the roller bearing with ST.
Page 388 SERVICE PROCEDURE 4. Overall Transmission 4) Force-fit the oil seal to the torque converter clutch case with ST. 398437700 DRIFT G3M0379 5) Install the differential assembly to the case, paying spe- cial attention not to damage the speedometer gears (drive and driven) and the inside of the case (particularly, the dif- ferential side retainer contact surface).
Page 389 SERVICE PROCEDURE 4. Overall Transmission 9) Using the ST, screw in the retainer until light contact is felt. 499787000 WRENCH ASSY NOTE: Screw in the RH side slightly deeper than the LH side. G3M0381 10) Hypoid gear backlash adjustment and tooth contact check (1) Assemble the drive pinion assembly to the oil pump housing.
Page 390 SERVICE PROCEDURE 4. Overall Transmission (5) Tighten the LH retainer until contact is felt while rotating the shaft. Then loosen the RH retainer. Keep tightening the LH retainer and loosening the RH retainer until the pinion shaft can no longer be turned. This is the “zero”...
Page 391 SERVICE PROCEDURE 4. Overall Transmission (8) Apply red lead evenly to the surfaces of three or four teeth of the crown gear. Rotate the drive pinion in the forward and reverse directions several times. Then remove the oil pump housing, and check the tooth con- tact pattern.
Page 392 SERVICE PROCEDURE 4. Overall Transmission (9) If tooth contact is correct, mark the retainer position and loosen it. After fitting the O-ring, screw in the retainer to the marked position. Then tighten the lock plate to the specified torque. Tightening torque: 23 —...
Page 393 SERVICE PROCEDURE 4. Overall Transmission 15) Apply vaseline to the groove on the oil pump cover, and install two (R) seal rings and two (H) seal rings. NOTE: ¼ Fit the seal ring after compressing, and rub vaseline into the seal ring to avoid expansion. ¼...
Page 394 SERVICE PROCEDURE 4. Overall Transmission 4) Assemble the manual lever and parking rod to the inside shaft, and secure with a nut. Tightening torque: 45 — 49 N⋅m (4.6 — 5.0 kg-m, 33.3 — 36.2 ft-lb) G3M0398 5) Install the detention spring. NOTE: Position the spring so that its center is aligned with the center of the manual plate.
Page 395 SERVICE PROCEDURE 4. Overall Transmission (3) Place the spring retainer on the inner race. Install the spring to the recessed portion of the piston. Then tighten eight socket head bolts from the rear side of the transmission case. Tightening torque: 23 —...
Page 396 SERVICE PROCEDURE 4. Overall Transmission (2) Apply compressed air intermittently to check for operation. G3M0405 (3) Check the clearance (Selection of retaining plate) Standard value: 1.1 — 1.7 mm (0.043 — 0.067 in) Allowable limit: 2.7 mm (0.106 in) NOTE: Before measuring clearance, place the same thickness of shim on both sides to prevent retaining plate from tilting.
Page 397 SERVICE PROCEDURE 4. Overall Transmission 14) Install the one-way clutch outer race. NOTE: Make sure the forward clutch splines are engaged cor- rectly. G3M0409 15) Assemble the rear internal gear. (1) Join the thrust needle bearing and thrust washer to the gear with vaseline, and install the gear while rotat- ing it.
Page 398 SERVICE PROCEDURE 4. Overall Transmission 18) Install the front planetary carrier. Attach the thrust needle bearings to both sides of the car- rier with vaseline. Install the carrier carefully, while aligning with the splines of the forward clutch drum, and while rotat- ing the pinion.
Page 399 SERVICE PROCEDURE 4. Overall Transmission 23) Install the brake band. CAUTION: Be careful not to damage the brake band when install- ing. NOTE: Install the strut to the band servo piston stem. Then tighten it temporarily to avoid tilting the band. G3M0418 24) Adjustment of total end play and reverse clutch end play...
Page 400 SERVICE PROCEDURE 4. Overall Transmission (2) Measure the distance from the oil pump housing mating surface to the top surface of the oil pump cover with needle bearing, and to the thrust surface of the reverse clutch. G3M0420 (3) Equation for calculation ¼...
Page 401 SERVICE PROCEDURE 4. Overall Transmission ¼ Reverse clutch end play Unit: mm C = (M + 0.4) − m Clearance between oil pump housing hose and end of reverse clutch Distance from case mating surface to upper surface of reverse clutch 0.4: Gasket thickness Height from housing mating surface to thrust-receiv-...
Page 402 SERVICE PROCEDURE 4. Overall Transmission (4) Secure the housing with two nuts. Tightening torque: 38 — 44 N⋅m (3.9 — 4.5 kg-m, 28 — 33 ft-lb) G3M0424 3. TORQUE CONVERTER CLUTCH CASE AND TRANSMISSION CASE 1) Apply proper amount of liquid gasket (THREE-BOND #1215) to the entire torque converter clutch case mating surface.
Page 403 SERVICE PROCEDURE 4. Overall Transmission 2) Install and route the transmission harness. CAUTION: Be careful not to damage the harness. G3M0367 3) Install the control valve assembly. (1) Set the select lever in range “2”. (2) Install the two brackets to the control valve by engaging the manual valve and manual lever, then tighten the 17 bolts.
Page 404 SERVICE PROCEDURE 4. Overall Transmission 6) Install the oil cooler outlet pipe, and secure with two bolts. Tightening torque: 7 — 9 N⋅m (0.7 — 0.9 kg-m, 5.1 — 6.5 ft-lb) CAUTION: Fit the pipe into position. Be careful to avoid twisting. G3M0345 7) Install the oil pan.
Page 405 SERVICE PROCEDURE 4. Overall Transmission 3) Install the transfer clutch assembly to the case. CAUTION: Be careful not to damage the seal rings. NOTE: Insert the clutch assembly fully into position until the bear- ing shoulder bottoms. G3M0894 6. CONNECTION OF EACH SECTION 1) Install vehicle speed sensor 1 on transmission case.
Page 406 SERVICE PROCEDURE 4. Overall Transmission (2) Measure the distance “ ” from the transmission case mating surface to the reduction drive gear end surface with ST1 and ST2. (On FWD models, measure distance from end of case to end of bearing.) Unit: mm = Measured value −...
Page 407 SERVICE PROCEDURE 4. Overall Transmission 7) Installation of extension case (AWD), transmission cover (FWD) and transmission case. ¼ AWD model: (1) Attach the selected thrust needle bearing to the end surface of reduction drive gear with vaseline. (2) Set the parking return spring. (3) Remove the transfer clutch from the extension case.
Page 408 SERVICE PROCEDURE 4. Overall Transmission 2) Installation and adjustment of inhibitor switch: (1) Install the inhibitor switch to the transmission case. Fit the projecting portion of the switch in the recessed portion of the case, and tighten three bolts temporarily. (2) Insert the range select lever into the shaft, and tighten the nut.
Page 409 SERVICE PROCEDURE 4. Overall Transmission 6) Install the oil charge pipe. Tightening torque: Upper 38 — 44 N⋅m (3.9 — 4.5 kg-m, 28 — 33 ft-lb) Lower 5.9 — 6.9 N⋅m (0.60 — 0.70 kg-m, 4.3 — 5.1 ft-lb) CAUTION: Be careful not to damage the O-ring.
Page 410 SERVICE PROCEDURE 4. Overall Transmission 10) Tighten the drain plugs. Tightening torque: Diff. 41 — 47 N⋅m (4.2 — 4.8 kg-m, 30 — 35 ft-lb) 23 — 26 N⋅m (2.3 — 2.7 kg-m, 17 — 20 ft-lb) G3M0325 11) Insert the input shaft while turning lightly by hand. CAUTION: Be careful not to damage the bushing.
Page 411: Reduction Drive Gear Assembly
SERVICE PROCEDURE 5. Reduction Drive Gear Assembly 5. Reduction Drive Gear Assembly A: DISASSEMBLY 1) Take out the seal rings. CAUTION: Be careful not to damage the seal rings. G3M0438 2) Take out the snap ring (outer k CAUTION: Be careful not to damage the splines. 3) Using a press, remove the ball bearing k from shaft k (FWD only)
Page 412 SERVICE PROCEDURE 5. Reduction Drive Gear Assembly B: INSPECTION Make sure that each component is free of harmful gouges, cuts, or dust. C: ASSEMBLY 1) Press-fit the ball bearing and reduction drive gear to the shaft. G3M0442 2)AWD: Fit the snap ring k securely in the snap ring groove on the shaft k FWD: Press ball bearing k...
Page 413: Control Valve Body
SERVICE PROCEDURE 6. Control Valve Body 6. Control Valve Body The control valve is composed of parts which are accu- rately machined to a high degree and should be handled carefully during disassembly and assembly. As these parts are similar in shape, they should be arranged in neat order on a table after disassembly so that they can be easily installed to their original positions.
Page 414 SERVICE PROCEDURE 6. Control Valve Body Unit: mm (in) Part name Wire dia. Outer dia. Effective turn Free length Pressure regulator spring 1.6 (0.063) 14.0 (0.551) 31.5 (1.240) Pressure modifier spring 0.8 (0.031) 6.8 (0.268) 10.0 31.95 (1.2579) Modifier accumulator spring 1.3 (0.051) 9.8 (0.386) 30.5 (1.201)
Page 415 SERVICE PROCEDURE 6. Control Valve Body CAUTION: ¼ Do not lose the nine (9) steel balls contained in the upper valve body. ¼ Do not lose an orifice and a strainer contained in the lower valve body. NOTE: Remove the upper-lower valve body tightening bolts. Then remove two locating bolts.
Page 416 SERVICE PROCEDURE 6. Control Valve Body 3) Install the orifice check valve, orifice check spring and filter to the lower valve body. G3M0904 4) Install lower separate gasket and separate plate on lower body in that order, then temporarily tighten three support plates and two brackets.
Page 417: Oil Pump Assembly
SERVICE PROCEDURE 6. Control Valve Body - 7. Oil Pump Assembly 6) Install the duty solenoid B, ATF temperature sensor and four bracket. 7) Tighten twenty seven bolts & washers and two reamer bolts. Tightening torque: T1: 8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb) T2: 11.3±1.5 N⋅m (1.15±0.15 kg-m, 8.3±1.1 ft-lb) Unit: mm (in) Length...
Page 418 SERVICE PROCEDURE 7. Oil Pump Assembly 3) Remove the retainer and return spring. Then remove the rotor, two vane rings and nine vanes. G3M0447 4) Remove the cam ring and control piston. Also remove the O-ring, friction ring, two side seals, and plain seal.
Page 419 SERVICE PROCEDURE 7. Oil Pump Assembly (2) Using a depth gauge, measure the depth of the oil pump housing from the contact/sliding surface of the above mentioned component parts in the same manner as above. G3M0451 (3) Make sure that the clearances are within the speci- fied wear limits.
Page 420 SERVICE PROCEDURE 7. Oil Pump Assembly 3) Install the return spring and retainer between the hous- ing and cam ring. G3M0455 4) Install the control piston to the oil pump housing. NOTE: Fit the seal in the piston groove, with the red seals facing the top side.
Page 421: Drive Pinion Shaft
SERVICE PROCEDURE 8. Drive Pinion Shaft 8. Drive Pinion Shaft A: DISASSEMBLY 1) Straighten the staked portion of the lock nut, and remove the lock nut while locking the rear spline portion of the shaft with ST1 and ST2. Then pull off the drive pinion collar.
Page 422 SERVICE PROCEDURE 8. Drive Pinion Shaft C: ASSEMBLY 1) Measure dimension “A” of the drive pinion shaft. G3M0461 2) Using a press, force-fit the roller bearing in position. CAUTION: Do not change the relative positions of the outer race and bearing cone. 3) After fitting the O-ring to the shaft, attach the drive pin- ion collar to the shaft.
Page 423 SERVICE PROCEDURE 8. Drive Pinion Shaft 6) Stake the lock nut securely at two places. 7) Measure dimension “B” of the drive pinion shaft. G3M0465 8) Determine the thickness t (mm) of the drive pinion shim. t = 6.5±0.0625 − (B − A) NOTE: The number of shims must be three or less.
Page 424: Reverse Clutch
SERVICE PROCEDURE 9. Reverse Clutch 9. Reverse Clutch G3M0909 Reverse clutch drum Dish plate Lip seal Driven plate Reverse clutch piston Drive plate Lathe cut seal ring Retaining plate Spring Snap ring Spring retainer High clutch drum Snap ring A: DISASSEMBLY 1) Remove the snap ring k , and take out the retaining plate k...
Page 425 SERVICE PROCEDURE 9. Reverse Clutch C: ASSEMBLY G3M0909 Reverse clutch drum Spring Dish plate Retaining plate Lip seal Snap ring Spring retainer Driven plate Reverse clutch piston High clutch drum Snap ring Drive plate Lathe cut seal ring 1) Using the ST1, ST2 and ST3 as those used in disassembling, assemble piston k the return spring k spring retainer k...
Page 426: High Clutch
SERVICE PROCEDURE 10. High Clutch 10. High Clutch G3M0469 High clutch drum Drive plate Lathe cut seal ring Driven plate (Thicker) High clutch piston Retaining plate Lathe cut seal ring Snap ring Spring retainer Thrust needle bearing Snap ring High clutch hub Driven plate (Thinner) A: DISASSEMBLY 1) Remove the snap ring k...
Page 427 SERVICE PROCEDURE 10. High Clutch C: ASSEMBLY G3M0469 High clutch drum Drive plate Lathe cut seal ring Driven plate (Thicker) High clutch piston Retaining plate Lathe cut seal ring Snap ring Spring retainer Thrust needle bearing Snap ring High clutch hub Driven plate (Thinner) 1) Using the ST1, ST2 and ST3 as those used in disassembling, assemble the piston k...
Page 428: Forward Clutch Drum
SERVICE PROCEDURE 10. High Clutch - 11. Forward Clutch Drum Part No. Thickness mm (in) 31567AA190 3.6 (0.142) 31567AA200 3.8 (0.150) 31567AA210 4.0 (0.157) ¼ Available retaining plates 31567AA220 4.2 (0.165) 31567AA230 4.4 (0.173) 31567AA240 4.6 (0.181) 31567AA250 4.8 (0.189) 31567AA260 5.0 (0.197) 11.
Page 429 SERVICE PROCEDURE 11. Forward Clutch Drum 7) Remove the one-way clutch after taking out the snap ring. G3M0475 8) Remove the needle bearing after taking out the snap ring. G3M0476 B: INSPECTION 1) Drive plate facing for wear and damage 2) Snap ring for wear, return spring for setting and breakage, and snap ring retainer for deformation 3) Lip seal and lathe cut ring for damage...
Page 430 SERVICE PROCEDURE 11. Forward Clutch Drum C: ASSEMBLY G3M0910 Snap ring Forward clutch piston Snap ring Retainer Lathe cut seal ring Outer race Lathe cut seal ring Drift ball Driven plate Dish plate Forward clutch drum Driven plate (Thicker) Snap ring Overrunning clutch piston Driven plate (Thinner) Snap ring...
Page 431 SERVICE PROCEDURE 11. Forward Clutch Drum 2) Set the retainer on the piston with a press using ST1 and ST2, and attach the snap ring. 498627000 SEAT 398673600 COMPRESSOR G3M0473 3) Install the dish plate, driven plates, drive plates, and retaining plate, and secure with the snap ring.
Page 432 SERVICE PROCEDURE 11. Forward Clutch Drum 7) Checking clearance: ¼ Forward clutch Standard value: 0.45 — 0.85 mm (0.0177 — 0.0335 in) Allowable limit: 1.6 mm (0.063 in) ¼ Overrunning clutch Standard value: 1.0 — 1.4 mm (0.039 — 0.055 in) G3M0482 Allowable limit: 2.0 mm (0.079 in)
Page 433: One-Way Clutch Outer Race
SERVICE PROCEDURE 11. Forward Clutch Drum - 12. One-way Clutch Outer Race 9) Install the one-way clutch (1-2) and plate, and secure with the snap ring. NOTE: Set the inner race. Make sure that the forward clutch is free in the clockwise direction and locked in the counterclock- wise direction, as viewed from the front of the vehicle.
Page 434: Servo Piston
SERVICE PROCEDURE 13. Servo Piston 13. Servo Piston A: DISASSEMBLY 1) Remove the spring k 2) Remove the band servo piston (3-4) k 3) While compressing the retainer k from above, remove the snap ring k . Then remove the retainer k , spring k stem k 4) Take out the band servo piston (1-2) k...
Page 435: Differential Case Assembly
SERVICE PROCEDURE 14. Differential Case Assembly 14. Differential Case Assembly A: DISASSEMBLY 1) Using a press and ST, remove the taper roller bearing. 498077000 REMOVER CAUTION: Be careful not to damage the speedometer drive gear. G3M0488 2) Secure the case in a vise and remove the crown gear tightening bolts, then separate the crown gear, case (RH) and case (LH).
Page 436 SERVICE PROCEDURE 14. Differential Case Assembly 2) Install the washer and differential bevel gear to the dif- ferential case (LH). Then put the case over the differential case (RH), and connect both cases. 3) Install the crown gear and secure by tightening the bolt. Standard tightening torque: 59 —...
Page 437: Transfer Clutch
SERVICE PROCEDURE 15. Transfer Clutch 15. Transfer Clutch A: DISASSEMBLY 1) Remove the seal ring. CAUTION: Be careful not to damage the seal ring. G3M0493 2) Using a press and ST, remove the ball bearing. 498077000 REMOVER CAUTION: Do not reuse the bearing. G3M0494 3) Remove the snap ring, and take out the pressure plate, drive plates, and driven plates.
Page 438 SERVICE PROCEDURE 15. Transfer Clutch B: INSPECTION 1) Check the drive plate facing for wear and damage. 2) Check the snap ring for wear, return spring for perma- nent set and breakage, and spring retainer for deformation. 3) Check the lathe cut ring for damage. C: ASSEMBLY 1) Install the lathe cut seal ring to the I.D./O.D.
Page 439 SERVICE PROCEDURE 15. Transfer Clutch 3) Install the driven plates, drive plates, and pressure plate, and secure with a snap ring with ST1, ST2 and a press. 398673600 COMPRESSOR 498627000 SEAT G3M0501 4) Apply compressed air to see if the assembled parts move smoothly.
Page 440: Transfer Valve Body
SERVICE PROCEDURE 15. Transfer Clutch - 16. Transfer Valve Body 7) Coat the seal ring with vaseline, and install it in the seal ring groove of the shaft. CAUTION: Do not expand the seal ring excessively when install- ing. G3M0506 16.
Page 441 TRANSMISSION CONTROL SYSTEM Page C COMPONENT PARTS ..................2 1. Manual Transmission (FWD Model) ............2 2. Manual Transmission (AWD Model) ............3 3. Automatic Transmission................4 W SERVICE PROCEDURE ................5 1. Manual Transmission .................5 2. Automatic Transmission ................11...
Page 442: Manual Transmission (Fwd Model)
COMPONENT PARTS 1. Manual Transmission (FWD Model) 1. Manual Transmission (FWD Model) H3M1150A Gear shift knob Joint Console boot Boot plate Bracket Gear shift lever Spring Bush Stay Spacer Tightening torque: N⋅m (kg-m, ft-lb) Locking wire T1: 4 — 5 (0.4 — 0.5, 2.9 — 3.6) Boot T2: 3 —...
Page 443: Manual Transmission (Awd Model)
COMPONENT PARTS 2. Manual Transmission (AWD Model) 2. Manual Transmission (AWD Model) H3M1151A Gear shift knob Console boot Bracket Boot plate Spring Gear shift lever Washer Bush Stay Spacer Tightening torque: N⋅m (kg-m, ft-lb) Locking wire T1: 4 — 5 (0.4 — 0.5, 2.9 — 3.6) Boot T2: 3 —...
Page 444: Automatic Transmission
COMPONENT PARTS 3. Automatic Transmission 3. Automatic Transmission H3M1152A Button Selector lever Spring Lock plate Grip Detention spring Indicator cover “P” position switch Spacer Indicator light bulb Washer Shift-lock solenoid Boot Plate Spacer Packing Snap pin Outer cable Tightening torque: N⋅m (kg-m, ft-lb) T1: 9 —...
Page 445: Manual Transmission
SERVICE PROCEDURE 1. Manual Transmission 1. Manual Transmission A: REMOVAL 1) Remove knob from gearshift lever. G3M0676 2) Remove console cover and console boot. G3M0677 3) Remove rear console box, center console and instru- ment console. G3M0678 4) Remove boot plate from the body. G3M0679 5) Remove the spring between the joint and bracket.
Page 446 SERVICE PROCEDURE 1. Manual Transmission 6) Remove stay from bracket. G3M0681 7) Remove rod from joint. G3M0682 8) Remove gearshift lever. G3M0683 9) Remove the exhaust cover and remove cushion rubber from the body. G3M0684 B: DISASSEMBLY 1) Disconnect locking wires. G3M0685...
Page 447 SERVICE PROCEDURE 1. Manual Transmission 2) Remove rod from gearshift lever. G3M0686 3) Disconnect snap ring. G3M0687 4) Remove gearshift lever from stay. G3M0688 5) Disconnect spring pin and bush from gearshift lever. 6) Remove boot from gearshift lever. G3M0689 7) Remove the following parts from the stay.
Page 448 SERVICE PROCEDURE 1. Manual Transmission C: INSPECTION Check the following parts for deformation, damage and wear. Repair or replace any defective parts. Determine defective parts by comparing with new parts. Bush Cushion Spacer Boot Stay, rod and lever Spring G3M0691 D: ASSEMBLY 1) Clean all parts before assembly.
Page 449 SERVICE PROCEDURE 1. Manual Transmission 6) Tighten with locking wire to the extent that the boot will not come off. CAUTION: Always use new locking wire. G3M0685 7) Insert the rod into the boot hole. 8) Connect rod to gearshift lever. Tightening torque: 9 —...
Page 450 SERVICE PROCEDURE 1. Manual Transmission 3) Install rear console box, center console and instrument console. G3M0678 4) Install console cover and boot. 5) Install gearshift knob. G3M0677 6) Mount cushion rubber on the body. Tightening torque: 13 — 23 N⋅m (1.3 — 2.3 kg-m, 9 — 17 ft-lb) G3M0684 7) Connect rod to the joint.
Page 451: Automatic Transmission
SERVICE PROCEDURE 2. Automatic Transmission 2. Automatic Transmission A: REMOVAL 1) Remove the cable. (1) Prior to removal, set lever to “N” position. (2) Remove front exhaust pipe. G3M0698 (3) Separate cable from transmission lever. (4) Remove clamp from transmission case. G3M0699 (5) Disconnect cable from selector lever.
Page 452 SERVICE PROCEDURE 2. Automatic Transmission 4) Remove the screws to take off the plate from the body. G3M0703 B: DISASSEMBLY 1) Remove grip from selector lever. 2) Remove indicator from plate. G3M0704 3) Remove the following parts from the grip. Button Spring Manual switch...
Page 453 SERVICE PROCEDURE 2. Automatic Transmission 6) Remove lock plate. 7) Remove selector lever from the plate. G3M0708 8) Remove detention spring. G3M0709 C: INSPECTION 1) Inspect removed parts by comparing with new ones for deformation, damage and wear. Correct or replace if defec- tive.
Page 454 SERVICE PROCEDURE 2. Automatic Transmission 4) Assemble detention spring, shift-lock solenoid and “P” position switch. G3M0710 5) Adjust the position of shift-lock plate and solenoid. Then, tighten the bolts. G3M0711 6) Assemble indicator to the plate. Tightening torque: 1.2 — 2.0 N⋅m (0.12 — 0.2 kg-m, 0.9 — 1.5 ft-lb) G3M0712 7) Assemble the following parts to the grip.
Page 455 SERVICE PROCEDURE 2. Automatic Transmission 9) After completion of fitting, transfer selector lever to range “P” ∼ “1”, pressing the button of the grip; then check whether the indicator and select lever agree, whether the pointer and position mark agree and what the operating force is.
Page 456 SERVICE PROCEDURE 2. Automatic Transmission 8) Insert the thread portion of the other inner cable and into the connector hole of the selector lever, and fix the other outer cable end to the bracket. 9) Adjust the inner cable length. (1) Put connector into contact with nut k (2) Tighten nut k Tightening torque:...
Page 457 AWD SYSTEM Page S SPECIFICATIONS AND SERVICE DATA.............2 1. AWD System....................2 C COMPONENT PARTS ..................4 1. Rear Differential Mounting System ............4 2. Propeller Shaft and Drive Shaft..............5 3. Rear Differential Assembly ................6 W SERVICE PROCEDURE ................7 1. Propeller Shaft ...................7 2.
Page 458: Awd System
SPECIFICATIONS AND SERVICE DATA 1. AWD System 1. AWD System A: SPECIFICATIONS 1. REAR FINAL REDUCTION GEAR RATIO Type of gear Hypoid Gear ratio (Number of gear teeth) 4.111 (37/9) Oil capacity (0.8 US qt, 0.7 Imp qt) 2. PROPELLER SHAFT Front propeller shaft 489 (19.25) Joint-to-joint Length:...
Page 459 SPECIFICATIONS AND SERVICE DATA 1. AWD System B: SERVICE DATA 1. REAR DIFFERENTIAL ¼ Front and rear bearing preload at 12.7 — 32.4 N New bearing companion flange bolt hole (1.3 — 3.3 kg, 2.9 — 7.3 lb) Part No. Length mm (in) 38336AA000 1.500 (0.0591)
Page 460: Rear Differential Mounting System
COMPONENT PARTS 1. Rear Differential Mounting System 1. Rear Differential Mounting System G3M0780 Differential front member Tightening torque: N⋅m (kg-m, ft-lb) Plate T1: 32±8 (3.3±0.8, 23.9±5.8) Rear bushing T2: 64±8 (6.5±0.8, 47.0±5.8) Differential rear member T3: 69±10 (7±1, 51±7) T4: 78±10 (8±1, 58±7) Differential mount lower bracket T5: 98±10 (10±1, 72±7) Stopper...
Page 461: Propeller Shaft And Drive Shaft
COMPONENT PARTS 2. Propeller Shaft and Drive Shaft 2. Propeller Shaft and Drive Shaft G3M0017 Front propeller shaft Boot band (DOJ) Center bearing Boot (DOJ) Companion flange Boot band Stake nut Boot (BJ) Rear propeller shaft Boot band (BJ) Rear differential BJ ASSY Circlip Tightening torque: N⋅m (kg-m, ft-lb)
Page 462: Rear Differential Assembly
COMPONENT PARTS 3. Rear Differential Assembly 3. Rear Differential Assembly G3M0781 Pinion crown gear set Pinion mate gear Pinion height adjusting shim Pinion shaft lock pin Rear bearing Differential case Bearing preload adjusting spacer Pinion mate shaft Bearing preload adjusting washer Air breather cap Differential carrier Stud bolt...
Page 463: Propeller Shaft
SERVICE PROCEDURE 1. Propeller Shaft 1. Propeller Shaft A: ON-CAR SERVICE Check the following points with propeller shaft installed in vehicle. 1) Joints and connections Check for any looseness of yoke flange connecting bolts and center bearing retaining bolts. 2) Splines and bearing locations Turn propeller shaft by hand to see if abnormal free play exists at splines.
Page 464 SERVICE PROCEDURE 1. Propeller Shaft 6) Remove front exhaust cover. G3M0021 7) Remove differential mount front cover. G3M0022 8) Remove the four bolts which hold propeller shaft to rear differential. NOTE: ¼ Put matching marks on affected parts before removal. ¼...
Page 465 SERVICE PROCEDURE 1. Propeller Shaft 11) Install the extension cap to transmission. G3M0026 C: DISASSEMBLY Before removing center bearing, check its condition. If it does not operate smoothly or if there is any free play or leakage, remove as follows: 1) Put matching marks on affected parts.
Page 466 SERVICE PROCEDURE 1. Propeller Shaft 5) Lightly tap the head of front propeller shaft with a cop- per hammer until center bearing is removed. CAUTION: Be careful not to damage the thread portion. G3M0031 D: INSPECTION NOTE: Do not disassemble propeller shaft. Check the following and replace if necessary.
Page 467 SERVICE PROCEDURE 1. Propeller Shaft 4) Align matching marks and connect front and rear pro- peller shafts. Tightening torque: 24 — 32 N⋅m (2.4 — 3.3 kg-m, 17 — 24 ft-lb) G3M0027 F: INSTALLATION 1) Insert sleeve yoke into transmission and attach center bearing to car body.
Page 468: Rear Differential
SERVICE PROCEDURE 2. Rear Differential 2. Rear Differential A: ON-CAR SERVICE 1. FRONT OIL SEAL 1) Disconnect ground cable from battery. 2) Move selector lever or gear shift lever to “N”. 3) Release the parking brake. 4) Remove oil drain plug, and drain gear oil. G3M0032 5) Jack-up rear wheels and support the vehicle body with sturdy racks.
Page 469 SERVICE PROCEDURE 2. Rear Differential 9) Extract companion flange with a puller. G3M0035 10) Remove oil seal using ST. 398527700 PULLER ASSY G3M0036 11) Fit a new oil seal using ST. 498447120 OIL SEAL INSTALLER G3M0037 12) Install companion flange. 13) Tighten self-locking nut within the specified torque range so that the turning resistance of companion flange becomes the same as that before replacing oil seal.
Page 470 SERVICE PROCEDURE 2. Rear Differential 2. SIDE OIL SEAL 1) Disconnect ground cable from battery. 2) Move selector lever or gear shift lever to “N”. 3) Release the parking brake. 4) Loosen both wheel nuts. 5) Jack up the vehicle and support it with rigid racks. 6) Remove wheels.
Page 471 SERVICE PROCEDURE 2. Rear Differential (5) Remove the bolts which secure the trailing link to the rear housing. G3M0042 (6) Remove the bolts which secure the front and rear lateral link to the rear housing. G3M0043 (7) Remove the DOJ from the rear differential with tire lever.
Page 472 SERVICE PROCEDURE 2. Rear Differential 10) Remove oil seal with screwdriver. G3M0047 11) Drive in a new side oil seal with ST. CAUTION: Apply chassis grease between the oil seal lips. 498447100 OIL SEAL INSTALLER G3M0048 12) Insert the DOJ into rear differential. CAUTION: Before inserting, replace the circlip at the end of the spline shaft with a new one.
Page 473 SERVICE PROCEDURE 2. Rear Differential 13) Hereafter, re-assemble in reverse order of disassem- bly. B: IDENTIFICATION When replacing a rear differential assembly, select the cor- rect one according to the following table. CAUTION: Using the different rear differential assembly causes the drive line and tires to “drag”...
Page 474 SERVICE PROCEDURE 2. Rear Differential 8) Remove front exhaust cover. G3M0021 9) Remove front cover of rear differential mount. G3M0022 10) Remove propeller shaft. CAUTION: When removing propeller shaft, pay attention not to damage the sliding surfaces of rear drive shaft (exten- sion) spline, oil seal and sleeve yoke.
Page 475 SERVICE PROCEDURE 2. Rear Differential 13) Remove DOJ of rear drive shaft from rear differential. <Ref. to 3-4 [W2A2].> G3M0257 14) Secure rear drive shaft to rear crossmember using wire. G3M0046 15) Remove lower differential bracket. G3M0054 16) Support rear differential with transmission jack. G3M0055 17) Remove self-locking nuts connecting rear differential to rear crossmember.
Page 476 SERVICE PROCEDURE 2. Rear Differential 18) Remove bolts which secure rear differential front member to body. Loosen bolt k first, then removal bolts k NOTE: Support front member with the use of a helper to prevent it from dropping. G3M0057 19) While slowly lowering transmission jack, move rear differential forward and remove bolts from rear crossmem- ber.
Page 477 SERVICE PROCEDURE 2. Rear Differential 3) Remove rear cover by loosening retaining bolts. G3M0061 4) Replace air breather cap. NOTE: Do not attempt to replace the air breather cap unless nec- essary. G3M0062 5) Remove right and left lock plates. G3M0063 6) Remove right and left holders with ST.
Page 478 SERVICE PROCEDURE 2. Rear Differential 8) Remove bearing race from right and left holders with ST1 and ST2. 499705401 BEARING OUTER RACE PULLER ASSY 499705404 OUTER RACE PULLER SEAT G3M0066 9) Remove oil seal from right and left holders with ST. CAUTION: Perform this operation only when changing oil seal.
Page 479 SERVICE PROCEDURE 2. Rear Differential 13) Draw out pinion mate shaft and remove pinion mate gears, side gears and thrust washers. NOTE: The gears as well as thrust washers should be marked or kept separated left and right, and front and rear. G3M0071 14) Hold companion flange with ST and remove drive pin- ion nut.
Page 480 SERVICE PROCEDURE 2. Rear Differential 18) Remove front oil seal from differential carrier. G3M0076 19) Remove pilot bearing together with front bearing cone using ST. 398467700 DRIFT G3M0077 20) When replacing bearings, tap front bearing cup and rear bearing cup in this order out of case by using a brass bar.
Page 481 SERVICE PROCEDURE 2. Rear Differential 4) Thrust washers of side gear and pinion mate gear Replace if seizure, flaw, abnormal wear or other defect is evident. 5) Oil seal Replace if deformed or damaged, and at every disassem- bling. 6) Differential carrier Replace if the bearing bores are worn or damaged.
Page 482 SERVICE PROCEDURE 2. Rear Differential 2) Adjust preload for front and rear bearings. Adjust the bearing preload with spacer and washer between front and rear bearings. Pinion height adjusting washer are not affected by this adjustment. The adjustment must be carried out without oil seal inserted. (1) Press rear bearing race into differential carrier with ST1 and ST2.
Page 483 SERVICE PROCEDURE 2. Rear Differential Front and rear bearing preload For new bearing: 12.7 — 32.4 N (1.3 — 3.3 kg, 2.9 — 7.3 lb) at companion flange bolt hole G3M0082 Part No. Length mm (in) 38336AA000 1.500 (0.0591) 38336AA120 1.513 (0.0596) 38336AA010 1.525 (0.0600)
Page 484 SERVICE PROCEDURE 2. Rear Differential (2) Measure the clearance N between the end of ST3 and the end surface of ST1 by using a thickness gauge. NOTE: Make sure there is no clearance between the case and ST3. 498447140 DUMMY SHAFT 32285AA000 DUMMY COLLAR 498505501...
Page 485 SERVICE PROCEDURE 2. Rear Differential 6) Press-fit front bearing cone into case with ST1, ST2 and ST3. 32285AA000 DUMMY COLLAR 399780104 WEIGHT 899580100 INSTALLER G3M0085 7) Insert spacer, then press-fit pilot bearing with ST1 and ST2. 399780104 WEIGHT 899580100 INSTALLER G3M0719 8) Fit a new oil seal with ST.
Page 486 SERVICE PROCEDURE 2. Rear Differential 10) Install self-locking nut. Then tighten self-locking nut with ST. 398427700 FLANGE WRENCH Tightening torque: 167 — 196 N⋅m (17.0 — 20.0 kg-m, 123 — 145 ft-lb) G3M0721 11) Assembling differential case Install side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into differential case.
Page 487 SERVICE PROCEDURE 2. Rear Differential 12) Press side bearing cone onto differential case with ST. 498485400 DRIFT G3M0091 13) Assemble holders. (1) Install oil seal into right and left holders. 498447100 AXLE SHAFT OIL SEAL INSTALLER G3M0092 (2) Install bearing race into right and left holders. 398477702 BEARING OUTER RACE DRIFT G3M0093...
Page 488 SERVICE PROCEDURE 2. Rear Differential (2) Screw in side (left-side) holder until light contact is made with ST. (3) Screw in left-side holder until light contact is made with ST. 399780111 WRENCH G3M0064 (4) Back off side (left-side) holder approximately 1 1/2 teeth of holder, and tighten left-side holder by approxi- mately 2 teeth (approximately 1 1/2 + 1/2 teeth).
Page 489 SERVICE PROCEDURE 2. Rear Differential 16) Tighten bolt of lock plate to specified torque. Tightening torque: 22 — 27 N⋅m (2.2 — 2.8 kg-m, 16 — 20 ft-lb) G3M0063 17) Re-check crown gear-to-pinion backlash. Backlash: 0.10 — 0.15 mm (0.0039 — 0.0059 in) G3M0095 18) Check the crown gear runout on its back surface, and make sure pinion and crown gear rotate smoothly.
Page 490 SERVICE PROCEDURE 2. Rear Differential 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 tooth ends.
Page 491 SERVICE PROCEDURE 2. Rear Differential 21) Install rear cover and tighten bolts to specified torque. Tightening torque: 23 — 26 N⋅m (2.3 — 2.7 kg-m, 17 — 20 ft-lb) G3M0099 G: INSTALLATION To install, reverse the removal sequence. 1) Position front member on body by passing it under park- ing brake cable and securing to rear differential.
Page 492: Rear Differential Front Member
SERVICE PROCEDURE 3. Rear Differential Front Member 3. Rear Differential Front Member A: REMOVAL 1) Disconnect ground cable from battery. 2) Move selector lever or gear shift lever to “N”. 3) Release the parking brake. 4) Loosen wheel nuts. 5) Jack-up vehicle and support it with sturdy racks. 6) Remove wheels.
Page 493 SERVICE PROCEDURE 3. Rear Differential Front Member (2) Secure rear drive shaft to rear crossmember using wire. G3M0046 (3) Remove heat sealed cover. (4) Remove clamps and bracket of parking brake cable. G3M0053 (5) Remove lower differential bracket. G3M0054 (6) Support rear differential with transmission jack. G3M0055 (7) Remove self-locking nuts connecting rear differen- tial to rear crossmember.
Page 494 SERVICE PROCEDURE 3. Rear Differential Front Member (8) Remove bolts which secure rear differential front member to body. Loosen bolt k first, then removal bolts k NOTE: Support front member with the help of another person to prevent it from dropping. G3M0057 (9) While slowly lowering transmission jack, move rear differential forward and remove stud bolts from rear...
Page 495 SERVICE PROCEDURE 3. Rear Differential Front Member 3) Installing procedure hereafter is in the reverse order of removal.
Page 496: Rear Differential
DIAGNOSTICS 1. Rear Differential 1. Rear Differential Symptom and possible cause Remedy 1. Oil leakage Worn, scratched, or incorrectly seated front or side oil seal. Repair or replace. Scored, battered, or excessively worn sliding surface of com- panion flange. Clogged or damaged air breather. Clean, repair or replace.
Page 497: Propeller Shaft
DIAGNOSTICS 1. Rear Differential - 2. Propeller Shaft Symptom and possible cause Remedy 5. Noises when cornering Damaged differential gear. Replace. Excessive wear or damage of thrust washer. Replace. Broken pinion mate shaft. Replace. Seized or damaged side bearing. Replace. 6.
Page 498 SUSPENSION Page S SPECIFICATIONS AND SERVICE DATA.............2 1. Suspension ....................2 C COMPONENT PARTS ..................4 1. Suspension ....................4 W SERVICE PROCEDURE ................7 1. On-car Services ..................7 2. Front Transverse Link ................14 3. Front Ball Joint..................18 4. Front Strut ....................19 5. Front Stabilizer..................24 6.
Page 499: Suspension
SPECIFICATIONS AND SERVICE DATA 1. Suspension 1. Suspension A: SPECIFICATIONS 1. STABILIZER Bar dia. mm (in) Model Front Rear L⋅L+ 18 (0.71) — 19 (0.75) 13 (0.51) SEDAN L⋅L+ 18 (0.71) — 19 (0.75) 13 (0.51) L⋅L+ 19 (0.75) — 19 (0.75) 13 (0.51) WAGON...
Page 500 SPECIFICATIONS AND SERVICE DATA 1. Suspension B: WHEEL ALIGNMENT Sedan Wagon Camber −0° 0° −0° 0° (tolerance: ±0°30′) Caster 3° 3° 3° 3° (tolerance: ±1°) Front Toe-in 0±3 (0±0.12) Toe-in angle: −0°09′ [when toe-in is −3 (−0.12)] mm (in) Toe-out angle: 0°09′ [when toe-out is 3 (0.12)] Kingpin angle 14°...
Page 501: Suspension
COMPONENT PARTS 1. Suspension 1. Suspension 1. FRONT SUSPENSION G4M0476 Crossmember Stabilizer Tightening torque: N⋅m (kg-m, ft-lb) Bolt ASSY Jack-up plate T1: 20±6 (2.0±0.6, 14.5±4.3) Housing Dust seal T2: 25±4 (2.5±0.4, 18.1±2.9) Washer T3: 29±5 (3.0±0.5, 21.7±3.6) Strut mount T4: 32±10 (3.3±1.0, 24±7) Stop rubber (Rear) Spacer T5: 39 (4, 29)
Page 502 COMPONENT PARTS 1. Suspension 2. REAR SUSPENSION (AWD MODEL) G4M0477 Stabilizer Trailing link bracket Tightening torque: N⋅m (kg-m, ft-lb) Stabilizer bracket T1: 20±6 (2.0±0.6, 14.5±4.3) Stabilizer bushing Washer T2: 25±7 (2.5±0.7, 18.1±5.1) Clamp T3: 44±6 (4.5±0.6, 32.5±4.3) Crossmember Floating bushing T4: 59±10 (6.0±1.0, 43±7) T5: 98±15 (10.0±1.5, 72±11) Stopper...
Page 503 COMPONENT PARTS 1. Suspension 3. REAR SUSPENSION (FWD MODEL) G4M0478 Stabilizer Trailing link rear bushing Tightening torque: N⋅m (kg-m, ft-lb) Stabilizer bracket Trailing link T1: 20±6 (2.0±0.6, 14.5±4.3) Stabilizer bushing Trailing link front bushing T2: 25±7 (2.5±0.7, 18.1±5.1) Clamp T3: 44±6 (4.5±0.6, 32.5±4.3) Trailing link bracket Stabilizer link T4: 59±10 (6.0±1.0, 43±7)
Page 504: On-Car Services
SERVICE PROCEDURE 1. On-car Services 1. On-car Services A: WHEEL ALIGNMENT Check, adjust and/or measure wheel alignment in accor- dance with procedures indicated below: 1. Wheel arch height (Front and rear) 2. Caster (Front) 3. Camber (Front and rear) 4. Rear toe-in 5.
Page 505 SERVICE PROCEDURE 1. On-car Services 1. WHEEL ARCH HEIGHT 1) Adjust tire pressure to specifications. 2) Set vehicle under “curb weight” conditions. (Empty lug- gage compartment, install spare tire, jack, service tools, and top up fuel tank.) 3) Set steering wheel in a wheel-forward position. 4) Suspend thread from wheel arch (point “A”...
Page 506 SERVICE PROCEDURE 1. On-car Services 2. CAMBER AND CASTER ¼ Inspection 1) Place front wheel to be measured on turning radius gauge. Make sure vehicle is level and ground contacting surfaces of front and rear wheels are set at the same height.
Page 507 SERVICE PROCEDURE 1. On-car Services 3. FRONT WHEEL TOE-IN ¼ Inspection 1) Using a toe gauge, measure front wheel toe-in. Toe-in: 0±3 mm (0±0.12 in) 2) Mark rear sides of left and right tires at height corre- sponding to center of spindles and measure distance “B” between marks.
Page 508 SERVICE PROCEDURE 1. On-car Services 4. REAR WHEEL TOE-IN (FWD MODEL) ¼ Inspection Using a toe gauge, measure rear wheel toe-in. Toe-in: 0±3 mm (0±0.12 in) 2) Mark rear sides of left and right tires at height corre- sponding to center of spindles and measure distance “B” between marks.
Page 509 SERVICE PROCEDURE 1. On-car Services NOTE: ¼ When toe-ins for left and right wheels are adjusted at the same time, moving one scale graduation changes toe-in by approximately 4 mm (0.16 in.) ¼ Turn adjusting wheel and adjusting bolt equally in oppo- site directions so that same scale graduations are posi- tioned directly above center of the adjusting bolt.
Page 510 SERVICE PROCEDURE 1. On-car Services 6. THRUST ANGLE ¼ Inspection 1) Position vehicle on a level surface. 2) Move vehicle 3 to 4 meters directly forward. 3) Determine locus of both front and rear axles. 4) Measure distance “L” between center line of loci of the axles.
Page 511: Front Transverse Link
SERVICE PROCEDURE 2. Front Transverse Link 2. Front Transverse Link A: REMOVAL G4M0490 Front crossmember Tightening torque: N⋅m (kg-m, ft-lb) Transverse link T1: 29±5 (3.0±0.5, 21.7±3.6) Stabilizer link T2: 44±6 (4.5±0.6, 32.5±4.3) T3: 98±15 (10.0±1.5, 72±11) Front stabilizer T4: 196±25 (20.0±2.5, 145±18) Self-locking nut T5: 245±49 (25.0±5.0, 181±36) 1) Disconnect stabilizer link from transverse link.
Page 512 SERVICE PROCEDURE 2. Front Transverse Link 3) Remove nuts (do not remove bolts.) securing trans- verse link to crossmember. 4) Remove two bolts securing bushing bracket of trans- verse link to car body at rear bushing location. G4M0492 5) Extract ball joint from housing. 6) Remove bolts securing transverse link to crossmember and extract transverse link from crossmember.
Page 513 SERVICE PROCEDURE 2. Front Transverse Link D: ASSEMBLY 1. FRONT BUSHING To reassemble, reverse disassembly procedures. CAUTION: Install front bushing in correct direction, as shown in figure. G4M0496 2. REAR BUSHING 1) Install rear bushing to transverse link and align aligning marks scribed on the two.
Page 514 SERVICE PROCEDURE 2. Front Transverse Link 4) Connect stabilizer link to transverse link, and tempo- rarily tighten bolts. CAUTION: Discard loosened self-locking nut and replace with a new one. 5) Tighten the following points in the order shown below when wheels are in full contact with the ground and vehicle is curb weight.
Page 515: Front Ball Joint
SERVICE PROCEDURE 3. Front Ball Joint 3. Front Ball Joint A: REMOVAL 1) Remove the wheels. 2) Pull out the cotter pin from the ball stud, remove the castle nut, and extract the ball stud from the transverse link. 3) Remove the bolt securing the ball joint to the housing. 4) Extract the ball joint from the housing.
Page 516: Front Strut
SERVICE PROCEDURE 4. Front Strut 4. Front Strut A: REMOVAL G4M0502 Dust seal Helper Tightening torque: N⋅m (kg-m, ft-lb) Strut mount Coil spring T1: 20±6 (2.0±0.6, 14.5±4.3) Spacer Damper strut T2: 49 (5.0 , 36 − 0 − 0 − 0 Upper spring seat T3: 152±20 (15.5±2.0, 112±14) Adjusting bolt...
Page 517 SERVICE PROCEDURE 4. Front Strut 4) Remove brake hose clamp and disconnect brake hose from strut. Attach brake hose to body using gum tape. 5) Scribe an alignment mark on the camber adjusting bolt which secures strut to housing. 6) Remove bolt securing the A.B.S. sensor harness on models equipped with A.B.S.
Page 518 SERVICE PROCEDURE 4. Front Strut C: INSPECTION Check the disassembled parts for cracks, damage and wear, and replace with new parts if defective. 1. DAMPER STRUT 1) Check for oil leakage. 2) Move the piston rod up and down to check its operates smoothly without any binding.
Page 519 SERVICE PROCEDURE 4. Front Strut D: ASSEMBLY 1) Before installing coil spring, strut mount, etc., on the strut, check for the presence of air in the dampening force generating mechanism of the strut since air prevents proper dampening force from being produced. 2) Checking for the presence of air (1) Place the strut vertically with the piston rod facing (2) Move the piston rod to the center of its entire...
Page 520 SERVICE PROCEDURE 4. Front Strut 7) Pull the piston rod fully upward, and install rubber seat and spring seat. NOTE: Ensure that upper spring seat is positioned with “OUT” mark facing outward. 8) Install strut mount to the piston rod, and tighten the self-locking nut temporarily.
Page 521: Front Stabilizer
SERVICE PROCEDURE 5. Front Stabilizer 5. Front Stabilizer G4M0514 Front crossmember Tightening torque: N⋅m (kg-m, ft-lb) Transverse link T1: 25±4 (2.5±0.4, 18.1±2.9) Jack-up plate T2: 29±5 (3.0±0.5, 21.7±3.6) Stabilizer link T3: 32±10 (3.3±1.0, 24±7) Front stabilizer T4: 44±6 (4.5±0.6, 32.5±4.3) Self-locking nut A: REMOVAL 1) Jack-up the front part of the vehicle.
Page 522 SERVICE PROCEDURE 5. Front Stabilizer B: INSPECTION 1) Check bushing for cracks, fatigue or damage. 2) Check stabilizer links for deformities, cracks, or damage, and bushing for protrusions from the hole of sta- bilizer link. C: INSTALLATION 1) To install, reverse the removal procedure. NOTE: ¼...
Page 523: Front Crossmember
SERVICE PROCEDURE 6. Front Crossmember 6. Front Crossmember A: REMOVAL 1) Disconnect ground cable from battery. 2) Loosen front wheel nuts. 3) Jack-up vehicle, support it with safety stands (rigid racks), and remove front tires and wheels. 4) Remove both stabilizer and jack-up plate. 5) Disconnect tie-rod end from housing.
Page 524: Rear Trailing Link
SERVICE PROCEDURE 7. Rear Trailing Link 7. Rear Trailing Link A: REMOVAL G4M0522 Trailing link Tightening torque: N⋅m (kg-m, ft-lb) Front bushing T1: 98±20 (10.0±2.0, 72±14) Rear bushing T2: 113±15 (11.5±1.5, 83±11) Bracket Housing Self-locking nut 1) Loosen rear wheel nuts. 2) Jack-up vehicle, support it with safety stands (rigid racks) and remove rear wheels.
Page 525 SERVICE PROCEDURE 7. Rear Trailing Link B: DISASSEMBLY 1. FRONT BUSHING Using ST, press front bushing out of place. 927720000 INSTALLER & REMOVER SET G4M0524 2. REAR BUSHING 1) Remove housing. Refer to “4-2. WHEELS AND AXLES” for removal procedures. 2) Using ST, press rear bushing out of place.
Page 526 SERVICE PROCEDURE 7. Rear Trailing Link D: ASSEMBLY To assemble, reverse above disassembly procedures. 1. FRONT BUSHING Using ST, press bushing into trailing link. 927720000 INSTALLER & REMOVER SET G4M0517 CAUTION: Install front bushing in the proper direction, as shown in figure.
Page 527 SERVICE PROCEDURE 7. Rear Trailing Link 2. REAR BUSHING Using ST, press bushing into trailing link. 927730000 INSTALLER & REMOVER SET G4M0526 E: INSTALLATION Installation is in the reverse order of removal. CAUTION: Always tighten rubber bushing location when wheels are in full contact with the ground and vehicle is curb weight.
Page 528: Lateral Link
SERVICE PROCEDURE 8. Lateral Link 8. Lateral Link G4M0528 Crossmember Bushing (B) Tightening torque: N⋅m (kg-m, ft-lb) Adjusting bolt Washer T1: 44±6 (4.5±0.6, 32.5±4.3) Stabilizer link T2: 98±15 (10.0±1.5, 72±11) Rear lateral link Bushing (D) T3: 113±15 (11.5±1.5, 83±11) T4: 137±20 (14.0±2.0, 101±14) Bushing (C) Trailing link Bushing (A)
Page 529 SERVICE PROCEDURE 8. Lateral Link A: REMOVAL 1. FWD MODEL 1) Remove rear exhaust pipe and muffler. 2) Remove stabilizer from rear lateral link. 3) Scribe an aligning mark on adjusting bolt, adjusting wheel and crossmember. 4) Remove bolts securing lateral links to housing. 5) Turn cap (lateral link) counterclockwise until it contacts stopper, then remove cap.
Page 530 SERVICE PROCEDURE 8. Lateral Link B: DISASSEMBLY Using ST, press bushing out of place. NOTE: ¼ Using the following figure as a guide, verify the type of bushings. ¼ Select ST according to the type of bushings used. Bushing INSTALLER & REMOVER SET Bushing A 927700000 Bushing B...
Page 531 SERVICE PROCEDURE 8. Lateral Link D: ASSEMBLY Using ST, press bushing into place. CAUTION: Select ST according to the type of bushings used. NOTE: Use the same ST as that used during disassembly. G4M0533 NOTE: Pay attention to the direction of bushing “D” as shown in figure.
Page 532 SERVICE PROCEDURE 8. Lateral Link E: INSTALLATION To install, reverse removal procedures, observing the fol- lowing instructions. CAUTION: ¼ Always tighten rubber bushing location when wheels are in full contact with the ground and vehicle is curb weight. ¼ Tighten nut when installing adjusting bolt. ¼...
Page 533: Rear Strut
SERVICE PROCEDURE 9. Rear Strut 9. Rear Strut A: REMOVAL G4M0535 Coil spring Tightening torque: N⋅m (kg-m, ft-lb) Strut mount Helper T1: 20±6 (2.0±0.6, 14.5±4.3) Spring seat Rubber seat lower T2: 59±10 (6.0±1.0, 43±7) +4.0 T3: 196 (20.0 , 145 Rubber seat upper Damper strut −10...
Page 534 SERVICE PROCEDURE 9. Rear Strut 3) Remove rear speaker grille and service hole cap. (Wagon model) 4) Remove strut mount cap. 5) Loosen rear wheel nuts. 6) Jack-up vehicle, support it with safety stands (rigid racks) and remove rear wheels. 7) Remove brake hose clip.
Page 535 SERVICE PROCEDURE 9. Rear Strut D: ASSEMBLY Refer to Front Strut <Ref. to 4-1 [W4D0].> as a guide for assembly procedures. CAUTION: Install rear strut with “FWD” or “4WD” mark on strut mount facing outside of car body. G4M0540 E: INSTALLATION 1) Tighten self-locking nut used to secure strut mount to car body.
Page 536 SERVICE PROCEDURE 9. Rear Strut NOTE: Check wheel alignment and adjust if necessary.
Page 537: Rear Crossmember (Fwd Model)
SERVICE PROCEDURE 10. Rear Crossmember (FWD Model) 10. Rear Crossmember (FWD Model) A: REMOVAL G4M0541 Crossmember Self-locking nut Tightening torque: N⋅m (kg-m, ft-lb) Adjusting bolt Front lateral link T1: 44±6 (4.5±0.6, 32.5±4.3) Adjusting wheel Washer T2: 127±20 (13.0±2.0, 94±14) T3: 137±20 (14.0±2.0, 101±14) Stabilizer link Rear lateral link 1) Disconnect lateral links from housing.
Page 538 SERVICE PROCEDURE 10. Rear Crossmember (FWD Model) B: INSPECTION Check removed parts for wear, damage and cracks, and correct or replace if defective. C: INSTALLATION Installation is in reverse order of removal procedure. CAUTION: ¼ Discard loosened self-locking nut and replace with a new one.
Page 539: Rear Crossmember (Awd Model)
SERVICE PROCEDURE 11. Rear Crossmember (AWD Model) 11. Rear Crossmember (AWD Model) A: REMOVAL G4M0543 Crossmember Front lateral link Tightening torque: N⋅m (kg-m, ft-lb) Floating bushing Washer T1: 44±6 (4.5±0.6, 32.5±4.3) Adjusting bolt T2: 98±15 (10.0±1.5, 72±11) T3: 113±15 (11.5±1.5, 83±11) Stopper Trailing link T4: 127±20 (13.0±2.0, 94±14)
Page 540 SERVICE PROCEDURE 11. Rear Crossmember (AWD Model) 4) Place transmission jack under rear crossmember. G4M0544 5) Remove bolts securing crossmember to car body, and remove crossmember. G4M0545 6) Scribe an alignment mark on rear lateral link cam bolt and crossmember. 7) Remove front and rear lateral links by loosening nuts.
Page 541: Suspension
DIAGNOSTICS 1. Suspension 1. Suspension 1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT Possible causes Countermeasures (1) Permanent distortion or breakage of coil spring Replace. (2) Unsmooth operation of damper strut Replace. (3) Installation of wrong strut Replace with proper parts. (4) Installation of wrong coil spring Replace with proper parts.
Page 542 WHEELS AND AXLES Page S SPECIFICATIONS AND SERVICE DATA............. 2 1. Wheels and Axles ................... 2 C COMPONENT PARTS .................. 5 1. Front Axle....................5 2. Rear Axle ....................6 W SERVICE PROCEDURE ................8 1. Front Axle....................8 2. Rear Axle (AWD Model) .................15 3.
Page 543: Wheels And Axles
SPECIFICATIONS AND SERVICE DATA 1. Wheels and Axles 1. Wheels and Axles A: SPECIFICATIONS 1. TIRE AND WHEEL SIZE G4M0208 Front and Rear Spare Model Rim offset P.C.D. Rim offset Tire size Rim size Tire size Rim size mm (in) mm (in) mm (in) P165/80R13...
Page 544 SPECIFICATIONS AND SERVICE DATA 1. Wheels and Axles 3. FRONT DRIVE SHAFT ASSEMBLY SHAFT Type of axle shaft No. of identification assembly No. of spline teeth paddings on shaft 82AC-25 1 (One) 87AC-23 2 (Two) 87AC-25 2 (Two) G4M0209 4. REAR DRIVE SHAFT ASSEMBLY (AWD MODEL) SHAFT Type of axle shaft assembly No.
Page 545 SPECIFICATIONS AND SERVICE DATA 1. Wheels and Axles B: SERVICE DATA Wheel balancing Standard Service limit Dynamic unbalance Less than 5 g (0.18 oz) Balance weight part number Weight g (oz) (For steel wheel) 28101AA001 5 (0.18) 28101AA011 10 (0.35) 28101AA021 15 (0.53) 28101AA031...
Page 546: Front Axle
COMPONENT PARTS 1. Front Axle 1. Front Axle G4M0211 Spring pin Boot (DOJ) Tone wheel Baffle plate (DOJ) Boot (UFJ) Hub bolt Outer race (DOJ) UFJ ASSY Snap ring Baffle plate Axle nut Inner race (DOJ) Oil seal (IN) Tightening torque: N⋅m (kg-m, ft-lb) Ball Snap ring T1: 13±3 (1.3±0.3, 9.4±2.2)
Page 547 COMPONENT PARTS 2. Rear Axle 2. Rear Axle 1. AWD MODEL G4M0212 Circlip Boot (DOJ) Tone wheel Baffle plate (DOJ) Boot (BJ) Hub bolt Outer race (DOJ) BJ ASSY Snap ring Oil seal (IN. No. 2) Axle nut Inner race Oil seal (IN.
Page 548 COMPONENT PARTS 2. Rear Axle 2. FWD MODEL G4M0213 Hub cap Hub unit Tightening torque: N⋅m (kg-m, ft-lb) O-ring Spindle T: 186±20 (19±2, 137±14) Axle nut Washer...
Page 549 SERVICE PROCEDURE 1. Front Axle 1. Front Axle A: REMOVAL 1) Disconnect ground cable from battery. 2) Jack-up vehicle, support it with safety stands, and remove front wheels. 3) Unlock axle nut. 4) Remove axle nut using a socket wrench. CAUTION: Be sure to loose and retighten axle nut after removing wheel from vehicle.
Page 550 SERVICE PROCEDURE 1. Front Axle 9) Remove disc rotor from hub. If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on the rotor. G4M0217 10) Remove cotter pin and castle nut which secure tie-rod end to housing knuckle arm.
Page 551 SERVICE PROCEDURE 1. Front Axle 14) After scribing an alignment mark on camber adjusting bolt head, remove bolts which connect housing and strut, and disconnect housing from strut. G4M0222 B: DISASSEMBLY 1) Using ST1, support housing and hub securely. 2) Attach ST2 to housing and drive hub out. 927080000 HUB STAND 927060000...
Page 552 SERVICE PROCEDURE 1. Front Axle 5) Using pliers, remove snap ring. G4M0226 6) Using ST1, support housing securely. 7) Using ST2, press inner race to drive out outer bearing. 927400000 HOUSING STAND 927100000 BEARING REMOVER CAUTION: ¼ Do not remove outer race unless it is faulty. ¼...
Page 553 SERVICE PROCEDURE 1. Front Axle D: ASSEMBLY 1) Attach hub to ST securely. 927080000 HUB STAND 2) Using a hydraulic press, press new hub bolts into place. CAUTION: Be sure to press hub bolts until their seating surfaces contact the hub. NOTE: Use 12 mm (0.47 in) dia.
Page 554 SERVICE PROCEDURE 1. Front Axle 7) Using ST1 and ST2, press outer oil seal until it contacts the bottom of housing. 927410000 OIL SEAL INSTALLER 927400000 HOUSING STAND G4M0233 8) Using ST1 and ST2, press inner oil seal until it contacts circlip.
Page 555 SERVICE PROCEDURE 1. Front Axle E: INSTALLATION 1) Install transverse link ball joint to housing. Tightening torque: 44±6 N⋅m (4.5±0.6 kg-m, 32.5±4.3 ft-lb) 2) While aligning alignment mark on camber adjusting bolt head, connect housing and strut. CAUTION: Use a new self-locking nut. Tightening torque: 147±15 N⋅m (15±1.5 kg-m, 108±11 ft-lb) 3) Install speed sensor and harness on housing (only...
Page 556: Rear Axle
SERVICE PROCEDURE 1. Front Axle - 2. Rear Axle (AWD Model) 10) After tightening axle nut, lock it securely. 11) Install wheel and tighten wheel nuts to specified torque. Tightening torque: 88±10 N⋅m (9±1 kg-m, 65±7 ft-lb) G4M0238 2. Rear Axle (AWD Model) A: REMOVAL 1) Disconnect ground cable from battery.
Page 557 SERVICE PROCEDURE 2. Rear Axle (AWD Model) 8) Remove brake drum from hub. 9) If it is difficult to remove brake drum, remove adjusting hole cover from back plate, and then turn adjusting screw using a slot-type screwdriver until brake shoe separates from the drum.
Page 558 SERVICE PROCEDURE 2. Rear Axle (AWD Model) 12) Remove bolts which secure trailing link assembly to rear housing. CAUTION: Discard old self-locking nut. Replace with a new one. G4M0246 13) Remove bolts which secure lateral link assembly to rear housing. CAUTION: Discard old self-locking nut.
Page 559 SERVICE PROCEDURE 2. Rear Axle (AWD Model) B: DISASSEMBLY 1) Using ST1 and ST2, remove hub from rear housing. 927080000 HUB STAND 927420000 HUB REMOVER 2) Remove back plate from rear housing. 3) Using a standard screwdriver, remove outer and inner oil seals.
Page 560 SERVICE PROCEDURE 2. Rear Axle (AWD Model) D: ASSEMBLY 1) Using ST, press new hub bolt into place. CAUTION: ¼ Ensure hub bolt closely contacts hub. ¼ Use a 12 mm (0.47 in) hole in the ST to prevent hub bolt from tilting during installation.
Page 561 SERVICE PROCEDURE 2. Rear Axle (AWD Model) 6) Invert both ST1 and housing. 7) Using ST2, press inner oil seal into housing until it touches bottom. 927430000 HOUSING STAND 927460000 OIL SEAL INSTALLER G4M0259 8) Using ST1 and ST2, press sub seal into place. 927430000 HOUSING STAND 927460000...
Page 562 SERVICE PROCEDURE 2. Rear Axle (AWD Model) E: INSTALLATION 1) Connect rear housing assembly and strut assembly. CAUTION: Use a new self-locking nut. Tightening torque: 147±15 N⋅m (15±1.5 kg-m, 108±11 ft-lb) 2) Fit BJ (bell joint) to rear housing splines. CAUTION: Be careful not to damage inner oil seal lip.
Page 563: Rear Axle (Fwd Model)
SERVICE PROCEDURE 2. Rear Axle (AWD Model) - 3. Rear Axle (FWD Model) Drum brake: Perform steps 9) through 11). 9) Clean brake pipe connection. Using a flare-nut wrench, connect brake pipe to wheel cylinder. 10) Connect parking brake cable to lever. 11) Install brake drum on rear housing assembly.
Page 564 SERVICE PROCEDURE 3. Rear Axle (FWD Model) 6) Return parking brake lever and loosen adjuster. (1) Disc brake: Perform steps 7) through 9). (2) Drum brake: Perform steps 10) through 13). G4M0417 7) Remove disc brake assembly from back plate. Suspend disc brake assembly from strut using a wire.
Page 565 SERVICE PROCEDURE 3. Rear Axle (FWD Model) NOTE: If brake drum seizes up within hub, drive it out by installing an 8-mm bolt in bolt hole on brake drum. 12) Disconnect end of parking brake cable. 13) Using a flare-nut wrench, disconnect brake pipe from wheel cylinder.
Page 566 SERVICE PROCEDURE 3. Rear Axle (FWD Model) 2) Remove back plate from rear spindle. G4M0276 3) Using ST, press hub bolts out. CAUTION: Do not hammer hub bolt since this may deform hub. 927080000 HUB STAND G4M0277 C: INSPECTION Clean the removed parts and check them for wear, dam- age and corrosion.
Page 567 SERVICE PROCEDURE 3. Rear Axle (FWD Model) 5) Install hub on rear spindle. Temporarily tighten axle nut and washer to hold hub in place. CAUTION: Discard old axle nut. Replace with a new one. G4M0275 E: INSTALLATION 1) Connect rear spindle assembly to strut assembly. Tightening torque: 147±15 N⋅m (15±1.5 kg-m, 108±11 ft-lb) CAUTION:...
Page 568: Front And Rear Drive Shafts
SERVICE PROCEDURE 3. Rear Axle (FWD) - 4. Front and Rear Drive Shafts Tightening torque: 186±20 N⋅m (19±2 kg-m, 137±14 ft-lb) CAUTION: ¼ Use a new axle nut. ¼ Always tighten axle nut before installing wheel on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged.
Page 569 SERVICE PROCEDURE 4. Front and Rear Drive Shafts 7) Remove front drive shaft assembly. If it is hard to remove, use ST1 and ST2. 926470000 AXLE SHAFT PULLER 927140000 PLATE CAUTION: ¼ Be careful not to damage oil seal lip when removing front drive shaft.
Page 570 SERVICE PROCEDURE 4. Front and Rear Drive Shafts CAUTION: When removing the DOJ from the rear differential, fit tire lever to the bolt as shown in figure so as not to damage the axle shaft holder. G3M0045 9) Remove axle nut and drive shaft. If it is hard to remove, use ST1 and ST2.
Page 571 SERVICE PROCEDURE 4. Front and Rear Drive Shafts 9) Remove snap ring, which fixes inner race to shaft, by using pliers. 10) Take out DOJ inner race. 11) Take off DOJ cage from shaft and remove DOJ boot. CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches.
Page 572 SERVICE PROCEDURE 4. Front and Rear Drive Shafts MT model — Molylex No. 2 (Part No. 723223010) or Sunlight TB2-A 1) Install BJ boot in specified position, and fill it with 60 to 70 g (2.12 to 2.47 oz) of specified grease. 2) Place DOJ boot at the center of shaft.
Page 573 SERVICE PROCEDURE 4. Front and Rear Drive Shafts 10) Install circlip in the groove on DOJ outer race. NOTE: ¼ Assure that the balls, cage and inner race are com- pletely fitted in the outer race of DOJ. ¼ Exercise care not to place the matched position of circlip in the ball groove of outer race.
Page 574 SERVICE PROCEDURE 4. Front and Rear Drive Shafts 17) Cut off band with an allowance of about 10 mm (0.39 in) left from the clip and bend this allowance over the clip. CAUTION: Be careful so that the end of the band is in close con- tact with clip.
Page 575 SERVICE PROCEDURE 4. Front and Rear Drive Shafts CAUTION: ¼ Use a new axle nut. ¼ Always tighten axle nut before installing wheel on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged.
Page 576 SERVICE PROCEDURE 4. Front and Rear Drive Shafts 6) Insert DOJ spline end into bore of side oil seal, and remove ST. CAUTION: Do not allow DOJ splines to damage side oil seal. 28099PA090 SIDE OIL SEAL PROTECTOR G3M0049 7) Align DOJ and differential splines. 8) Push housing to insert DOJ into differential.
Page 577: Full Wheel Cap
SERVICE PROCEDURE 4. Front and Rear Drive Shafts - 5. Full Wheel Cap 5. Full Wheel Cap A: REMOVAL Pry off the full wheel cap with a wheel cap remover inserted between openings in the cap. G4M0296 B: INSTALLATION Align the valve hole in the wheel cap with the valve on the wheel and secure the wheel cap by tapping four points by hand.
Page 578: Wheel Balancing
SERVICE PROCEDURE 7. Wheel Balancing - 8. Installation of Wheel Assembly to Vehicle A: INSPECTION OF WHEEL RUNOUT 1) Jack-up vehicle until wheels clear the floor. 2) Slowly rotate wheel to check rim “runout” using a dial gauge. G4M0298 Axial runout limit Radial runout limit Steel wheel 1.5 mm (0.059 in)
Page 579: Installation Of Wheel Assembly To Vehicle
1) Attach the wheel to the hub by aligning the wheel bolt hole with the hub bolt. 2) Temporarily attach the wheel nuts to the hub bolts. (In the case of aluminum wheel, use SUBARU genuine wheel nut for aluminum wheel.) 3) Manually tighten the nuts making sure the wheel hub hole is aligned correctly to the guide portion of hub.
Page 580: T-Type" Tire
SERVICE PROCEDURE 10. “T-type” Tire 10. “T-type” Tire “T-type” tire for temporary use is prepared as a spare tire. CAUTION: ¼ Keep the inflation pressure at 412 kPa (4.2 kg/cm 60 psi) at all times. ¼ When the wear indicator appears on the tread surface, replace the tire with a new one.
Page 581 ¼ To avoid rendering the Airbag system inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all maintenance must be performed by an authorized SUBARU dealer. ¼ Improper maintenance, including incorrect removal and installation of the Airbag system, can lead to personal injury caused by unintentional activation of the Air- bag system.
Page 582: Steering System
SPECIFICATIONS AND SERVICE DATA 1. Steering System 1. Steering System A: SPECIFICATIONS Minimum turning radius m (ft) 5.1 (16.7) Steering angle (Inside-Outside) 37.5 — 32.6 Whole system With AIRBAG 385 (15.16) Steering wheel diameter mm (in) Without AIRBAG 375 (14.76) Overall gear ratio (Turns, lock to lock) 16.5 (3.2) Type...
Page 583 SPECIFICATIONS AND SERVICE DATA 1. Steering System B: SERVICE DATA Steering wheel Free play mm (in) 17 (0.67) Inner tire & wheel 37.5° Turning angle Outer tire & wheel 32.6° Clearance between steering wheel and col- Steering shaft umn cover 3.0 (0.118) mm (in) Sliding resistance...
Page 584: Steering Wheel And Column (Tilt)
COMPONENT PARTS 1. Steering Wheel and Column (Tilt) 1. Steering Wheel and Column (Tilt) 1. WITH AIRBAG MODEL G4M0660 Bushing Tightening torque: N⋅m (kg-m, ft-lb) Steering shaft T1: 3.4±1.0 (0.35±0.1, 2.5±0.7) Knee protector T2: 25±5 (2.5±0.5, 18.1±3.6) Steering roll connector T3: 34±5 (3.5±0.5, 25.3±3.6) Column cover Steering wheel...
Page 585 COMPONENT PARTS 1. Steering Wheel and Column (Tilt) 2. WITHOUT AIRBAG MODEL G4M0080 Bushing Tightening torque: N⋅m (kg-m, ft-lb) Steering shaft T1: 25±5 (2.5±0.5, 18.1±3.6) Combination switch T2: 34±5 (3.5±0.5, 25.3±3.6) Column cover Steering wheel Pad ASSY...
Page 586: Power Steering System
COMPONENT PARTS 2. Power Steering System 2. Power Steering System G4M0895 Tightening torque: N⋅m (kg-m, ft-lb) T1: 5.4±1.5 (0.55±0.15, 4.0±1.1) T2: 7.4±2.0 (0.75±0.2, 5.4±1.4) T3: 13±3 (1.3±0.3, 9.4±2.2) T4: 15±5 (1.5±0.5, 10.8±3.6) T5: 20.1±2.5 (2.05±0.25, 14.8±1.8) T6: 22±2 (2.2±0.2, 15.9±1.4) T7: 24±3 (2.4±0.3, 17.4±2.2) T8: 25±5 (2.5±0.5, 18.1±3.6) T9: 52±10 (5.3±1.0, 38±7)
Page 587 COMPONENT PARTS 2. Power Steering System Clamp Sleeve Adapter Spring Hose bracket Adjusting screw Pipe C Lock nut Pipe D Housing ASSY Back-up washer Strainer Oil seal Tank Adapter Oil pump Clamp Pulley Pipe A Belt cover Pipe B Bracket Lock washer Pipe E Tie-rod...
Page 588: Power Steering Oil Pump
COMPONENT PARTS 3. Power Steering Oil Pump 3. Power Steering Oil Pump G4M0082 Pulley Spring Rotor Side plate Snap ring Pressure switch Bearing Front casing Tightening torque: N⋅m (kg-m, ft-lb) Oil seal Rear cover T1: 16±2 (1.6±0.2, 11.6±1.4) Shaft Gasket T2: 20±3 (2.0±0.3, 14.5±2.2) Connector Knock pin...
Page 589: Supplemental Restraint System "Airbag
SERVICE PROCEDURE 1. Supplemental Restraint System “Airbag” - 2. Tilt Steering Column 1. Supplemental Restraint System “Airbag” Airbag system wiring harness is routed near the steering wheel, steering shaft and column. WARNING: ¼ All Airbag system wiring harness and connectors are colored yellow.
Page 590 SERVICE PROCEDURE 2. Tilt Steering Column 4) Remove lower screw and slide horn pad assembly forward, then disconnect connector. (without airbag model) 5) Remove horn pad by pulling on it. (without airbag model) G4M0084 6) Remove steering wheel nut, then draw out steering wheel from shaft using steering puller.
Page 591 SERVICE PROCEDURE 2. Tilt Steering Column C: INSPECTION 1. BASIC INSPECTION Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary, repair or replace faulty parts. Part name Inspection Corrective action ¼ Free play ¼...
Page 592 SERVICE PROCEDURE 2. Tilt Steering Column 2) Check steering wheel free play in axial and radial direc- tions: Specifications: Axial free play A Less than ±6 mm (0.24 in) Radial free play L Less than ±7 mm (0.28 in) 3) Check to ensure that new airbag module is properly installed in steering wheel.
Page 593 SERVICE PROCEDURE 2. Tilt Steering Column D: ASSEMBLY 1) Insert combination switch to upper column shaft, and install lower column cover with tilt lever held in the lowered position. Then route ignition key harness and combination switch harness between column cover mounting bosses. 2) Fit upper column cover to lower column cover, and tighten combination switch and column cover.
Page 594 SERVICE PROCEDURE 2. Tilt Steering Column 6) Align center of roll connector. (with airbag model) <Ref. to 5-5 [W601].> CAUTION: Ensure that front wheels are set in straightforward direction. 7) Set steering wheel to neutral and install it onto steering shaft.
Page 595: Steering Gearbox (Power Steering System)
SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) 3. Steering Gearbox (Power Steering System) NOTE: For disassembly and assembly of gearbox unit, refer to section Control Valve (Power Steering Gearbox). EPA0021 Cotter pin O-ring Valve housing Dust seal Castle nut Rack Universal joint Dust cover...
Page 596 SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) A: REMOVAL 1) Disconnect battery minus terminal. 2) Loosen front wheel nut. 3) Lift vehicle and remove front wheels. 4) Remove front exhaust pipe assembly. WARNING: Be careful, exhaust pipe is hot. 5) Using a puller, remove tie-rod end from knuckle arm after pulling off cotter pin and removing castle nut.
Page 597 SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) 9) Disconnect pipes C and D from pipe of gearbox. CAUTION: Be careful not to damage these pipes. NOTE: Disconnect upper pipe D first, and lower pipe C second. G4M0101 10) Remove clamp bolts securing...
Page 598 SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) 6) Straighten lock washer under ball joint. CAUTION: ¼ Be extremely careful not to hit surface of right hand rack; otherwise, oil leakage may result. ¼ Tie-rod lock washer must be replaced with a new one whenever it is removed.
Page 599 SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) C: INSPECTION 1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as nec- essary. 2) When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing.
Page 600 SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) 1. SERVICE LIMIT Make a measurement as follows. If it exceeds the specified service limit, adjust or replace. NOTE: When making a measurement, vise gearbox by using ST. Never vise gearbox by inserting aluminum plates, etc. between vise and gearbox.
Page 601 12.7 N (1.3 kg, 2.9 lb) G4M0115 D: ASSEMBLY CAUTION: Use only SUBARU genuine grease for gearbox. Grease: VALIANT GREASE M2 [Part No. 003608001, net 0.5 kg (1.1 lb)] 1) Apply grease to teeth of rack so that grease applied is about as high as teeth, and also apply a thin film of grease to sliding portion of rack shaft.
Page 602 SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) 4) Press-fit dust seal into gearbox housing while tapping it via a spanner or the like so that stepping between gearbox and dust seal is normally 2 mm (0.08 in). G4M0116 Depth: A 2 mm (0.08 in) G4M0117 5) Apply grease to sliding surface of sleeve and spring...
Page 603 SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) 7) Bend lock washer using a chisel. CAUTION: Be careful not to scratch rack when bending lock washer. G4M0120 8) Rack and pinion backlash adjustment (1) Loosen adjusting screw. (2) Rotate input shaft so that rack is in the straight ahead direction.
Page 604 SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) ¼ Make adjustment so that steering wheel can be rotated fully from lock to lock without binding. 9) Check for service limit as per article of “Service limit”. <Ref. to [W3C1].> Make replacement and adjustment if necessary.
Page 605 SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) 14) If tie-rod end was removed, screw in lock nut and tie- rod end to screwed portion of tie-rod, and tighten lock nut temporarily in a position as shown in figure. Installed tie-rod length: L 15 mm (0.59 in) NOTE: Pay attention to difference between right and left tie-rod...
Page 606 SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) 3) How to install the joint. (1) Push the long yoke of the joint, all the way into the serrated portion of the steering shaft, setting the bolt hole in the cutout. (2) Then pull the short yoke all way out of the serrated portion of the gear box, setting the bolt hole in the cut- out.
Page 607 SERVICE PROCEDURE 3. Steering Gearbox (Power Steering System) 15) After adjusting toe-in and steering angle, tighten lock nut on tie-rod end. Tightening torque: 83±5 N⋅m (8.5±0.5 kg-m, 61.5±3.6 ft-lb) CAUTION: When adjusting toe-in, hold boot as shown to prevent it from being rotated or twisted. If twisted, straighten it. G4M0132 F: ADJUSTMENT 1) Adjust front toe.
Page 608: Control Valve (Power Steering Gearbox)
SERVICE PROCEDURE 4. Control Valve (Power Steering Gearbox) 4. Control Valve (Power Steering Gearbox) NOTE: This section focuses on the disassembly and reassembly of control valve. For the inspection and adjustment and the service procedures for associated parts, refer to “Steering Gearbox”...
Page 609 SERVICE PROCEDURE 4. Control Valve (Power Steering Gearbox) 2. OIL LEAK CHECK PROCEDURE AND REPLACEMENT PARTS NOTE: Parts requiring replacement are described in the smallest unit of spare parts including damaged parts and spare parts damaged. In actual disassembly work, accidental damage as well as inevitable damage to some related parts must be taken into account, and spare parts for them must also be prepared.
Page 610 SERVICE PROCEDURE 4. Control Valve (Power Steering Gearbox) B: DISASSEMBLY 1. VALVE ASSEMBLY 1) Loosen two bolts securing valve assembly. G4M0137 2) Carefully draw out input shaft and remove valve assem- bly. G4M0138 3) Draw out pinion and valve assembly from valve housing, as necessary, using pipe of I.D.
Page 611 SERVICE PROCEDURE 4. Control Valve (Power Steering Gearbox) NOTE: If ST is used, grind area (shown in figure) by 1 mm (0.04 in) in advance. 926340000 WRENCH G4M0142 3) Pull rack assembly from cylinder side, and draw out rack bushing and rack stopper together with rack assem- bly.
Page 612 SERVICE PROCEDURE 4. Control Valve (Power Steering Gearbox) ¼ Installation 1) Press-fit oil seal into valve housing using ST and press. 927610000 INSTALLER NOTE: Before fitting, coat oil seal fully with ATF DEXRON II. G4M0146 2) Fit snap ring in snap ring groove using snap ring pliers. CAUTION: Be careful not to scratch oil seal with snap ring pliers.
Page 613 SERVICE PROCEDURE 4. Control Valve (Power Steering Gearbox) ¼ Installation 1) Fit pinion and valve assembly into valve housing. NOTE: Apply ATF DEXRON II to outer diameter surface of input shaft and outer surface of valve body seal ring, and pay special attention not to damage seal when inserting pinion and valve assembly.
Page 614 SERVICE PROCEDURE 4. Control Valve (Power Steering Gearbox) ¼ Installation 2) Force-fit oil seal and back-up washer using ST. 927650000 INSTALLER CAUTION: Be careful not to damage or scratch cylinder inner wall. NOTE: ¼ Apply ATF DEXRON II to oil seal. ¼...
Page 615 SERVICE PROCEDURE 4. Control Valve (Power Steering Gearbox) ¼ After fitting cover, check air passage hole for clogging. If clogged, open by removing grease from the hole. ¼ Check rack shaft for damage. ¼ Apply ATF DEXRON II to this ST and surface of piston ring to prevent seal from being damaged.
Page 616: Pipe Assembly (Power Steering System)
SERVICE PROCEDURE 4. Control Valve (Power Steering Gearbox) - 5. Pipe Assembly (Power Steering System) 2. VALVE ASSEMBLY 1) Apply genuine grease to pinion gear and bearing of valve assembly. G4M0158 2) Install packing on valve assembly. Insert valve assem- bly into place while facing rack teeth toward pinion.
Page 617 SERVICE PROCEDURE 5. Pipe Assembly (Power Steering System) 2) Lift vehicle and remove jack-up plate. 3) Remove one pipe joint at the center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning steering wheel fully clockwise and counterclock- wise.
Page 618 SERVICE PROCEDURE 5. Pipe Assembly (Power Steering System) 6) Remove bolt A. Disconnect pipe C from oil pump. Disconnect pipe D from oil tank. CAUTION: ¼ Do not allow fluid from the hose end to come into contact with pulley belt. ¼...
Page 619 SERVICE PROCEDURE 5. Pipe Assembly (Power Steering System) 3) Temporarily connect pipes C and D to pipes (on the gearbox side). 4) Temporarily install clamp E on pipes C and D. CAUTION: Ensure that the “8” letter side of clamp E is on the pipe C side.
Page 620 SERVICE PROCEDURE 5. Pipe Assembly (Power Steering System) G4M0167 11) Finally check clearance between pipes and/or hoses, as shown above. If clearance between cruise control pump and power steer- ing hose is less than 10 mm (0.39 in), proceed as follows: (1) Move clamped section k (refer to figure above) down to a point where pipe is close to crossmember...
Page 621: Oil Pump (Power Steering System)
SERVICE PROCEDURE 6. Oil Pump (Power Steering System) 6. Oil Pump (Power Steering System) A: REMOVAL 1) Remove ground cable from battery. 2) Drain the working fluid about 0.3 (0.3 US qt, 0.3 Imp qt) from oil tank. 3) Remove pulley belt cover bracket. G4M0168 4) Loosen oil pump pulley nut, then remove bolts which secure alternator.
Page 622 SERVICE PROCEDURE 6. Oil Pump (Power Steering System) 10) Place oil pump in a vise, remove two bolts from the upper side of oil tank and detach oil tank. CAUTION: Do not place oil pump directly in the vise; use soft pads and hold oil pump lightly to protect the pump.
Page 623 SERVICE PROCEDURE 6. Oil Pump (Power Steering System) 1. SERVICE LIMIT Make a measurement as follows. If it exceeds the specified service limit, replace the parts with new ones. CAUTION: ¼ Fix oil pump on a vise to make a measurement. At this time, hold oil pump with the least possible force between two wood pieces.
Page 624 SERVICE PROCEDURE 6. Oil Pump (Power Steering System) C: DISASSEMBLY G4M0176 Pulley Spring Rotor Snap ring Pressure switch Side plate Bearing Front casing Tightening torque: N⋅m (kg-m, ft-lb) Oil seal Rear cover T1: 16±2 (1.6±0.2, 11.6±1.4) Shaft Knock pin T2: 20±3 (2.0±0.3, 14.5±2.2) Connector Seal washer T3: 52±10 (5.3±1.0, 38±7)
Page 625 SERVICE PROCEDURE 6. Oil Pump (Power Steering System) (2) Remove four bolts which secure rear cover. G4M0178 (3) Remove the following parts from front casing. Seal washer Knock pin ...............2 ea. Cam ring Rotor Vane ..............10 ea. Side plate Wave washer ............2 ea. O-ring ..............2 ea.
Page 626 SERVICE PROCEDURE 6. Oil Pump (Power Steering System) (2) Remove shaft using a hand press. CAUTION: ¼ Discard old shaft assembly; replace with a new one. ¼ Be careful not to scratch or dent casing’s surface which serves as a seal. G4M0182 (3) Pry oil seal off using a screwdriver.
Page 627 SERVICE PROCEDURE 6. Oil Pump (Power Steering System) E: ASSEMBLY 1) Reassembly precautions (1) Whenever O-rings, oil seals, and snap rings are removed, they must be replaced with new ones. (2) Thoroughly wash parts and allow to dry. They must be kept free from cleaning oil and dust.
Page 628 SERVICE PROCEDURE 6. Oil Pump (Power Steering System) 3) Cartridge assembly (1) Apply specified hydraulic oil to O-rings and fit them into front casing. (2) Install side plate to front casing. CAUTION: Use care not to let side plate gall. G4M0186 (3) Mount rotor onto shaft.
Page 629 SERVICE PROCEDURE 6. Oil Pump (Power Steering System) 6) Check (1) When reassembly procedures have been completed, turn shaft by hand to ensure it turns smoothly. If it binds or other unusual conditions are evident, disassemble again and check for foreign mat- ter trapped on sliding surfaces and improper installa- tion.
Page 630 SERVICE PROCEDURE 6. Oil Pump (Power Steering System) 5) Interconnect pipes C and D. Tightening torque: Joint nut 15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb) CAUTION: If a hose is twisted at this step, the hose may come into contact with some other parts. 6) Install pulley belt to oil pump.
Page 631: Power Steering Fluid
SERVICE PROCEDURE 7. Power Steering Fluid 7. Power Steering Fluid A: RECOMMENDED AIR BLEEDING AND POWER STEERING FLUID Recommended power steering Manufacturer fluid B.P. CALTEX CASTROL ATF DEXRON II MOBIL SHELL TEXACO 1) Feed the specified fluid with its level being about 4 cm (1.6 in) lower than the mouth of tank.
Page 632 SERVICE PROCEDURE 7. Power Steering Fluid 10) Check the fluid leakage at flare nuts after turning steering wheel from lock to lock with engine running. CAUTION: ¼ Before checking, wipe off any fluid on flare nuts and piping. ¼ In case the fluid leaks from flare nut, it is caused by dust (or the like) and/or damage between flare and tapered seat in piping.
Page 633: Power Steering
DIAGNOSTICS 1. Power Steering 1. Power Steering 1. STEERING CONDITION Heavy steering Heavy steering Steering wheel Vehicle leads to Poor return of effort in all range effort at stand still surges when turn- one side or the steering wheel to ing.
Page 634 DIAGNOSTICS 1. Power Steering 2. MEASUREMENT OF HYDRAULIC PRESSURE CAUTION: Be sure to complete all items aforementioned in “STEERING CONDITION” [T101], prior to measuring hydraulic pressure. Otherwise, pressure can not be measured correctly. NOT GOOD Measure regular pressure at Flattened pipes or hoses Replace bad parts.
Page 635 DIAGNOSTICS 1. Power Steering Using STs, measure regulator pressure. Regular pressure: 981 kPa (10 kg/cm , 142 psi) or less 925711000 PRESSURE GAUGE 926220000 ADAPTER B 926210000 ADAPTER A G4M0195 Using STs, measure relief pressure. Relief pressure: 7,355 — 7,846 kPa (75 — 80 kg/cm , 1,067 —...
Page 636 DIAGNOSTICS 1. Power Steering 3. MEASUREMENT OF STEERING EFFORT NOT GOOD Measure steering efforts in stand still with engine idling on Adjust backlash. concrete road. Result: 29.4 N (3.0 kg, 6.6 lb) or less in both directions GOOD *4 When turning steering more Measure steering efforts in stand still with engine stalled on quickly than necessary from concrete road.
Page 637 DIAGNOSTICS 1. Power Steering NOT GOOD Check tie-rod ends, tie-rods and ball Inspect, replace if necessary. joints of suspension for unsteady revolution or rattling. GOOD NOT GOOD Measure rotating and sliding resistance Readjust backlash, if ineffective replace of gearbox. bad parts. Result: Rotating resistance is 11.18 N (1.14 kg, 2.51 lb) or less around center position and 1.79 N (1.61...
Page 638 DIAGNOSTICS 1. Power Steering NOTE: Measurement of folding torque of universal joint G4M0199 G4M0200 G4M0201 G4M0202 NOTE: Using ST, measure resistances of gearbox. 926230000 SPANNER Rotating resistance: Straight-ahead position within 30 mm (1.18 in) from rack center Less than 11.18 N (1.14 kg, 2.51 lb) Maximum allowable torque 15.7 N (1.6 kg, 3.5 lb) G4M0203...
Page 639 DIAGNOSTICS 1. Power Steering Sliding resistance: Right-turn steering 304 N (31 kg, 68 lb) or less Left-turn steering 304 N (31 kg, 68 lb) or less G4M0204 G4M0205...
Page 640 DIAGNOSTICS 1. Power Steering 4. FLUID LEAKAGE CAUTION: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance.
Page 641 DIAGNOSTICS 1. Power Steering G4M0206...
Page 642 DIAGNOSTICS 1. Power Steering 5. NOISE AND VIBRATION Hiss noise (continu- Relief valve sound Generates at max. Normal (Don’t keep ous) turning angle. this condition over 5 While engine is run- seconds.) ning with maximum turning angle. Generates without Defective steering operation.
Page 643 DIAGNOSTICS 1. Power Steering Grinding noise (continuous) Vane pump aeration Inspect and retighten fluid line While engine is running. connection. Refill fluid and vent air. Vane pump seizing Replace oil pump. Pulley bearing seizing of oil pump Folded hose, flat pipe Replace.
Page 644 DIAGNOSTICS 1. Power Steering Whine or growl (continuous or Loosened installation of Oil pump, Retighten. intermittent) oil pump bracket While engine is running with/ without steering turned. Abnormal inside of oil pump, hose Replace oil pump, hose, if the noise can be heard when running as well as stand still.
Page 645 DIAGNOSTICS 1. Power Steering 6. CLEARANCE TABLE CAUTION: This table lists various clearances that must be cor- rectly adjusted to ensure normal vehicle driving with- out interfering noise, or any other faults. Minimum Minimum Location allowance Location allowance mm (in) mm (in) 5 (0.20) 15 (0.59)
Page 646 DIAGNOSTICS 1. Power Steering 7. BREAKAGE OF HOSES Pressure hose burst Excessive holding time of relief Instruct customers. status Malfunction of relief valve Replace oil pump. Poor cold characteristic of fluid Replace fluid. Forced out return hose Poor connection Correct. Poor holding of clip Retighten.
Page 647 ¼ To avoid rendering the Airbag system inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all maintenance must be performed by an authorized SUBARU dealer. ¼ Improper maintenance, including incorrect removal and installation of the Airbag system, can lead to personal injury caused by unintentional activation of the Airbag system.
Page 648 SPECIFICATIONS AND SERVICE DATA 1. Brakes 1. Brakes A: SPECIFICATIONS Model 4-Door Sedan Sports Wagon Engine (cc) 1800 1800 Driving system Type Disc (Floating type, ventilated) Effective disc diameter mm (in) (7.64) (8.27) (7.64) (8.27) Disc thickness x outer 18 x 242 24 x 260 18 x 242 24 x 260...
Page 649 SPECIFICATIONS AND SERVICE DATA 1. Brakes Model 4-Door Sedan Sports Wagon Engine (cc) 1800 1800 Driving system Type Mechanical on rear brake drums Effective drum 228.6 228.6 228.6 228.6 diameter (6.69) (6.69) (6.69) (6.69) mm (in) Lining or pad 162.6 x 162.6 x 162.6 x 162.6 x...
Page 650 SPECIFICATIONS AND SERVICE DATA 1. Brakes B: SERVICE DATA ITEM STANDARD SERVICE LIMIT Pad thickness 17 mm (0.67 in) 7.5 mm (0.295 in) (including back metal) Front brake 13-inch type: 18 mm (0.71 in) 13-inch type: 16 mm (0.63 in) Disc thickness 14-inch type: 24 mm (0.94 in) 14-inch type: 22 mm (0.87 in)
Page 651: Front Disc Brake
COMPONENT PARTS 1. Front Disc Brake 1. Front Disc Brake G4M0351 Lock pin Piston boot Disc rotor Disc cover Lock pin sleeve Boot ring Lock pin boot Support Tightening torque: N⋅m (kg-m, ft-lb) Caliper body Pad clip T1: 8±1 (0.8±0.1, 5.8±0.7) Air bleeder screw Outer shim T2: 14±4 (1.4±0.4, 10.1±2.9)
Page 652: Rear Disc Brake
COMPONENT PARTS 2. Rear Disc Brake 2. Rear Disc Brake G4M0909 Lock pin Pad clip Strut shoe spring Lock pin sleeve Outer pad Shoe guide plate Lock pin boot Outer shim Secondary shoe return spring Air bleeder screw Shoe hold-down pin Primary shoe return spring Caliper body Cover...
Page 653: Rear Drum Brake
COMPONENT PARTS 3. Rear Drum Brake 3. Rear Drum Brake G4M0910 Air bleeder cap Upper shoe return spring Lower shoe return spring Air bleeder screw Retainer Adjusting spring Boot Washer Drum Piston Parking brake lever Plug Brake shoe (Trailing) Tightening torque: N⋅m (kg-m, ft-lb) Spring Brake shoe (Leading) T1: 8±1 (0.8±0.1, 5.8±0.7)
Page 654: Master Cylinder
COMPONENT PARTS 4. Master Cylinder 4. Master Cylinder G4M0354 C-ring Tightening torque: N⋅m (kg-m, ft-lb) Reserve tank Level indicator ASSY T1: 14±4 (1.4±0.4, 10.1±2.9) Seal Supply valve stopper T2: 14.7 −2 Cylinder body (With A.B.S.) +0.3 +2.2 (1.5 , 10.8 −0.2 −1.4 Secondary piston...
Page 655: Brake Booster
COMPONENT PARTS 5. Brake Booster 5. Brake Booster 1. MODELS WITH A.B.S. G4M0355 Push rod Filter Valve body Return spring Silencer Plunger valve Reaction disc Operating rod Diaphragm plate Poppet valve Valve return spring 2. MODELS WITHOUT A.B.S. G4M0356 Push rod Plunger valve Operating rod Return spring...
Page 656: System
COMPONENT PARTS 6. A.B.S. System 6. A.B.S. System 1. SENSOR AND CONTROL MODULE G4M0911 G sensor (AWD MT only) A.B.S. control module Tightening torque: N⋅m (kg-m, ft-lb) Rear A.B.S. sensor RH Front A.B.S. sensor LH T1: 5.9±1.5 (0.60±0.15, 4.3±1.1) A.B.S. spacer Front A.B.S.
Page 657 COMPONENT PARTS 6. A.B.S. System 2. HYDRAULIC UNIT G4M0358 Connector Tightening torque: N⋅m (kg-m, ft-lb) T1: 1.2±0.2 (0.125±0.025, 0.9±0.2) Motor relay T2: 18±5 (1.8±0.5, 13.0±3.6) T3: 32±10 (3.3±1.0, 24±7) Valve relay T4: 52±15 (5.3±1.5, 38±11) Hydraulic control unit Bracket...
Page 658: Hill Holder
COMPONENT PARTS 7. Hill Holder 7. Hill Holder G4M0359 PHV cable Adjusting nut Tightening torque: N⋅m (kg-m, ft-lb) Clamp Snap pin T1: 3.4±1.0 (0.35±0.10, 2.5±0.7) Bracket A Clip T2: 18±5 (1.8±0.5, 13.0±3.6) T3: 33±3 (3.4±0.3, 24.6±2.2) PHV (Pressure hold valve) Bushing Bracket Release fork...
Page 659: Parking (Hand) Brake
COMPONENT PARTS 8. Parking (Hand) Brake 8. Parking (Hand) Brake G4M0360 Parking brake lever Clamp Tightening torque: N⋅m (kg-m, ft-lb) Parking brake switch Parking brake cable RH T1: 5.9±1.5 (0.60±0.15, 4.3±1.1) Adjusting nut Cable guide T2: 18±5 (1.8±0.5, 13.0±3.6) Cover Clamp T3: 32±10 (3.3±1.0, 24±7) Equalizer...
Page 660: Front Disc Brake
SERVICE PROCEDURE 1. Front Disc Brake 1. Front Disc Brake G4M0351 Lock pin Piston boot Disc rotor Disc cover Lock pin sleeve Boot ring Lock pin boot Support Tightening torque: N⋅m (kg-m, ft-lb) Caliper body Pad clip T1: 8±1 (0.8±0.1, 5.8±0.7) Air bleeder screw Outer shim T2: 14±4 (1.4±0.4, 10.1±2.9)
Page 661 SERVICE PROCEDURE 1. Front Disc Brake A: ON-CAR SERVICE 1. PAD 1) Remove lock pin. 2) Raise caliper body. 3) Remove pad. G4M0361 4) Check pad thickness A. Pad thickness Standard value 17 (0.67) (including back metal) Wear limit 7.5 (0.295) mm (in) CAUTION: ¼...
Page 662 SERVICE PROCEDURE 1. Front Disc Brake 3) Measure disc rotor thickness. NOTE: Make sure that micrometer is set 5 mm (0.20 in) inward of rotor outer perimeter. Standard Service Disc out- Tire dia. value limit side dia. Disc rotor thickness A 18.0 16.0 13″...
Page 663 SERVICE PROCEDURE 1. Front Disc Brake 5) Remove disc rotor from hub. NOTE: If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in holes B on the rotor. 6) Clean mud and foreign particles from caliper body assembly and support.
Page 664 SERVICE PROCEDURE 1. Front Disc Brake D: INSPECTION 1) Repair or replace faulty parts. 2) Check caliper body and piston for uneven wear, dam- age or rust. 3) Check rubber parts for damage or deterioration. E: ASSEMBLY 1) Clean caliper body interior using brake fluid. 2) Apply a coat of brake fluid to piston seal and fit piston seal in groove on caliper body.
Page 665 SERVICE PROCEDURE 1. Front Disc Brake G4M0375 F: INSTALLATION 1) Install disc rotor on hub. 2) Install support on housing. Tightening torque: 78±10 N⋅m (8±1 kg-m, 58±7 ft-lb) CAUTION: ¼ Always replace the pads for both the left and right wheels at the same time.
Page 666: Rear Disc Brake
SERVICE PROCEDURE 2. Rear Disc Brake 2. Rear Disc Brake G4M0912 Guide pin Piston boot Disc rotor Lock pin Boot ring Tightening torque: N⋅m (kg-m, ft-lb) Lock pin boot Pad clip T1: 8±1 (0.8±0.1, 5.8±0.7) Lock pin sleeve Shim T2: 20±4 (2.0±0.4, 14.5±2.9) Air bleeder screw Inner shim T3: 26±5 (2.7±0.5, 19.5±3.6)
Page 667 SERVICE PROCEDURE 2. Rear Disc Brake 2) Raise caliper body. 3) Remove pad from support. G4M0379 4) Check pad thickness (including back metal). Pad thickness: A Standard value 15.0 mm (0.591 in) Wear limit 6.5 mm (0.256 in) CAUTION: ¼ Always replace the pads for both the left and right wheels at the same time.
Page 668 SERVICE PROCEDURE 2. Rear Disc Brake 2. DISC ROTOR 1) Install disc rotor by tightening the five wheel nuts. 2) Set a dial gauge on the disc rotor. Turn disc rotor to check runout. NOTE: Make sure that dial gauge is set 5 mm (0.20 in) inward of rotor outer perimeter.
Page 669 SERVICE PROCEDURE 2. Rear Disc Brake 2) Remove the piston boot. G4M0474 3) Gradually supply compressed air via inlet of caliper body to force piston out. CAUTION: ¼ Place a wooden block as shown in Figure to prevent damage to piston. ¼...
Page 670 SERVICE PROCEDURE 2. Rear Disc Brake 5) Apply a coat of specified grease to boot and fit in groove on ends of cylinder and piston. Grease: NIGLUBE RX-2 (Part No. 003606000) 6) Install the piston boot to the caliper body, and attach boot ring.
Page 671 SERVICE PROCEDURE 2. Rear Disc Brake ¼ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad.
Page 672: Rear Drum Brake
SERVICE PROCEDURE 3. Rear Drum Brake 3. Rear Drum Brake A: REMOVAL 1. BRAKE DRUM AND SHOE 1) Loosen wheel nuts, jack-up vehicle, support it with rigid racks, and remove wheel. 2) Release parking brake. 3) Remove brake drum from brake assembly. G4M0393 NOTE: If it is difficult to remove brake drum, remove adjusting hole...
Page 673 SERVICE PROCEDURE 3. Rear Drum Brake 9) Remove the following. Retainer Washer Parking lever Upper shoe return spring Trailing shoe Leading shoe Shoe hold-down spring Shoe hold-down cup Adjusting lever G4M0398 Adjuster spring Adjuster Lower shoe return spring 2. BRAKE ASSEMBLY 1) Remove wheel.
Page 674 SERVICE PROCEDURE 3. Rear Drum Brake B: DISASSEMBLY 1. WHEEL CYLINDER 1) Remove right and left dust boots from wheel cylinder. 2) Remove piston, cup, spring and air bleeder screw and cap. Bleeder cap Bleeder screw Spring Cylinder G4M0402 Piston Boot C: INSPECTION 1) If the inside surface of brake drum is streaked, correct...
Page 675 SERVICE PROCEDURE 3. Rear Drum Brake D: ASSEMBLY 1. WHEEL CYLINDER Clean all parts in brake fluid. Check and replace faulty parts. ¼ Cup and boot for damage or fatigue ¼ Cylinder, piston and spring or damage or rust formation 1) Assembly is the reverse order of disassembly.
Page 676 SERVICE PROCEDURE 3. Rear Drum Brake 2. BRAKE DRUM AND SHOE 1) Clean back plate and wheel cylinder. 2) Apply grease to portions indicated by arrows in Figure. Brake grease: Dow Corning Molykote No. 7439 (Part No. 725191460) G4M0407 3) Apply grease to adjusting screw and both ends of adjuster.
Page 677: Parking Brake (Rear Disc Brake)
SERVICE PROCEDURE 4. Parking Brake (Rear Disc Brake) 4. Parking Brake (Rear Disc Brake) A: REMOVAL G4M0411 Back plate Strut Shoe hold down spring Shoe hold down pin Retainer Shoe guide plate Adjusting hole cover Spring washer Primary return spring Lever Secondary return spring Tightening torque: N⋅m (kg-m, ft-lb)
Page 678 SERVICE PROCEDURE 4. Parking Brake (Rear Disc Brake) 10) Remove parking cable from parking lever. 11) Using a standard screwdriver, raise retainer. Remove parking lever and washer from brake shoe. G4M0413 B: INSPECTION 1) Measure brake disc inside diameter. If the disc is scored or worn, replace the brake disc.
Page 679 SERVICE PROCEDURE 4. Parking Brake (Rear Disc Brake) 2) Installation is in reverse order of removal. CAUTION: ¼ Use new retainers and clinch them when installing brake shoes to levers. ¼ Ensure that parking lever moves smoothly. ¼ Do not confuse left parking lever with right one. ¼...
Page 680: Master Cylinder
SERVICE PROCEDURE 4. Parking Brake (Rear Disc Brake) - 5. Master Cylinder D: PARKING BRAKE ADJUSTMENT 1. SHOE CLEARANCE ADJUSTMENT 1) Remove adjusting hole cover from back plate. 2) Turn adjusting screw using a slot-type screwdriver until brake shoe is in close contact with disc rotor. 3) Turn back (downward) adjusting screw 3 or 4 notches.
Page 681 SERVICE PROCEDURE 5. Master Cylinder B: DISASSEMBLY 1. PRECAUTIONS FOR DISASSEMBLING 1) Remove mud and dirt from the surface of brake master cylinder. 2) Prepare tools necessary for disassembly operation, and arrange them neatly on work bench. 3) Clean work bench. 4) Tools for disassembly operation: ¼...
Page 682 SERVICE PROCEDURE 5. Master Cylinder D: ASSEMBLY 1. PRECAUTIONS FOR ASSEMBLING 1) When assembling, be sure to use recommended brake fluid. 2) Ensure that the inside wall of cylinder, pistons, and pis- ton cups are free from dirt when assembling. 3) Be extremely careful not to damage, scratch, or dent cylinder inside wall, pistons, and piston cups.
Page 683: Brake Booster
SERVICE PROCEDURE 6. Brake Booster 6. Brake Booster A: REMOVAL 1) Remove the following parts at engine compartment. (1) Disconnect connector for brake fluid level indicator. (2) Remove brake pipes from master cylinder. (3) Remove master cylinder installing nuts. (4) Disconnect vacuum hose from brake booster. 2) Remove the following parts from the pedal bracket.
Page 684 SERVICE PROCEDURE 6. Brake Booster 7) Adjust operating rod of brake booster as follows: (1) Be sure engine is off. (No vacuum is applied to brake booster.) (2) There should be play between brake booster clevis and pin at brake pedal installing portion. (Depress brake pedal pad with a force of less than 10 N [1 kg, 2 lb] to a stroke of 1 to 3 mm [0.04 to 0.12 in].) G4M0421...
Page 685 SERVICE PROCEDURE 6. Brake Booster 2. AIR TIGHTNESS CHECK Start engine, and run it for 1 to 2 minutes, then turn it off. Depress brake pedal several times applying the same pedal force as that used in ordinary braking operations. The pedal stroke should be greatest on the 1st depression, and it should become smaller with each successive depression.
Page 686 SERVICE PROCEDURE 6. Brake Booster 5. CHECKING WITH GAUGES Connect gauges as shown in Figure. After bleeding air from pressure gauges, proceed to each check. G4M0423 6. AIR TIGHTNESS CHECK 1) Start engine and keep it running until a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A is indicated on vacuum gauge.
Page 687 SERVICE PROCEDURE 6. Brake Booster 8. LACK OF BOOSTING ACTION CHECK Turn off engine, and set the vacuum gauge reading at “0”. Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the stan- dard value listed below.
Page 688 SERVICE PROCEDURE 6. Brake Booster (2) Whether or not reaction disc has dropped can be determined by measuring the dimension “L”. The projected amount “L” of pushrod should be as fol- lows: Standard (Correct): L = 10.4 mm (0.409 in) Incorrect: L = 4.4 mm (0.173 in) (3) If protector is fitted correctly, reaction disc will not...
Page 689: Brake Hose
SERVICE PROCEDURE 7. Brake Hose 7. Brake Hose A: REMOVAL 1) Separate brake pipe from brake hose. (Always use flare nut wrench and be careful not to deform flare nut.) 2) Pull out clamp to remove brake hose. 3) Remove clamp at strut and union bolt. G4M0426 B: INSTALLATION 1.
Page 690: Hill Holder
SERVICE PROCEDURE 8. Hill Holder 8. Hill Holder A: REMOVAL 1) Drain brake fluid from reservoir of master cylinder. 2) Remove adjusting nut and cable clamp, and disconnect PHV cable from cable bracket on engine. 3) Detach PHV cable from clips. 4) Remove cable clamp, and disconnect PHV cable from PHV stay.
Page 691 SERVICE PROCEDURE 8. Hill Holder C: INSTALLATION 1) Install PHV onto side frame. Torque: 18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb) 2) Connect brake pipes to PHV. Torque: +0.3 +2.2 14.7 N⋅m (1.5 kg-m, 10.8 ft-lb) −2 −0.2 −1.4 CAUTION: Confirm that brake pipes are not deformed and/or dam- aged.
Page 692: Parking Brake Lever
SERVICE PROCEDURE 8. Hill Holder - 9. Parking Brake Lever NOTE: Whenever turning adjust nut, prevent PHV cable from revolving as shown in Figure. G4M0429 9. Parking Brake Lever A: REPLACEMENT 1) Remove console box from front floor. 2) Disconnect electric connector for parking brake switch. 3) Loosen parking brake adjuster, and remove inner cable end from equalizer.
Page 693: Parking Brake Cable
SERVICE PROCEDURE 10. Parking Brake Cable 10. Parking Brake Cable G4M0431 Adjuster Cable guide (Trailing link) Tightening torque: N⋅m (kg-m, ft-lb) Equalizer Parking brake ASSY T1: 5.9±1.5 (0.60±0.15, 4.3±1.1) Clamp T2: 18±5 (1.8±0.5, 13.0±3.6) T3: 32±10 (3.3±1.0, 24±7) Grommet Bracket A: REPLACEMENT 1) Remove rear tires and wheels.
Page 694 SERVICE PROCEDURE 10. Parking Brake Cable 6) Unbend parking brake lever pawls and remove cable. G4M0665 7) Roll up floor mat and remove clamps. 8) Remove equalizer cover. G4M0666 9) Remove inner cable end from equalizer. G4M0667 10) Pull out parking brake cable from parking brake assembly.
Page 695: Air Bleeding
SERVICE PROCEDURE 10. Parking Brake Cable - 11. Air Bleeding 16) Detach parking brake cable from cable guide at rear trailing link. 17) Install (new) parking brake assembly in the reverse order of removal. NOTE: ¼ Be sure to pass cable through cable guide inside the tunnel.
Page 696 SERVICE PROCEDURE 11. Air Bleeding 1) Make sure that there is no leak from joints and connec- tions of the brake system. 2) Fit one end of vinyl tube into the air bleeder and put the other end into a brake fluid container. 3) Slowly depress the brake pedal and keep it depressed.
Page 697 SERVICE PROCEDURE 11. Air Bleeding 6) Check the pedal stroke. While the engine is idling, depress the brake pedal with a 490 N (50 kg, 110 lb) load and measure the distance between the brake pedal and steering wheel. With the brake pedal released, measure the distance between the pedal and steering wheel again.
Page 698: Brake Fluid Replacement
SERVICE PROCEDURE 12. Brake Fluid Replacement 12. Brake Fluid Replacement NOTE: To always maintain the brake fluid characteristics, replace the brake fluid according to maintenance schedule or ear- lier than that when used in severe condition. A: REPLACEMENT CAUTION: ¼ The FMVSS No. 116, fresh DOT3 or 4 brake fluid must be used.
Page 699 SERVICE PROCEDURE 12. Brake Fluid Replacement 5) Install one end of a vinyl tube onto the air bleeder of and insert the other end of the tube into a container to collect the brake fluid. 6) Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed.
Page 700: Proportioning Valve
SERVICE PROCEDURE 13. Proportioning Valve 13. Proportioning Valve G4M0440 G4M0668 A: INSPECTION 1) Install the oil pressure gauges to measure the master cylinder fluid pressure (front wheel brake fluid pressure) and rear wheel cylinder fluid pressure. 2) Bleed air from the oil pressure gauges. 3) Check the master cylinder fluid pressure and rear wheel cylinder fluid pressure.
Page 701: Sensor
SERVICE PROCEDURE 13. Proportioning Valve - 14. A.B.S. Sensor Proportioning valve to bracket Normal brake vehicle: 22±4.4 N⋅m (2.25±0.45 kg-m, 16.3±3.3 ft-lb) A.B.S. equipped vehicle: 18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb) 14. A.B.S. Sensor A: REMOVAL 1. FRONT A.B.S. SENSOR 1) Disconnect front A.B.S.
Page 702 SERVICE PROCEDURE 14. A.B.S. Sensor 2. REAR A.B.S. SENSOR 1) Remove rear seat and disconnect rear A.B.S. sensor connector. 2) Remove rear sensor harness bracket from rear trailing link. 3) Remove rear A.B.S. sensor from rear back plate. 4) Remove rear tone wheel while removing hub from housing and hub assembly.
Page 703 SERVICE PROCEDURE 14. A.B.S. Sensor 2. TONE WHEEL 1) Check tone wheel’s teeth (44 pieces) for cracks or dents. If necessary, replace tone wheel with a new one. 2) Clearances (sensor gaps) should be measured one by one to ensure tone wheel and speed sensor are installed correctly.
Page 704 SERVICE PROCEDURE 14. A.B.S. Sensor 2) Temporarily install front A.B.S. sensor on housing. CAUTION: Be careful not to strike A.B.S. sensor’s pole piece and tone wheel’s teeth against adjacent metal parts during installation. G4M0443 3) Install front drive shaft to hub spline. <Ref. to 4-2 [W1E0].>...
Page 705 SERVICE PROCEDURE 14. A.B.S. Sensor 2) Temporarily install rear A.B.S. sensor on back plate. CAUTION: Be careful not to strike A.B.S. sensor’s pole piece and tone wheel’s teeth against adjacent metal parts. G4M0445 3) Install rear drive shaft to rear housing and rear differen- tial spindle.
Page 706: Hydraulic Unit For A.b.s. System
SERVICE PROCEDURE 15. Hydraulic Unit for A.B.S. System 15. Hydraulic Unit for A.B.S. System G4M0358 Connector Tightening torque: N⋅m (kg-m, ft-lb) T1: 1.2±0.2 (0.125±0.025, 0.9±0.2) Motor relay T2: 18±5 (1.8±0.5, 13.0±3.6) T3: 32±10 (3.3±1.0, 24±7) Valve relay T4: 52±15 (5.3±1.5, 38±11) Hydraulic control unit Bracket A: REMOVAL...
Page 707 SERVICE PROCEDURE 15. Hydraulic Unit for A.B.S. System ¼ When a new hydraulic unit is installed, apply a coat of rust-preventive wax (Nippeco LT or GB) to bracket attaching bolts after tightening. ¼ Do not pull harness disconnecting harness connec- tor.
Page 708 SERVICE PROCEDURE 15. Hydraulic Unit for A.B.S. System 2. CHECKING THE HYDRAULIC UNIT OPERATION BY PRESSURE GAUGE 1) Remove the FL and FR pipes from the hydraulic unit. 2) Connect a pressure gauge to the end of the removed FL and FR pipes.
Page 709 SERVICE PROCEDURE 15. Hydraulic Unit for A.B.S. System 5) When the hydraulic unit begins to work, and first the FL side performs decompression, holding, and compression, and then the FR side performs decompression, holding, and compression. 6) Read values indicated on the pressure gauge and check if the fluctuation of the values between decompres- sion and compression meets the standard values.
Page 710 SERVICE PROCEDURE 15. Hydraulic Unit for A.B.S. System 3. CHECKING THE HYDRAULIC UNIT WITH BRAKE TESTER 1) In the case of AWD AT vehicles, install a spare fuse with the FWD connector in the engine compartment to simulate FWD vehicles. G4M0462 2) Ground check connector body K and L terminals which are accessible after removing A.B.S.
Page 711 SERVICE PROCEDURE 15. Hydraulic Unit for A.B.S. System 7) Read values indicated on the brake tester and check if the fluctuation of values, when decompressed and compressed, meet the standard values. Initial value When decompressed When compressed Front wheel 1,961 N (200 kg, 441 lb) 245 N (25 kg, 55 lb) 1,961 N (200 kg, 441 lb) Rear wheel...
Page 712 SERVICE PROCEDURE 15. Hydraulic Unit for A.B.S. System 2. CONDITIONS FOR COMPLETION OF SEQUENCE CONTROL 1) When the speed of at least one wheel reaches 10 km/h (6 MPH), the operation is returned to the normal control mode. 2) When L terminal is separated from ground, the opera- tion is returned to the normal control mode.
Page 713: Control Module
SERVICE PROCEDURE 15. Hydraulic Unit for A.B.S. System - 16. A.-B.S. Control Module D: INSTALLATION 1) Install relay box cover on hydraulic unit. 2) Install hydraulic unit to bracket. Tightening torque: 18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb) 3) Tighten bracket and motor ground lead as a unit. Tightening torque: 32±10 N⋅m (3.3±1.0 kg-m, 24±7 ft-lb) 4) Connect brake pipes to their correct hydraulic unit con-...
Page 714: G Sensor For A.b.s. System
SERVICE PROCEDURE 16. A.B.S. Control Module - 17. G Sensor for A.B.S. System B: INSPECTION Check that connector is connected correctly and that con- nector terminal sliding resistance is correct. C: INSTALLATION 1) Connect connector to A.B.S. control module. 2) Install A.B.S. control module on body. G4M0469 17.
Page 715: Brake Hose And Pipe
SERVICE PROCEDURE 18. Brake Hose and Pipe 18. Brake Hose and Pipe SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG” Airbag system wiring harness is routed near the center brake pipe. CAUTION: ¼ All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equip- ment on these circuit.
Page 716 SERVICE PROCEDURE 18. Brake Hose and Pipe 2. MODELS WITH A.B.S. G4M0473 Union bolt Two-way connector Tightening torque: N⋅m (kg-m, ft-lb) Front brake hose RH Connector bolt T1: 13±3 (1.3±0.3, 9.4±2.2) Valve bracket Rear brake hose RH T2: 14.7 −2 +0.3 +2.2 (1.5...
Page 717: Entire Brake System
DIAGNOSTICS 1. Entire Brake System 1. Entire Brake System Trouble and possible cause Corrective action 1. Insufficient braking Repair or replace (cup, piston seal, piston boot, master cylinder (1) Fluid leakage from the hydraulic mechanism piston kit, pipe or hose). (2) Entry of air into the hydraulic mechanism Bleed the air.
Page 718 DIAGNOSTICS 1. Entire Brake System Trouble and possible cause Corrective action 4. Brake dragging or improper brake return (1) Insufficient pedal play Adjust play. (2) Improper master cylinder return Clean or replace the cylinder. (3) Clogged hydraulic system Replace. (4) Improper return or adjustment of parking brake Correct or adjust.
Page 719: Hill Holder
DIAGNOSTICS 2. Hill Holder 2. Hill Holder Trouble and possible cause Corrective action 1. Counterforce of clutch pedal is too strong. (1) PHV cable is damaged or does not operate properly. Repair or replace. (2) Lever of PHV is defective. Replace entire PHV assembly.
Page 720 PEDAL SYSTEM AND CONTROL CABLES Page S SPECIFICATIONS AND SERVICE DATA........... 2 1. Pedal System................... 2 C COMPONENT PARTS ................3 1. Pedal (MT Model) ..................3 2. Pedal (AT Model) ..................4 W SERVICE PROCEDURE ................5 1. Pedal ......................5 2.
Page 721: Pedal System
SPECIFICATIONS AND SERVICE DATA 1. Pedal System 1. Pedal System A: SERVICE DATA 1 — 3 mm (0.04 — 0.12 in) Brake pedal Free play [Depress brake pedal pad with a force of less than 10 N (1 kg, 2 lb).] Free play At clutch pedal pad 10 —...
Page 722: Pedal (Mt Model)
COMPONENT PARTS 1. Pedal (MT Model) 1. Pedal (MT Model) G4M0315 Accelerator pedal Pedal bracket Clutch pedal Bushing Clutch switch (Starter interlock) Bushing assist Holder Stop light switch Spring assist Accelerator bracket Clutch switch (Cruise control) Clutch cable clamp Stopper Brake pedal Clutch cable Clip...
Page 723: Pedal (At Model)
COMPONENT PARTS 2. Pedal (AT Model) 2. Pedal (AT Model) G4M0903 Accelerator pedal Accelerator stopper Brake pedal Bushing Clip Clevis pin Holder Accelerator plate Brake spacer Accelerator bracket Plug Brake pedal spring Stopper Pedal bracket Tightening torque: N⋅m (kg-m, ft-lb) Clip Stop light switch T1: 8±2 (0.8±0.2, 5.8±1.4)
Page 724: Pedal
SERVICE PROCEDURE 1. Pedal 1. Pedal A: ON-CAR SERVICE 1. BRAKE PEDAL 1) Check position of pedal pad. Stop light switch Toe board Pedal height: L G4M0905 158 mm (6.22 in) If it is not in specified value, adjust it by adjusting brake booster operating rod length.
Page 725 SERVICE PROCEDURE 1. Pedal 2) If it is not in specified value, adjust it by turning adjust- ing nut on engine side end of clutch cable. Free play: L 3 — 4 mm (0.12 — 0.16 in) Full stroke: A 25.5 —...
Page 726 SERVICE PROCEDURE 1. Pedal 4) Remove accelerator pedal connecting bolt from accel- erator pedal bracket. G4M0321 5) Disconnect accelerator cable from accelerator pedal lever. G4M0322 2. BRAKE AND CLUTCH PEDAL (MT model) 1) Disconnect ground cable from battery. 2) Disconnect clutch cable from release lever. 3) Remove instrument panel lower cover from instrument panel.
Page 727 SERVICE PROCEDURE 1. Pedal 3. BRAKE PEDAL (AT model) 1) Disconnect ground cable from battery. 2) Remove instrument panel lower cover from instrument panel. 3) Remove clevis pin which secures brake pedal to brake booster operating rod. Also disconnect stop lamp switch connector.
Page 728 SERVICE PROCEDURE 1. Pedal D: ASSEMBLY 1. BRAKE AND CLUTCH PEDAL 1) Attach stop light switch, etc. to pedal bracket tempo- rarily. 2) Clean inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores. 3) Align bores of pedal bracket, clutch pedal and brake pedal, attach brake pedal return spring and clutch pedal effort reducing spring (vehicle with Hill holder), and then...
Page 729 SERVICE PROCEDURE 1. Pedal E: INSTALLATION 1. BRAKE AND CLUTCH PEDAL 1) Insert clutch cable into hole on toe board, and set pedal bracket above steering column. CAUTION: Be careful not to bend clutch cable too much. 2) Insert bolts of brake booster into holes on toe board, support it from engine room, and fit holes of pedal bracket onto the bolts.
Page 730: Clutch Cable
SERVICE PROCEDURE 2. Clutch Cable 2. Clutch Cable A: REMOVAL 1) Disconnect clutch cable from release lever. 2) Remove clutch cable clamp from pedal bracket. 3) Disconnect clutch cable from pedal bracket and pedal end. 4) Remove clutch cable from body. CAUTION: Before removing clutch cable from toe board, remove grommet.
Page 731: Accelerator Cable
SERVICE PROCEDURE 3. Accelerator Cable 3. Accelerator Cable G4M0334 A: REMOVAL 1) Disconnect accelerator cable from connector inside engine compartment first. 2) Remove lock nut from accelerator cable bracket. 3) Separate accelerator cable k from bracket, then unlock inner cable. 4) Remove cable end from throttle cam using your finger- tips.
Page 732 SERVICE PROCEDURE 3. Accelerator Cable B: INSTALLATION 1) Pass inner cable through toe board hole and route inside driver compartment. Install cable bushing on accel- erator pedal end. 2) While turning accelerator cable counterclockwise, transfer it to driver compartment through toe board hole. 3) Connect accelerator cable to upper holder of accelera- tor pedal.
Page 733: Speedometer Cable
SERVICE PROCEDURE 4. Speedometer Cable 4. Speedometer Cable G4M0336...
Page 734 SERVICE PROCEDURE 4. Speedometer Cable A: REMOVAL 1) Remove speedometer cable, starting with its midpoint connection inside engine compartment. 2) While holding up boot located at speedometer cable connection, slightly expand clip. Extract speedometer cable by pulling it upward 2 to 3 mm (0.08 to 0.12 in) on speedometer side.
Page 735: Pedal System And Control Cables
DIAGNOSTICS 1. Pedal System and Control Cables 1. Pedal System and Control Cables Trouble Corrective action Excessively worn brake pedal pad Replace. Failure of clutch and/or accelerator pedals to operate Connect cables correctly. Speedometer does not work. Connect speedometer cable correctly. Stop light switch does not light up.
Page 736 HEATER AND VENTILATOR Page S SPECIFICATIONS AND SERVICE DATA.............2 1. Heater and Ventilation ................2 C COMPONENT PARTS ..................3 1. Heater Unit....................3 2. Intake Unit....................4 3. Control Unit ....................5 W SERVICE PROCEDURE ................6 1. Supplemental Restraint System “Airbag” ..........6 2. Heater Unit....................6 3.
Page 737: Heater And Ventilation
SPECIFICATIONS AND SERVICE DATA 1. Heater and Ventilation 1. Heater and Ventilation A: SPECIFICATIONS Item Specifications Condition ¼ Mode selector : HEAT switch ¼ Temp. control : FULL HOT switch 4.652 kW (4,000 kcal/h, 15,872 BTU/h) or ¼ Temperature Heating capacity more difference between : 65°C (149°F)
Page 738: Heater Unit
COMPONENT PARTS 1. Heater Unit 1. Heater Unit G4M0551 Vent lever Mix rod Vent door Side link Mix link DEF. door DEF. lever Mix lever Foot lever upper Heater case upper Foot duct (RH) Tightening torque: N⋅m (kg-m, ft-lb) Heater grommet Foot duct (CTR) T: 7.35±1.96 Heater core...
Page 739: Intake Unit
COMPONENT PARTS 2. Intake Unit 2. Intake Unit G4M0552 Intake unit case upper Intake unit case lower Tightening torque: N⋅m (kg-m, ft-lb) Lever (A) Blower motor ASSY T: 7.35±1.96 Link Hose (0.750±0.200, 5.421±1.446) Actuator rod Lever (B) Actuator motor Door (A) Actuator bracket Bell mouth-intake Door (B)
Page 740: Control Unit
COMPONENT PARTS 3. Control Unit 3. Control Unit G4M0553 Harness ASSY Link Light box Shaft Switch ASSY Clip Mode lever LH TEMP. lever Control dial knob Clip Shaft Plate Grommet Bulb Base plate Base plate...
Page 741: Supplemental Restraint System "Airbag
SERVICE PROCEDURE 1. Supplemental Restraint System “Airbag” - 2. Heater Unit 1. Supplemental Restraint System “Airbag” Airbag system wiring harness is routed near the instrument panel, heater unit, blower motor and control unit. CAUTION: ¼ All Airbag system wiring harness and connectors are colored yellow.
Page 742: Blower Motor Assembly
SERVICE PROCEDURE 2. Heater Unit - 4. Control Unit B: INSTALLATION Installation is in the reverse order of removal. Fitted length of heater hose over pipe: 25 — 30 mm (0.98 — 1.18 in) 3. Blower Motor Assembly A: REMOVAL 1) Disconnect GND cable from battery.
Page 743 SERVICE PROCEDURE 4. Control Unit 4) Remove center panel. G4M0556 5) Remove control unit assembly and disconnect connec- tor. G4M0557 B: INSPECTION 1. FAN SWITCH Check continuity between terminals at each switch posi- tion. Terminals Switch position Med. 1 G4M0558 Med.
Page 744 SERVICE PROCEDURE 4. Control Unit 2. CONTROL UNIT 1) Ignition switch is turned OFF. 2) Disconnect connector from control unit. 3) Check circuit continuity between each terminal. Mode selector switch position ¼ MAX A/C Except Terminal Illumi. MAX A/C ¼ A/C MAX A/C (RECIRC) (FRESH)
Page 745: Intake Door Motor
SERVICE PROCEDURE 5. Intake Door Motor 5. Intake Door Motor A: REMOVAL 1) Disconnect GND cable from battery. 2) Remove glove box. 3) Remove heater duct (or cooling unit with A/C model). <Ref. to 4-7 [W14A0].> G5M0276 4) Remove intake unit from the vehicle. G4M0561 5) Remove screws which secure intake door motor to intake unit.
Page 746 SERVICE PROCEDURE 5. Intake Door Motor 1) Connect harness to intake door motor. 2) Turn ignition switch to “ACC” and set RECIRC switch to“ON” switch to “RECIRC”. NOTE: Ensure that intake door motor is set in the “RECIRC” mode. 3) Install intake door motor on intake unit. 4) Secure rod holder to link, and install link to intake unit.
Page 747 AIR CONDITIONING SYSTEM Page S SPECIFICATIONS ..................2 1. Air Conditioning System ................2 C COMPONENT PARTS ..................3 1. Air Conditioning System ................3 2. Evaporator ....................4 3. Compressor ....................5 W SERVICE PROCEDURE ................6 1. Safety Precautions..................6 2. Basic Information ..................6 3. Tools and Equipment ................7 4.
Page 748: Air Conditioning System
SPECIFICATIONS 1. Air Conditioning System 1. Air Conditioning System Item Specifications Type of air conditioner Reheat air-mix type 5.234 kW Cooling capacity (IMACA) (4,500 kcal/h, 17,856 BTU/h) R-12 (CCL Refrigerant [0.65 — 0.75 kg (1.43 — 1.65 lb)] Type 5-vane rotary, fix volume (CR-14) Compressor Discharge 144 cm...
Page 749: Air Conditioning System
COMPONENT PARTS 1. Air Conditioning System 1. Air Conditioning System G4M0567 A/C cut relay Fuse Tightening torque: N⋅m (kg-m, ft-lb) FICD Hose (High-pressure) T1: 5.39 — 9.31 (0.55 — 0.95, 4.0 — 6.9) Receiver drier bracket Compressor T2: 13 — 23 (1.3 — 2.3, 9 — 17) Pipe (Receiver drier —...
Page 750: Evaporator
COMPONENT PARTS 2. Evaporator 2. Evaporator G4M0568 Thermo control amplifier Expansion valve Tightening torque: N⋅m (kg-m, ft-lb) Case upper Drain hose T1: 5.5 — 9.5 (0.56 — 0.97, 4.1 — 7.0) Cooling unit Case lower T2: 13.2 — 16.2 Grommet Resistor (1.35 —...
Page 751: Compressor
COMPONENT PARTS 3. Compressor 3. Compressor G4M0569 Alternator bracket Compressor Tightening torque: N⋅m (kg-m, ft-lb) Alternator Condenser fan motor ASSY T1: 3 — 5 (0.3 — 0.5, 2.2 — 3.7) Alternator bracket nut Idler pulley ASSY T2: 5.39 — 9.31 Compressor belt cover Compressor bracket upper (0.55 —...
Page 752: Safety Precautions
SERVICE PROCEDURE 1. Safety Precautions - 2. Basic Information 1. Safety Precautions Because refrigerant boils at approx. −30°C (−22°F) at sea level, it is cold enough to give you severe frostbite. Always wear goggles to protect your eyes and gloves to protect your hands.
Page 753: Tools And Equipment
SERVICE PROCEDURE 3. Tools and Equipment 3. Tools and Equipment The following section provides information about the tools and equipment that will be necessary to properly service the A/C system. Since equipment may vary slightly depending on the manufacturer, it is important to always read and follow the manufacturer’s instructions.
Page 754 SERVICE PROCEDURE 3. Tools and Equipment Tools and Equipment Description A graduated plastic SYRINGE will be needed to add oil back into the system. The syringe can be found at a pharmacy or drug store. G4M0575 A VACUUM PUMP (in good working condition) is necessary, and may be obtained from either a commercial refrigeration supply house or an automotive equipment supplier.
Page 755 SERVICE PROCEDURE 3. Tools and Equipment Tools and Equipment Description An ELECTRONIC LEAK DETECTOR can be obtained from either a specialty tool supply or an A/C equipment supplier. G4M0579 A WEIGHT SCALE such as an electronic charging scale or a bathroom scale with digital display will be needed if a 13.6 kg (30 lb) refrigerant container is used.
Page 756: O-Ring Connections
SERVICE PROCEDURE 4. O-ring Connections 4. O-ring Connections 1. GENERAL The following points should be kept in mind when assem- bling O-ring connections: 1) Avoid unnecessary handling and contact of O-rings with your hands, since even clean fingers contain body acids, which can contaminate the O-ring surface.
Page 757 SERVICE PROCEDURE 4. O-ring Connections 3. LUBRICATE THE COMPONENTS For lubrication of the components, use only refrigerant oil as described in the appropriate service manual. Apply oil from an oil squirt gun or other closed container. Do not use your finger to spread the oil over the O-ring. Apply a small amount of refrigerant oil to the top and sides of the O-ring.
Page 758: Refrigerant Service Procedure
SERVICE PROCEDURE 5. Refrigerant Service Procedure 5. Refrigerant Service Procedure 1. WORK FLO EPA0002...
Page 759: Discharge The System
SERVICE PROCEDURE 6. Discharge the System - 7. Evacuating and Charging 6. Discharge the System CAUTION: The following points must be kept in mind when dis- charging the system. 1) Be certain that goggles and gloves are worn. 2) Connect refrigerant recovery system to manifold gauge set and remove recycle refrigerant from the A/C system.
Page 760 SERVICE PROCEDURE 7. Evacuating and Charging 3) The charging procedure described in this section begins by charging liquid refrigerant into the high-pressure side of the system with the engine off. The procedure is completed by charging refrigerant vapor into the low-pres- sure side of the system with the engine running.
Page 761 SERVICE PROCEDURE 7. Evacuating and Charging 4) Note the low side gauge reading. 5) After 5 minutes, re-check the low-pressure gauge read- ing. If the vacuum level has changed more than 4 kPa (25 mmHg, 1 inHg), perform an R-12 leak test. If the vacuum reading is about the same as noted in step 2-4), continue on to step 2-6).
Page 762 SERVICE PROCEDURE 7. Evacuating and Charging 5. CHECK THE GAUGE READINGS When both the high- and low-pressure gauge readings are about equal, or the R-12 source is empty, or the system has been filled to specifications, close the high-pressure manifold valve. G4M0605 6.
Page 763 SERVICE PROCEDURE 7. Evacuating and Charging 3) When the system is fully charged, close the low-pres- sure manifold valve. 4) Close the valve at the refrigerant source. ¼ Refrigerant capacity Unit: kg (lb) Refrigerant Minimum Maximum R-12 0.65 (1.43) 0.75 (1.65) 9.
Page 764: Leak Testing
SERVICE PROCEDURE 8. Leak Testing 8. Leak Testing The following points should be kept in mind when conduct- ing a refrigerant leak test. 1) The A/C system to be tested must have an adequate refrigerant charge to begin with. 2) The area where the leak test is conducted must be free of wind and drafts, with still air being the ideal condition.
Page 765 SERVICE PROCEDURE 8. Leak Testing 3. CALIBRATE LEAK DETECTOR Refer to the manufacturer’s instructions for the particular type of detector used and calibrate the instrument. CAUTION: Always make sure that the probe tip filter is clean and free of contamination. G4M0610 4.
Page 766 SERVICE PROCEDURE 8. Leak Testing (2) Check the area where the two parts of the fitting join each other. G4M0613 (3) Check the area where the nut meets the tube. G4M0614 3) Check the area of the sight glass and pressure switch (trinary switch), and also check the seams of the receiver drier.
Page 767 SERVICE PROCEDURE 8. Leak Testing (3) Check the area where the nut joins the tube. G4M0616 7. CHECK THE FLEXIBLE HOSES 1) Visually inspect the rubber portions of the flexible hoses for cracking. Probe the rubber section, including the ends of any insulators or protectors which may cover sections of the rubber hose, and near the ends where the rubber meets the metal collar.
Page 768: Lubrication
SERVICE PROCEDURE 9. Lubrication 9. Lubrication 1. SYSTEM OIL STABILIZATION Prior to opening the refrigerant system for repairs (except compressor seizure) the system must be stabilized for cor- rect oil replenishment. Follow these procedures: 1) Engine speed set to 1,500 rpm. 2) A/C “ON”.
Page 769: Performance Test
SERVICE PROCEDURE 10. Performance Test 10. Performance Test 1. VEHICLE SET UP In order to obtain meaningful test results, the vehicle must be set up to meet the following conditions: 1) Vehicle in shade 2) No wind 3) All vehicle doors closed 4) Front windows open 5) Hood open 6) Engine speed set at 1,500 rpm.
Page 770: Compressor
SERVICE PROCEDURE 11. Compressor 11. Compressor Compressor is a 5-vane rotary type. When trouble occurs, replace compressor as a single unit. G4M0620 1. COMPRESSOR CLUTCH Compressor clutch trouble is often caused by clutch slip- page and noise. Check and take corrective measures, as required.
Page 771 SERVICE PROCEDURE 11. Compressor 3) Low-pressure hose k (Flexible hose Ps) CAUTION: ¼ Be careful not to lose O-ring of low-pressure hose. ¼ Plug the opening to prevent foreign matter from entering. G4M0566 4) High-pressure hose k (Flexible hose Pd) CAUTION: ¼...
Page 772 SERVICE PROCEDURE 11. Compressor 8) Generator harness G4M0627 9) Compressor harness Disconnect compressor harness from body harness. 10) Lower bracket Remove bolts which secure lower compressor bracket. G4M0628 11) Compressor Remove bolts which secure compressor. Remove com- pressor from bracket. G4M0629 B: INSTALLATION 1) Compressor...
Page 773 SERVICE PROCEDURE 11. Compressor 5) Generator V-belt After adjusting V-belt tension, tighten generator bracket lock bolt securely. 6) Check drive belt tension and adjust it if necessary by changing generator position and/or idler pulley position. G4M0632 Pulley arrangement Tension mm (in)/98 N (10 kg, 22 lb) *New belt: *New belt: 7.0 —...
Page 774 SERVICE PROCEDURE 11. Compressor CAUTION: ¼ Ensure that the V-belt is aligned correctly. If it is not, check for loose bolts. ¼ The V-belt should not be too tight or too loose. A belt which is too tight may break bearing or cause gas to leak from the shaft seal.
Page 775: Condenser
SERVICE PROCEDURE 12. Condenser 12. Condenser A: REMOVAL AND INSTALLATION 1) Disconnect battery negative terminal. 2) Discharge refrigerant from low-pressure side. 3) Remove front grille. G4M0637 4) Remove the radiator bracket. 5) Disconnect high-pressure hose k and high-pressure pipe k from condenser.
Page 776: Receiver Drier
SERVICE PROCEDURE 12.Condenser - 13. Receiver Drier B: INSPECTION 1) Make sure the condenser fins are free from dust and insects. If the fins are clogged, clean by blowing air or water through them. NOTE: To prevent dust and water from getting into the condenser, this work must be done when the condenser is installed in an actual vehicle.
Page 777: Evaporator
SERVICE PROCEDURE 14. Evaporator 14. Evaporator A: REMOVAL AND INSTALLATION 1) Disconnect battery negative terminal. 2) Discharge refrigerant. 3) Disconnect discharge pipe, suction pipe and grommets. G4M0641 4) Remove glove box. G5M0276 5) Disconnect the harness connector from evaporator. 6) Disconnect drain hose. 7) Remove evaporator mounting bolt and nut.
Page 778: Condenser Fan Assembly
SERVICE PROCEDURE 14.Evaporator - 15. Condenser Fan Assembly 3) Disconnect the connection between the expansion valve and pipe from receiver drier. 4) Remove the expansion valve from pipes. 5) To install expansion valve, reverse removal procedures. Properly wrap capillary tube of expansion valve with seal. 6) Check to see if the evaporator fins are clogged.
Page 779: Flexible Hose
SERVICE PROCEDURE 16. Flexible Hose 16. Flexible Hose With the following cautions, replace flexible hoses with new ones if they are damaged or swollen. (1) The flexible hoses should be free from twists and tension after they have been connected. (2) The flexible hoses must not be bent or twisted forc- ibly.
Page 780: Relay And Fuse
SERVICE PROCEDURE 17. Relay and Fuse 17. Relay and Fuse A: LOCATION Relays used with A/C system are located as shown in fig- ure. 1) A/C relay 2) Main fan (radiator fan) relay 3) Sub fan (condenser fan) relay 4) Sub fan (condenser fan) water temperature relay 5) Fuses (10 A and 20 A) G4M0649 6) A/C cut relay...
Page 781: Pressure Switch (Dual Switch)
SERVICE PROCEDURE 18. Pressure Switch (Dual Switch) 18. Pressure Switch (Dual Switch) Pressure switch is attached to receiver dryer. It has two built-in switches. ¼ High and low pressure switch G4M0654 A: INSPECTION 1) Remove cap from high-pressure line service valve, and connect gauge manifold to service valve.
Page 782: Air Conditioning System Diagnosis
DIAGNOSTICS 1. Air Conditioning System Diagnosis 1. Air Conditioning System Diagnosis EPA0003...
Page 783: Sight Glass Inspection
DIAGNOSTICS 2. Sight Glass Inspection 2. Sight Glass Inspection 1. INSPECTION CONDITION 1) Operate the engine at approximately 1,500 rpm. 2) Open the door windows. 3) Set the fan switch to the 4th (High) position. 4) Set the mode selector switch to “A/C” position. 5) Set the temperature control switch to Full cold position.
Page 784: Performance Test Diagnosis
DIAGNOSTICS 3. Performance Test Diagnosis 3. Performance Test Diagnosis If various conditions caused to other air conditioning system, the characteristics revealed on manifold gauge reading are shown in the following. As to the method of a performance test, refer to the item of “Performance Test”.
Page 785 DIAGNOSTICS 3. Performance Test Diagnosis Condition Probable cause Corrective action Insufficient cooling. Expansion valve allows Check valve for opera- Sweated suction line. too much refrigerant tion. If suction side does No cooling. through evaporator. not show a pressure Sweating or frosted suc- Faulty seal of O-ring in decrease, replace valve.
Page 786 DIAGNOSTICS 3. Performance Test Diagnosis Condition Probable cause Corrective action ¼ Check condenser No cooling action: Condenser is often FAULTY CONDENSER Engine may overheat. found not functioning cooling fan. ¼ Check condenser for Bubbles appear in sight well. glass of drier: dirt accumulation.
Page 787: Blower Motor Diagnosis
DIAGNOSTICS 4. Blower Motor Diagnosis 4. Blower Motor Diagnosis EPA0004...
Page 788: Compressor Diagnosis
DIAGNOSTICS 5. Compressor Diagnosis 5. Compressor Diagnosis EPA0005...
Page 789: Compressor Clutch Diagnosis
DIAGNOSTICS 6. Compressor Clutch Diagnosis 6. Compressor Clutch Diagnosis EPA0006...
Page 790: Radiator Fan (Main Fan) Diagnosis
DIAGNOSTICS 7. Radiator Fan (Main Fan) Diagnosis 7. Radiator Fan (Main Fan) Diagnosis EPA0007...
Page 791: Condenser Fan (Sub Fan) Diagnosis (I)
DIAGNOSTICS 8. Condenser Fan (Sub Fan) Diagnosis (I) 8. Condenser Fan (Sub Fan) Diagnosis (I) EPA0008...
Page 792: Condenser Fan (Sub Fan) Diagnosis (Ii)
DIAGNOSTICS 9. Condenser Fan (Sub Fan) Diagnosis (II) 9. Condenser Fan (Sub Fan) Diagnosis (II) EPA0009...
Page 793 BODY AND EXTERIOR Page S SERVICE DATA ................2 1. Supplemental Restraint System “Airbag” ..........2 2. Body Datum Points ..................2 3. Datum Dimensions...................15 4. Datum Points and Dimensions Concerning On-Board Aiming Adjustment..............22 C COMPONENT PARTS ................23 1. Front Hood and Hood Lock ..............23 2.
Page 794: S Service Data
SERVICE DATA 1. Supplemental Restraint System “Airbag” - 2. Body Datum Points 1. Supplemental Restraint System “Airbag” Airbag system wiring harness is routed on and along body panels. CAUTION: ¼ All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equip- ment on these circuit.
Page 795 SERVICE DATA 2. Body Datum Points 1. ENGINE COMPARTMENT AND ROOM G5M0110 Radiator panel (UPR) repair bolt hole M8 (Right) Wax coat hole, 20 mm (0.79 in) dia. (Symmetrical) Radiator panel (UPR) repair bolt hole M8 (Left) Retainer attaching square hole 7 mm (0.28 in) (Symmetrical) Fender attaching bolt hole M6 (Symmetrical) Sun visor attaching hole 20 mm (0.79 in) dia.
Page 796 SERVICE DATA 2. Body Datum Points 2. LUGGAGE COMPARTMENT AND ROOM (SEDAN) G5M0111 Rear pillar (Inner) gauge hole 8 mm (0.31 in) dia. (Symmetri- Rear quarter bumper side gauge hole 20 mm (0.79 in) dia. cal) (Right) Rear roof trim attaching hole 8 mm (0.31 in) dia. (Symmetri- Instrument panel attaching square hole 22 x 34.5 mm (0.87 cal) x 1.358 in) (Right)
Page 797 SERVICE DATA 2. Body Datum Points 3. LUGGAGE COMPARTMENT AND ROOM (WAGON) G5M0113 Rear quarter glass attaching hole 8 mm (0.31 in) dia. (Symmetrical) Roof rail attaching hole 10 mm (0.39 in) dia. (Symmetrical) Rear quarter glass attaching hole 8 x 15 mm (0.31 x 0.59 in) dia. (Symmetrical) Rear roof trim attaching hole 8 mm (0.31 in) dia.
Page 798 SERVICE DATA 2. Body Datum Points 4. UNDER BODY G5M0112 Radiator panel (LWR) frame gauge hole 15 mm (0.59 in) dia. (Symmetrical) Front side frame gauge hole 20 mm (0.79 in) dia. (Symmetrical) Front crossmember attaching hole 12.4 mm (0.488 in) dia. (Symmetrical) Front suspension attaching bolt hole M14 Side frame gauge hole 20 mm (0.79 in) dia.
Page 799 SERVICE DATA 2. Body Datum Points G5M0114 G5M0207 G5M0209 G5M0208 G5M0211 G5M0210 G5M0212 G5M0213...
Page 800 SERVICE DATA 2. Body Datum Points G5M0214 G5M0215 G5M0216 G5M0217 G5M0218 G5M0219 G5M0220 G5M0221...
Page 801 SERVICE DATA 2. Body Datum Points G5M0222 G5M0223 G5M0224 G5M0225 G5M0226 G5M0227 G5M0228 G5M0229...
Page 802 SERVICE DATA 2. Body Datum Points G5M0230 G5M0231 G5M0232 G5M0233 G5M0234 G5M0235 G5M0236 G5M0237...
Page 803 SERVICE DATA 2. Body Datum Points G5M0238 G5M0239 G5M0240 G5M0241 G5M0242 G5M0243 G5M0244 G5M0245...
Page 804 SERVICE DATA 2. Body Datum Points G5M0246 G5M0247 G5M0248 G5M0249 G5M0250 G5M0251 G5M0252 G5M0253...
Page 805 SERVICE DATA 2. Body Datum Points G5M0254 G5M0255 G5M0257 G5M0256 G5M0259 G5M0258 G5M0260 G5M0261...
Page 806 SERVICE DATA 2. Body Datum Points G5M0262 G5M0263 G5M0264 G5M0265 H5M0670A G5M0267 G5M0268 G5M0269...
Page 807: Datum Dimensions
SERVICE DATA 3. Datum Dimensions 3. Datum Dimensions Use a tram tracking gauge to measure all dimensions. If a measuring tape is used, be extremely careful because it tends to deflect or twist, which results in a false reading. NOTE: ¼...
Page 808 SERVICE DATA 3. Datum Dimensions 2. CENTER STRUCTURE G5M0124...
Page 809 SERVICE DATA 3. Datum Dimensions 3. DOORS AND REAR QUARTER G5M0126 Unit: mm (in) — 1,495 (58.86) — 912 (35.91) — 947 (37.28) — 1,462 (57.56) (Wagon) — 976 (38.43) — 1,481 (58.31) — 803 (31.61) — 377 (14.84) (Wagon) —...
Page 810 SERVICE DATA 3. Datum Dimensions 4. FRONT WINDSHIELD AND REAR WINDOW G5M0127 Unit: mm (in) — 989 (38.94) — 714 (28.11) — 1,012 (39.84) — — — 1,116 (43.94) 856 (33.70) — — — 1,012 (39.84)
Page 811 SERVICE DATA 3. Datum Dimensions 5. TRUNK LID AND REAR GATE G5M0128 Unit: mm (in) TRUNK LID REAR GATE — — 606 (23.86) 988 (38.90) — — — — 831 (32.72) 926 (36.46) — — — 564 (22.20) — 1,043 (41.06) —...
Page 812 SERVICE DATA 3. Datum Dimensions 6. COMPARTMENT G5M0129 Unit: mm (in) — 1,197 (47.13) — — 1,140 (44.88) 1,168 (45.98) (Sedan) — 1,061 (41.77) — — — 1,453 (57.20) — — 733 (28.86) 1,050 (41.34) (Sedan) — 1,453 (57.20) — —...
Page 813 SERVICE DATA 3. Datum Dimensions 7. LUGGAGE ROOM G5M0130 Unit: mm (in) — — 1,122 (44.17) 1,237 (48.70) — — — — 1,225 (48.23) 971 (38.23) — — — 1,446 (56.93) — 1,235 (48.62)
Page 814: Datum Points And Dimensions Concerning On-Board Aiming Adjustment
SERVICE DATA 4. Datum Points and Dimensions Concerning On-Board Aiming Adjustment 4. Datum Points and Dimensions Concerning On-Board Aiming Adjustment If headlight aiming is misaligned due to damaged body panel, repair headlight mating surface using body and headlight datum points as a guide. G5M0270 Unit: mm (in) —...
Page 815: Front Hood And Hood Lock
COMPONENT PARTS 1. Front Hood and Hood Lock 1. Front Hood and Hood Lock H5M0671A Front hood Hood lock ASSY Tightening torque: N⋅m (kg-m, ft-lb) Hinge (RH, LH) Striker T1: 9 — 19 Hood hinge cover (RH, LH) (0.9 — 1.9, 6.5 — 13.7) Front hood stay Lever ASSY T2: 31 —...
Page 816: Trunk Lid
COMPONENT PARTS 2. Trunk Lid 2. Trunk Lid G5M0133 Torsion bar Striker Tightening torque: N⋅m (kg-m, ft-lb) Trunk lid Hinge ASSY T1: 10 — 18 (1.0 — 1.8, 7 — 13) Weatherstrip T2: 13 — 23 (1.3 — 2.3, 9 — 17) Trunk lid lock ASSY...
Page 817: Front Bumper
COMPONENT PARTS 3. Front Bumper 3. Front Bumper G5M0134 Plate Front beam Tightening torque: N⋅m (kg-m, ft-lb) Bumper face Bracket (Side) T: 69 — 118 (7 — 12, 51 — 87) Spacer Holder upper E/A from bumper...
Page 818: Rear Bumper
COMPONENT PARTS 4. Rear Bumper 4. Rear Bumper G5M0135 Holder upper Plate Tightening torque: N⋅m (kg-m, ft-lb) Bumper beam Bumper surface T: 69 — 127 (7 — 13, 51 — 94) Bracket (Side) E/A from bumper...
Page 819: Sunroof
COMPONENT PARTS 5. Sunroof 5. Sunroof G5M0136 Weatherstrip Harness Shutting ASSY (RH) Sunroof panel Sunroof trim Shutting ASSY (LH) Rear guide ASSY Guide rail Drain tube Lower panel Set bracket Garnish Lower panel Guide rail Tightening torque: N⋅m (kg-m, ft-lb) Rear guide ASSY Motor ASSY T: 5.5 —...
Page 820: Steering Support Beam
COMPONENT PARTS 6. Steering Support Beam 6. Steering Support Beam G5M0184 Bracket Tightening torque: N⋅m (kg-m, ft-lb) Steering beam T: 13 — 23 (1.3 — 2.3, 9 — 17)
Page 821: Hood
SERVICE PROCEDURE 1. Hood 1. Hood The hood lock has a dual locking design which consists of a main lock and a safety lock mechanism. When the release knob located at the front pillar on the driver’s side is pulled back, the main lock is released through the cable attached to the knob.
Page 822 SERVICE PROCEDURE 1. Hood C: INSTALLATION Installation is in the reverse order of removal. CAUTION: Adjust buffer assembly on each end so that main lock is applied securely when hood is released from a height of approx. 20 mm (0.79 in). NOTE: ¼...
Page 823 SERVICE PROCEDURE 2. Trunk Lid 2. Trunk Lid A: REMOVAL 1. TRUNK LID 1) Open trunk lid. 2) Remove trunk lid mounting bolts and detach trunk lid from hinges. G5M0144 2. TORSION BAR 1) Open trunk lid. Remove torsion bars from hinge links using ST.
Page 824 SERVICE PROCEDURE 2. Trunk Lid 4. TRUNK LID OPENER 1) Remove driver’s seat, rear seats, center pillar lower cover, floor mat, rear arch cover and side sill cover (on the driver’s side). 2) Remove all clips which hold cable. 3) Disconnect cable from pull handle assembly. 4) Remove bolts and detach pull handle assembly.
Page 825: Fuel Flap
SERVICE PROCEDURE 3. Fuel Flap 3. Fuel Flap A: REMOVAL 1. FUEL FLAP Remove bolts which hold hinge to car body, and detach fuel flap and hinge as a unit. G5M0150 2. FUEL FLAP OPENER 1) Remove driver’s seat, rear seats, center pillar lower cover, floor mat, rear arch cover/rear quarter trim (wagon), and side sill cover (on the driver’s side).
Page 826: Repair Instruction For Fuel Flap
SERVICE PROCEDURE 4. Repair Instruction for Fuel Flap 4. Repair Instruction for Fuel Flap 1. MOLDED PART SURFACE REPAIR The molded resin material differs in its properties from PP (polypropylene) used as bumper surface covering material. If its surface is scratched, the affected area can be easily repaired by sanding with grit sandpaper.
Page 827 SERVICE PROCEDURE 4. Repair Instruction for Fuel Flap Process Process name Job contents Apply clear coat to color Apply mica coat to color coat. coat. ¼ Film thickness: 20 — ¼ Film thickness: 20 — Top coating (II) Unnecessary. 30µ 30µ...
Page 828: Front Bumper
SERVICE PROCEDURE 5. Front Bumper 5. Front Bumper A: REMOVAL SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG” Airbag system wiring harness is routed near the front bumper assembly. CAUTION: ¼ All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equip- ment on these circuit.
Page 829 SERVICE PROCEDURE 5. Front Bumper 11) Remove bumper assembly. G5M0157 B: INSTALLATION To install the front bumper, reverse the above removal pro- cedures. CAUTION: ¼ Be extremely careful to prevent scratches on bumper face as it is made of resin. ¼...
Page 830: Rear Bumper
SERVICE PROCEDURE 6. Rear Bumper 6. Rear Bumper A: REMOVAL 1. SEDAN 1) Open trunk lid. Remove trunk trim panel clips and detach trim. 2) Disconnect license plate light connector. 3) Remove bolts from side of bumper. G5M0160 4) Remove bolts from bumper stay. G5M0161 5) Remove rear bumper.
Page 831 SERVICE PROCEDURE 7. Coating Method for PP Bumper 7. Coating Method for PP Bumper 1. PROCESS STEPS Process Process name Job contents Set bumper on paint worktable if required. Use Bumper mounting paint worktable conforming to inner shape of bumper when possible. G5M0164 Mask specified part (black base) with masking tape.
Page 832 SERVICE PROCEDURE 8. Repair Instructions for Colored PP Bumper 8. Repair Instructions for Colored PP Bumper All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be restored to its former condition. Damage limited to shallow scratches that cause only a change in the lustre of the base material or coating, can be almost fully restored.
Page 833 SERVICE PROCEDURE 8. Repair Instructions for Colored PP Bumper 3. DEEP DAMAGE SUCH AS A BREAK OR HOLE THAT REQUIRES FILLING Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not really worth the expense.
Page 834 SERVICE PROCEDURE 8. Repair Instructions for Colored PP Bumper Process Process name Job contents Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and damaged area. Welding G5M0167 NOTE: ¼ Melt the sections indicated by hatched area. ¼...
Page 835 SERVICE PROCEDURE 8. Repair Instructions for Colored PP Bumper Process Process name Job contents Cleaning/degreasing Same as Process No. 12. Solid color Metallic color Use a “block” coating method. Use a “block” coating method. ¼ Recommended paint: ¼ Recommended paint: Suncryl (SC) Suncryl (SC) No.
Page 836: Body Protector
SERVICE PROCEDURE 9. Body Protector - 10. Front Fender 9. Body Protector A: REMOVAL NOTE: Do not re-use protector. G5M0169 Type A and B: Protector is attached to body with clips. While holding end of protector by hand, force protector out. G5M0170 Type C: Protector is attached to body with clips.
Page 837 SERVICE PROCEDURE 10. Front Fender ¼ Be careful not to damage Airbag system wiring har- ness when servicing the front fender. 1) Disconnect ground cable from battery. 2) Remove mud guard. 3) Remove parking light and headlight. 4) Remove front bumper. 5) Remove bolts which secure fender to radiator panel and turn signal light connector.
Page 838: Mud Guard And Arch Protector
SERVICE PROCEDURE 11. Mud Guard and Arch Protector 11. Mud Guard and Arch Protector A: REMOVAL SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG” Airbag system wiring harness is routed near the mud guard. CAUTION: ¼ All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equip- ment on these circuit.
Page 839: Cowl Panel
SERVICE PROCEDURE 12. Cowl Panel 12. Cowl Panel A: REMOVAL 1) Remove wiper arms. 2) Open front hood. 3) Pry clip off front hood seal using a screwdriver. 4) Lift cowl panel and remove clips from windshield. B: INSTALLATION 1) Install clips on cowl panel. 2) Install cap on front panel.
Page 840: Molding And Retainer
SERVICE PROCEDURE 13. Molding and Retainer - 14.Front Grille 13. Molding and Retainer A: REMOVAL 1) Remove weatherstrip. 2) Remove tapping screws. G5M0181 B: INSTALLATION Installation is in the reverse order of removal. NOTE: Insert clips onto hooks, then fasten with screws. G5M0182 14.
Page 841: Sunroof
SERVICE PROCEDURE 15. Sunroof 15. Sunroof A: REMOVAL 1. SUNROOF PANEL 1) Open sunroof approx. 1/3. 2) Remove clips attached to front side of sunroof trim by pulling trim from inside of compartment. G5M0185 3) Move trim forward, and detach trim end from holder. G5M0186 4) Detach trim.
Page 842 SERVICE PROCEDURE 15. Sunroof 3. SUNROOF FRAME 1) Remove roof trim, rear quarter trim, pillar trim, etc. <Ref. to 5-3.> 2) Remove sunroof panel. 3) Disconnect front and rear drain tubes. G5M0193 4) Disconnect connector between body harness and sun- roof harness.
Page 843 SERVICE PROCEDURE 15. Sunroof B: INSTALLATION 1) Insert frame rear end slit to two bolts fitted temporarily to roof brace. G5M0198 2) Align frame to reference pin installed on roof. G5M0199 3) Tighten adjusting nut (that is, set frame at highest posi- tion).
Page 844 SERVICE PROCEDURE 15. Sunroof 6) Tighten set bracket mounting bolts. G5M0203 7) Tighten bolts. G5M0204 8) Install drain tubes. CAUTION: Insert drain tube securely into drain pipe. Length: A Approx. 20 mm (0.79 in) G5M0205 9) Install roof trim. 10) Install garnish. NOTE: Place garnish joint at rear center of body.
Page 845: Sunroof
DIAGNOSTICS 1. Sunroof 1. Sunroof Check roof panel and sunroof panel for improper or poor seal- ing. Entry of water into compartment Check drain tube for clogging. Check sunroof frame seal and body for improper fit. Check roof panel and roof panel for improper clearance. Booming noise Check sunroof trim and roof trim for improper clearance.
Page 846 DOORS AND WINDOWS Page S SERVICE DATA ..................2 1. Door Alignment ..................2 C COMPONENT PARTS ................3 1. Front Door ....................3 2. Rear Door ....................4 3. Front Door Glass ..................5 4. Rear Door Glass ..................6 5.
Page 847: Door Alignment
SERVICE DATA 1. Door Alignment 1. Door Alignment G5M0485...
Page 848: Front Door
COMPONENT PARTS 1. Front Door 1. Front Door G5M0546 Gusset Checker Tightening torque: N⋅m (kg-m, ft-lb) Weatherstrip Guide T1: 5.4 — 9.3 Stabilizer (Outer) Sealing cover (0.55 — 0.95, 4.0 — 6.9) T2: 10 — 16 (1.0 — 1.6, 7 — 12) Stabilizer (Inner) Door panel T3: 22 —...
Page 849: Rear Door
COMPONENT PARTS 2. Rear Door 2. Rear Door G5M0547 Weatherstrip Seating cover Tightening torque: N⋅m (kg-m, ft-lb) Stabilizer (Outer) Door panel T1: 5.4 — 9.3 Stabilizer (Inner) Lower hinge (0.55 — 0.95, 4.0 — 6.9) T2: 22 — 27 (2.2 — 2.8, 16 — 20) Stopper Upper hinge T3: 25 —...
Page 850: Front Door Glass
COMPONENT PARTS 3. Front Door Glass 3. Front Door Glass G5M0548 Door sash (Front) Regulator handle Tightening torque: N⋅m (kg-m, ft-lb) Glass (Except power window) T1: 5.4 — 9.3 Door sash (Rear) Retainer spring (0.55 — 0.95, 4.0 — 6.9) T2: 10 —...
Page 851: Rear Door Glass
COMPONENT PARTS 4. Rear Door Glass 4. Rear Door Glass G5M0549 Door sash (Front) Regulator handle Tightening torque: N⋅m (kg-m, ft-lb) Glass (Except power window) T1: 5.4 — 9.3 Weatherstrip (Inner) Retainer spring (0.55 — 0.95, 4.0 — 6.9) T2: 10 — 18 (1.0 — 1.8, 7 — 13) Door sash (Rear) Regulator ASSY Regulator and motor ASSY...
Page 852: Rear Gate And Glass
COMPONENT PARTS 5. Rear Gate and Glass 5. Rear Gate and Glass G5M0550 Rear gate Glass pin Hinge Clip Trim Tightening torque: N⋅m (kg-m, ft-lb) Key cylinder Glass T1: 5.4 — 9.3 Outer handle Buffer (0.55 — 0.95, 4.0 — 6.9) Auto-door lock actuator Rear gate side buffer T2: 10 —...
Page 853: Door Lock Assembly (Front)
COMPONENT PARTS 6. Door Lock Assembly (Front) 6. Door Lock Assembly (Front) G5M0481 Cover Tightening torque: N⋅m (kg-m, ft-lb) Inner remote ASSY T1: 4.4 — 8.3 (0.45 — 0.85, 3.3 — 6.1) Door outer handle T2: 5.4 — 9.3 (0.55 — 0.95, 4.0 — 6.9) Striker T3: 14 —...
Page 854: Door Lock Assembly (Rear)
COMPONENT PARTS 7. Door Lock Assembly (Rear) 7. Door Lock Assembly (Rear) G5M0482 Door outer handle Tightening torque: N⋅m (kg-m, ft-lb) Door latch T1: 4.4 — 8.3 (0.45 — 0.85, 3.3 — 6.1) Auto-door lock actuator T2: 5.4 — 9.3 (0.55 — 0.95, 4.0 — 6.9) Striker T3: 14 —...
Page 855: Trim
COMPONENT PARTS 8. Trim 8. Trim G5M0484 Trim panel Cover Gusset cover Bracket Pull handle Pocket...
Page 856: Weatherstrip
COMPONENT PARTS 9. Weatherstrip 9. Weatherstrip G5M0483 Rear gate weatherstrip Retainer (Center) (Wagon only) Weatherstrip (Rear door) Retainer and molding Weatherstrip (Front door) Upper and side weatherstrip...
Page 857: Procedure Chart For Removing And Installing Door And Related Parts
SERVICE PROCEDURE 1. Procedure Chart for Removing and Related Parts 1. Procedure Chart for Removing and Installing Door and Related Parts NOTE: This flowchart shows the main procedures for removing and installing the door and its related parts. For details, refer to the text.
Page 858: Door And Hinge
SERVICE PROCEDURE 2. Door and Hinge 2. Door and Hinge A: REMOVAL AND INSTALLATION 1) Remove lower trim and disconnect connectors from body harness. 2) Place a cloth or a wood block under door to prevent damage, and support it with a jack. 3) Remove checker pin by driving it upward.
Page 859: Trim Panel
SERVICE PROCEDURE 3. Trim Panel 3. Trim Panel A: REMOVAL AND INSTALLATION 1) Remove gusset cover. G5M0387 2) Remove retainer spring and then regulator handle. Use a wire bent at one end, as shown in figure, for easier removal of retainer spring. (models without power window) G5M0489 3) Remove remote handle cover.
Page 860: Sealing Cover
SERVICE PROCEDURE 4. Sealing Cover - 5. Checker 4. Sealing Cover A: REMOVAL 1) Remove trim panel. 2) Remove speaker, trim bracket and remote assembly and disconnect connectors. 3) Remove sealer with a spatula. CAUTION: Be careful because cover may break if sealer is removed forcefully.
Page 861: Inner Remote Assembly
SERVICE PROCEDURE 6. Inner Remote Assembly 6. Inner Remote Assembly A: REMOVAL 1) Remove trim panel. 2) Remove sealing cover. 3) Disconnect joints of two rods. 4) Unlatch rod holder. G5M0394 5) Remove screws holding remote assembly. G5M0395 B: INSTALLATION 1) After passing two rods through holder, attach remote assembly to inner panel.
Page 862: Door Latch
SERVICE PROCEDURE 7. Door Latch 7. Door Latch A: REMOVAL AND INSTALLATION 1) Remove trim panel. 2) Remove inner remote assembly. 3) Remove sealing cover around latch service hole. 4) Completely close door glass. 5) Remove latch and actuator assembly. (1) Turn rod holder to disconnect joint between key lock and rod.
Page 863: Outer Handle
SERVICE PROCEDURE 8. Outer Handle - 9. Key Lock 8. Outer Handle A: REMOVAL AND INSTALLATION 1) Remove trim panel. 2) Remove sealing cover. 3) Detach door latch rod from outer handle and key lock. 4) Loosen nut securing outer handle and then remove outer handle from outside.
Page 864: Gusset Assembly
SERVICE PROCEDURE 10. Gusset Assembly - 11. Rear Gate 10. Gusset Assembly A: REMOVAL AND INSTALLATION NOTE: Be sure window is all the way down. 1) Remove gusset cover. 2) Remove trim panel. 3) Remove door rearview mirror. 4) Remove outer weatherstrip. 5) Remove sealing cover.
Page 865 SERVICE PROCEDURE 11. Rear Gate 8) Gas stay (1) Completely open rear gate. (2) Remove bolts which hold gas stay to rear gate. CAUTION: ¼ Be careful because rear gate drops while removing bolts. Have an assistant support it while removing bolts.
Page 866 SERVICE PROCEDURE 11. Rear Gate 11) Rear gate outer handle (1) Remove trim panel. (2) Remove latch. (3) Remove two nuts used to hold outer handle to the inside of rear gate, and detach outer handle. CAUTION: Be careful not to damage packing when removing outer handle.
Page 867 SERVICE PROCEDURE 11. Rear Gate B: INSTALLATION Install in reverse order of removal. Some special items will be described below. 1. WEATHERSTRIP 1) Place weatherstrip so that its joints meet at lower cen- ter of vehicle body, and install by inserting flanged portion from below, as shown in section A—A in figure.
Page 868 SERVICE PROCEDURE 11. Rear Gate 4. HINGE Tightening torque: Hinge mounting bolt and nut Door side 20 — 29 N⋅m (2.0 — 3.0 kg-m, 14 — 22 ft-lb) Body side 20 — 29 N⋅m (2.0 — 3.0 kg-m, 14 — 22 ft-lb) CAUTION: ¼...
Page 869: Procedure Chart For Removal And Installing Window Glass
SERVICE PROCEDURE 12. Procedure Chart for Removal and Installing Window Glass 12. Procedure Chart for Removal and Installing Window Glass 1. PROCEDURES OF REMOVAL AND INSTALLATION Removal of molding Removal of glass Body Glass Finishing and cleaning of adhesion Cleaning of adhesion surface surface Application of primer Application of primer...
Page 870: Windshield
SERVICE PROCEDURE 13. Windshield 13. Windshield A: REMOVAL 1. USING WINDSHIELD KNIFE The following procedure for the front windshield can also be applied to other window glass. 1) Remove wiper arm and cowl panel. 2) Remove roof molding and front window molding upper. 3) Remove glass.
Page 871 SERVICE PROCEDURE 13. Windshield 3) Remove glass. (1) Put protective tape on body to prevent damage. (2) Using drill or putty knife, make through-hole (one place) in adhesive agent. (3) Pass piano wire through the hole from inside the compartment, and connect both ends of wire securely to wooden blocks.
Page 872 SERVICE PROCEDURE 13. Windshield 4) Positioning glass (1) Mount glass on body. (2) Adjust position of glass so that gap between body and glass is uniform on all sides. (3) Put matching pin on body and glass in several places. G5M0407 5) Cleaning glass (1) Dismount glass from body.
Page 873 SERVICE PROCEDURE 13. Windshield 8) Installation of glass (1) Hold glass with rubber suction cups. (2) Mount glass on body with matching pin aligned. (3) Stick them fast by pressing all sides lightly. G5M0409 9) Installation of molding (1) Remove adhesive overflowing from outside of glass until it becomes level with outer height of glass.
Page 874: Rear Window Glass (Sedan)
SERVICE PROCEDURE 14. Rear Window Glass (Sedan) 14. Rear Window Glass (Sedan) A: REMOVAL 1) Remove roof molding. 2) Remove rear window molding upper and lower. 3) Disconnect connector from rear defogger terminal. 4) Remove glass in same manner as in windshield. G5M0410 NOTE: A matching pin is cemented to the corners of glass on...
Page 875: Rear Window Glass (Wagon)
SERVICE PROCEDURE 15. Rear Window Glass (Wagon) 15. Rear Window Glass (Wagon) NOTE: It is impossible to remove the molding from the glass. If molding is broken, replace rear glass. A: REMOVAL 1) Remove rear wiper and rear gate trimming. 2) Disconnect connector from rear defogger terminal.
Page 876: Rear Quarter Glass
SERVICE PROCEDURE 16. Rear Quarter Glass 16. Rear Quarter Glass A: REMOVAL G5M0416 1) Remove rear quarter molding on corner. 2) Remove glass in same manner as in windshield. B: INSTALLATION 1) Finish surface of adhesive layer on body. Using a putty knife, etc., cut layer of adhesive stick firmly to body and finish it into a smooth surface of about 2 mm (0.08 in) in thickness.
Page 877 SERVICE PROCEDURE 16. Rear Quarter Glass 5) Application of adhesive (1) Cut nozzle tip as shown in figure. (2) Open cartridge and put it into a gun with nozzle attached. (3) Apply adhesive uniformly to all sides of adhesion surface while operating gun along glass end face. G5M0414 6) Installation of glass.
Page 878: Procedure Chart For Adjusting Door Glass
SERVICE PROCEDURE 17. Procedure Chart for Adjusting Door Glass 17. Procedure Chart for Adjusting Door Glass...
Page 879: Front Door Glass Adjustment
SERVICE PROCEDURE 18. Front Door Glass Adjustment 18. Front Door Glass Adjustment A: ADJUSTMENT G5M0420 1. DOOR GLASS FIT ADJUSTMENT Before adjusting door glass alignment, ensure adjusting bolts for stabilizers, upper stoppers and sashes are loose and glass is raised so that it is in contact with upper and side weatherstrip.
Page 880 SERVICE PROCEDURE 18. Front Door Glass Adjustment 3) Lower door glass 10 to 15 mm (0.39 to 0.59 in) from fully closed position. While applying outward pressure (load) to upper edge of glass above midpoint of two outer stabilizers, press inner stabilizer until it just touches the glass, then secure it.
Page 881 SERVICE PROCEDURE 18. Front Door Glass Adjustment 3) If clearance is improper, loosen adjusting nut k , bolt k and adjust glass to center pillar. G5M0500 4. REMEDY FOR IMPROPER UPPER STOP POINT OF DOOR GLASS 1) Loosen front and rear sash stoppers. 2) Increase the upward travel of window glass up to the position where upper edge just touches weatherstrip sur- face with door closed.
Page 882 SERVICE PROCEDURE 18. Front Door Glass Adjustment NOTE: Always adjust two rear sash adjusting bolts k by the same amount. Do not adjust the adjusting bolts with sash bracket inclined toward inner panel, as this increases effort required to operate regulator. G5M0510 2) Adjust front sash fit using rear sash adjustment proce- dure outlined above as a guide.
Page 883: Rear Door Glass Adjustment
SERVICE PROCEDURE 19. Rear Door Glass Adjustment 19. Rear Door Glass Adjustment A: ADJUSTMENT Alignment of rear door glass is basically the same as for the front door glass. Due to slight difference in adjustment dimensions for fore-aft, up-down, and in-out alignments, key points for rear door adjustment are described below.
Page 884 SERVICE PROCEDURE 19. Rear Door Glass Adjustment 2. FIT ADJUSTMENT Increasing contact pressure causes rear door glass to be caught in center pillar upper and lower weatherstrip; this will cause premature weatherstrip wear. For this reason, always use dimensions indicated below as a guide during glass fit adjustment.
Page 885: Door Glass
DIAGNOSTICS 1. Door Glass 1. Door Glass Condition Apparent cause/Correction ¼ Insufficient upward travel of glass Glass in fully closed 1) Glass runs out of weatherstrip lip when considerable hand position pressure is applied to it from inside. Increase upward travel of glass. G5M0502 (This condition may cause wind/booming noise during high- speed operation.)
Page 886 DIAGNOSTICS 1. Door Glass Condition Apparent cause/Correction ¼ Improper up-down and in-out glass Door in fully closed/ 1) Glass rides over weatherstrip lip when door is closed. open position alignments Adjust glass for up-down and in-out alignments (incl. rear sash, upper stopper adjustment, etc.).
Page 887 DIAGNOSTICS 1. Door Glass Condition Apparent cause/Correction ¼ Improper fore-aft or in-out Raise or lower 2) Center pillar weatherstrip is caught by rear window glass window glass when glass is raised. alignment of window glass Lower regulator “B” channel to tilt window glass back.
Page 888: Door Lock System
DIAGNOSTICS 2. Door Lock System - 3. Power Window 2. Door Lock System Trouble Possible cause Remedy Door cannot be opened by outer handle. Disconnect outer handle rod. Connect firmly. (Door can be opened by inner handle.) Door cannot be opened by inner a.
Page 889 ¼ To avoid rendering the Airbag system inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all maintenance must be performed by an authorized SUBARU dealer. ¼ Improper maintenance, including incorrect removal and installation of the Airbag system, can lead to personal injury caused by unintentional activation of the Air- bag system.
Page 890: Front Seat
COMPONENT PARTS 1. Front Seat 1. Front Seat G5M0334 Headrest free bushing Hinge cover Front cushion frame ASSY Protector Headrest lock bushing Cover (Bolt) (outer) Pad and cover ASSY Outer slide rail ASSY Tightening torque: N⋅m (kg-m, ft-lb) Front backrest frame ASSY Cover (Bolt) (inner) T1: 18 —...
Page 891: Rear Seat (Sedan)
COMPONENT PARTS 2. Rear Seat (Sedan) 2. Rear Seat (Sedan) 1. FOLD-DOWN TYPE G5M0335 Backrest Cushion Tightening torque: N⋅m (kg-m, ft-lb) Striker Lock ASSY T1: 7 — 13 (0.7 — 1.3, 5.1 — 9.4) Lock cover T2: 18 — 31 (1.8 — 3.2, 13 — 23) Backrest (RH) Bracket (LH) Bracket (RH)
Page 892 COMPONENT PARTS 2. Rear Seat (Sedan) 2. FIXED TYPE G5M0381 Rear seat reinforcement Tightening torque: N⋅m (kg-m, ft-lb) Hook T1: 7 — 13 (0.7 — 1.3, 5.1 — 9.4) Backrest T2: 18 — 31 (1.8 — 3.2, 13 — 23) Rear cushion...
Page 893: Rear Seat (Wagon)
COMPONENT PARTS 3. Rear Seat (Wagon) 3. Rear Seat (Wagon) G5M0336 Hinge bracket (RH) Hinge Tightening torque: N⋅m (kg-m, ft-lb) Backrest (RH) Hinge cover T1: 1 — 3 (0.1 — 0.3, 0.7 — 2.2) Backrest (LH) Backrest center hinge T2: 4.4 — 7.4 (0.45 —...
Page 894: Front Seat Belts
COMPONENT PARTS 4. Front Seat Belts 4. Front Seat Belts G5M0337 Adjuster anchor ASSY Tightening torque: N⋅m (kg-m, ft-lb) Through cover T1: 10 — 16 (1.0 — 1.6, 7 — 12) Webbing guide T2: 23 — 49 (2.3 — 5.0, 17 — 36) Inner belt ASSY Outer belt ASSY...
Page 895: Rear Seat Belts
COMPONENT PARTS 5. Rear Seat Belts 5. Rear Seat Belts G5M0338 Webbing cover (RH) Through cap (RH) Tightening torque: N⋅m (kg-m, ft-lb) Webbing cover (LH) Through cap (LH) T1: 10 — 16 (1.0 — 1.6, 7 — 12) Outer seat belt (LH) T2: 23 —...
Page 896: Inner Accessories
COMPONENT PARTS 6. Inner Accessories 6. Inner Accessories G5M0339 Hook Assist rail bracket Sun visor Assist grip (retractable) Rearview mirror Assist grip (fixed)
Page 897: Inner Trim
COMPONENT PARTS 7. Inner Trim 7. Inner Trim G5M0340 For Sedan For Wagon Speaker cover Front pillar upper trim Trim bracket Front pillar upper trim Rear pillar upper trim Rear quarter trim Rear quarter upper front trim Rear pillar lower trim Side sill rear upper cover Rear rail trim Side sill rear upper cover...
Page 898: Front Seat
SERVICE PROCEDURE 1. Front Seat 1. Front Seat A: REMOVAL 1) While operating knob (located on top of backrest), lift headrest out with hand placed between backrest and head- rest. 2) Pull reclining lever back to fold backrest all the way for- ward.
Page 899 SERVICE PROCEDURE 1. Front Seat B: INSTALLATION 1) While operating knob (located on top of backrest), lift headrest out by placing your hand between backrest and headrest. 2) Pull reclining lever back to fold backrest all the way for- ward. Pull slide adjuster lever and move lower slide rail all the way backward.
Page 900: Rear Seat (Sedan)
SERVICE PROCEDURE 2. Rear Seat (Sedan) 2. Rear Seat (Sedan) A: REMOVAL 1) Remove bolts securing hinges (located at front of cush- ion) to body. 2) Slightly raise front of cushion while pushing down on cushion in the direction of “C”. With cushion held in that position, move it forward until it is unhooked.
Page 901 SERVICE PROCEDURE 2. Rear Seat (Sedan) B: INSTALLATION 1) Before installing backrest, ensure that trim panel, insu- lator and seat belt are properly installed. 2) Transfer outer seat belt webbing to front of backrest and fold backrest forward. Attach seat belt webbing to upper hooks (2 places), and move pillow in the direction of “B”...
Page 902: Rear Seat (Wagon)
SERVICE PROCEDURE 3. Rear Seat (Wagon) 3. Rear Seat (Wagon) A: REMOVAL 1) Remove bolts securing hinges (located at front of seat) to body. 2) Pull strap (located in middle rear portion of cushion) to release lock. Lift cushion out and away from body. 3) Pull knobs (located at each side of backrest’s upper portion) up to release lock, and fold backrest all the way forward.
Page 903 SERVICE PROCEDURE 3. Rear Seat (Wagon) B: INSTALLATION 1) Install hinge bracket to body. 2) Insert right backrest hinge pin into hole in bracket. Tilt backrest backward until striker engages with lock. 3) Secure right backrest center hinge to body using a bolt. 4) Temporarily install left backrest side hinge to body using a bolt, and fold backrest forward to the floor.
Page 904: Front Seat Belt
SERVICE PROCEDURE 4. Front Seat Belt 4. Front Seat Belt A: REMOVAL 1. OUTER BELT 1) Remove through-anchor cover cap. 2) Remove shoulder anchor bolt. 3) Remove webbing guide. G5M0354 4) Remove center lower pillar trim panel. 5) Remove front cover side plate. 6) Roll up floor mat at the bottom of center pillar.
Page 905: Rear Seat Belt
SERVICE PROCEDURE 5. Rear Seat Belt 5. Rear Seat Belt A: REMOVAL 1. SEDAN MODEL 1) Remove rear cushion from body. 2) Remove rear backrest from body. 3) Remove screw from lower side of rear quarter trim, and lift up lower side of rear quarter trim. 4) Remove trim panel rear bracket upper.
Page 906: Front Pillar Upper Trim Panel
SERVICE PROCEDURE 5. Rear Seat Belt - 6. Front Pillar Upper Trim Panel B: INSTALLATION Installation is in the reverse order of removal. Ensure that seat belt is properly reeled on and off after installation of ELR. CAUTION: ¼ Be extremely careful not to confuse center seat anchor plate with outer seat anchor plate during instal- lation.
Page 907: Rear Pillar Upper Trim Panel (Sedan)
SERVICE PROCEDURE 7. Rear Pillar Upper Trim Panel (Sedan) - 8. Rear Quarter Pillar Upper Trim Panel (Wagon) 7. Rear Pillar Upper Trim Panel (Sedan) A: REMOVAL 1) Remove rear seat cushion and backrest. 2) Remove tapping screw from rear pillar lower trim panel, and remove trim panel by sliding it forward.
Page 908: Rear Quarter Trim Panel (Wagon)
SERVICE PROCEDURE 9. Rear Quarter Trim Panel (Wagon) - 10. Floor Mat 9. Rear Quarter Trim Panel (Wagon) A: REMOVAL 1) Set rear seat cushion up. 2) Remove rear seat backrest. 3) Remove sideshelf and rear skirt trim. 4) Remove clip and screw of rear quarter lower trim. 5) Remove rear quarter lower trim.
Page 909 SERVICE PROCEDURE 10. Floor Mat 9) Remove four clips under front seat. 10) Remove four clips in toe board area. NOTE: When pulling out edge, do not pull mat alone; pull mat together with edge. Pry off two steel clips on side sill front cover and one on side sill rear cover using screwdriver.
Page 910 INSTRUMENT PANEL Page C COMPONENT PARTS ..................2 1. Instrument Panel..................2 W SERVICE PROCEDURE ................3 1. Instrument Panel ................3...
Page 911 COMPONENT PARTS 1. Instrument Panel 1. Instrument Panel G5M0284 Pad & frame Reinf. CTR Panel (AT) ASSY Shift boot Grille SD def. (D) Panel CTR (A) Console cover Front def. grille Reinf. (P) Panel (Airbag) Grommet Grille CTR def. Housing (Ash tray) Grille SD def.
Page 912 SERVICE PROCEDURE 1. Instrument Panel 1. Instrument Panel Airbag system wiring harness is routed near combination meter. CAUTION: ¼ All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equip- ment on these circuits. ¼ Be careful not to damage Airbag system wiring har- ness when servicing the combination meter.
Page 913 SERVICE PROCEDURE 1. Instrument Panel 8) Remove lower cover and then disconnect seat belt timer connector. G5M0275 9) Remove glove box. G5M0276 10) Remove instrument panel console. G5M0277 11) Remove two bolts and lower steering column. G5M0278 12) Remove hood opener lever. G5M0279...
Page 914 SERVICE PROCEDURE 1. Instrument Panel 13) Set temperature control switch to Max. COLD, and mode selector switch to defroster position. 14) Disconnect both temperature control cable and mode selector cable from link. NOTE: Do not move switch and link when installing. G5M0280 G5M0281 : 15P/Gray, k...
Page 915 SERVICE PROCEDURE 1. Instrument Panel B: INSTALLATION 1) Installation is in the reverse order of removal. Observe the following: When setting instrument panel into position, push three pins into grommet on body panel CAUTION: ¼ Be careful not to snag the harness. ¼...
Page 916 SUPPLEMENTAL RESTRAINT SYSTEM Page S SPECIFICATIONS AND SERVICE DATA.............2 1. Inspection and Replacement Standards............2 C COMPONENT PARTS ..................4 1. SRS Airbag ....................4 W SERVICE PROCEDURE ................5 1. Precaution ....................5 2. Airbag Module....................9 3. Front Sensor ....................10 4. Main Harness...................12 5. Airbag Control Module ................13 6.
Page 917: Inspection And Replacement Standards
SPECIFICATIONS AND SERVICE DATA 1. Inspection and Replacement Standards 1. Inspection and Replacement Standards 1. VEHICLES WHICH BECOME INVOLVED IN A COLLISION If the vehicle equipped with an SRS airbag system is damaged in a collision, the airbag system parts must be checked and replaced in accordance with the following standards: After faulty parts are replaced, the warning light operation must be checked.
Page 918 SPECIFICATIONS AND SERVICE DATA 1. Inspection and Replacement Standards 5. AIRBAG CONTROL MODULE Inspection standard: ¼ A vehicle damaged in a collision (regardless of whether or not airbag is deployed). ¼ The designated trouble code is output during self-diagnosis. (Refer to “Troubleshooting” Section.) Replacement standard: ¼...
Page 919: Srs Airbag
COMPONENT PARTS 1. SRS Airbag 1. SRS Airbag G5M0290 Combination switch ASSY with roll TORX bolt Tightening torque: N⋅m (kg-cm, in-lb) connector Airbag control module T1: 2.5±0.5 (25±5, 21.7±4.3) Cover Protector RH T2: 9.8±2.0 (100±20, 87±17) TORX bolt Protector LH T3: 9.81±2.45 (100.0±25.0, 86.8±21.7) Airbag module ASSY...
Page 920: Precaution
SERVICE PROCEDURE 1. Precaution 1. Precaution 1. GENERAL CAUTIONS 1) If any of the airbag system parts such as sensors, air- bag module, control module and harness are damaged or deformed, replace with new genuine parts. G5M0291 2) When servicing, be sure to turn the ignition switch off, disconnect the negative (−) battery terminal then the posi- tive (+) terminal in advance, and wait for more than 20 seconds before starting.
Page 921 SERVICE PROCEDURE 1. Precaution 4) Do not drop the airbag modulator parts, subject it to high temperatures over 90°C (194°F), or apply oil, grease, or water to it; otherwise, the internal parts may be damaged and its reliability greatly lowered. G5M0295 5) If any damage or open is found on the SRS airbag sys- tem wire harness, do not attempt to repair using soldering,...
Page 922 SERVICE PROCEDURE 1. Precaution 8) Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals. G5M0298 2. AIRBAG MODULE 1) The airbag module must not be disassembled. The air- bag module cannot be used again once inflated. G5M0299 2) When removing and installing the airbag module, the operator should stand, as much as possible, on the side of...
Page 923 SERVICE PROCEDURE 1. Precaution 5) Replace airbag module with a new one, should any of the following conditions develop. ¼ Pad surface is scratched or cracked. ¼ Connector harness is damaged. ¼ Inflator side structure of module is cracked or deformed. ¼...
Page 924 SERVICE PROCEDURE 1. Precaution - 2. Airbag Module G5M0306 2. Airbag Module A: REMOVAL 1) Set front wheels in straight ahead position. 2) Turn ignition switch off. 3) Disconnect ground cable from battery and wait for at least 20 seconds before starting work. 4) Remove covers from both sides of steering wheel.
Page 925: Front Sensor
SERVICE PROCEDURE 3. Front Sensor 3. Front Sensor CAUTION: ¼ If the front end of the vehicle body is damaged by a collision, be sure to check the left and right front sensors, even if the airbag was not inflated. If any dam- age to the sensor or any deformation of the sensor mount is found, replace with a new genuine part.
Page 926 SERVICE PROCEDURE 3. Front Sensor 5) Roll up floor mat and side sill cover. <Refer to 5-3 [W10A0].> Remove front sensor harness from clip and pro- tector. G5M0314 6) Remove front wheels. 7) Remove front mud guard. <Refer to 5-1 [W11A1].> 8) Remove wiring harness clips.
Page 927: Main Harness
SERVICE PROCEDURE 3. Front Sensor - 4. Main Harness B: INSTALLATION Installation is in reverse order of removal procedures. CAUTION: Do not reuse front sensor, when deployed airbag mod- ule. 4. Main Harness A: REMOVAL 1) Turn ignition switch off. 2) Disconnect ground cable from battery and wait for at least 20 seconds before starting work.
Page 928: Airbag Control Module
SERVICE PROCEDURE 4. Main Harness - 5. Airbag Control Module 6) Roll up floor mat and side sill cover. (LH side). Remove main harness from clip and protector. G5M0321 B: INSTALLATION Installation is in reverse order of removal procedures. 5. Airbag Control Module CAUTION: ¼...
Page 929 SERVICE PROCEDURE 5. Airbag Control Module A: REMOVAL 1) Turn ignition switch off. 2) Disconnect ground cable from battery and wait for at least 20 seconds before starting work. 3) Remove lower cover. <Ref. to 5-4 [W1A0].> Disconnect airbag connector (AB3) and (AB8) below steer- ing column.
Page 930: Combination Switch
SERVICE PROCEDURE 6. Combination Switch 6. Combination Switch 1. CENTERING ROLL CONNECTOR Before installing combination switch and steering gearbox, make sure to center roll connector built into combination switch. 1) Make sure that front wheels are positioned straight ahead. 2) Install gearbox, steering shaft and combination switch properly.
Page 931 SERVICE PROCEDURE 6. Combination Switch 6) Disconnect airbag connector and horn connector on back of airbag module. Remove airbag module, and place it with pad side facing upward. <Ref. to 5-5 [W102].> G5M0308 7) Using steering puller, remove steering wheel. CAUTION: Do not allow connector to interfere when removing steering wheel.
Page 932 ENGINE ELECTRICAL SYSTEM Page S SPECIFICATIONS AND SERVICE DATA.............2 1. Engine Electrical ..................2 C COMPONENT PARTS ..................3 1. Starter ......................3 2. Generator ....................4 W SERVICE PROCEDURE ................5 1. Starter ......................5 2. Generator ....................12 3. Spark Plug ....................18 4. Ignition Coil ....................20 5.
Page 933: Engine Electrical
SPECIFICATIONS AND SERVICE DATA 1. Engine Electrical 1. Engine Electrical A: SPECIFICATIONS Item Designation Type Reduction type Model M001T77181 M1T-75681 Manufacturer Mitsubishi Electric Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW Direction of rotation Counterclockwise (when observed from pinion) Number of pinion teeth Voltage 11 V...
Page 934: Starter
COMPONENT PARTS 1. Starter 1. Starter G6M0026 Sleeve bearing Shaft ASSY Ball Front bracket Armature Internal gear ASSY Lever set Brush holder Over running clutch Magnet switch Assy Bearing Stopper set Yoke Rear bracket Packing Gear ASSY...
Page 935: Generator
COMPONENT PARTS 2. Generator 2. Generator G6M0028 Pulley Holder Brush Front cover IC regulator Bearing Ball bearing Rear cover Stator coil Bearing retainer Terminal Brush holder Rotor...
Page 936: Starter
SERVICE PROCEDURE 1. Starter 1. Starter A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. G6M0095 2) Disconnect connector and terminal from starter. 3) Remove starter from transmission. 4) Installation is in the reverse order of removal. Tightening torque: 46 — 54 N⋅m (4.7 — 5.5 kg-m, 34 — 40 ft-lb) G2M0309 B: TEST 1.
Page 937 SERVICE PROCEDURE 1. Starter If motor is running with the pinion forced endwise on the shaft, disconnect connector from terminal M of switch assembly and connect terminal M to ground terminal (−) of battery with a lead wire. Next, gently push pinion back with your fingertips and measure pinion gap.
Page 938 SERVICE PROCEDURE 1. Starter 3) Lock test With starter stalled, or not rotating, measure the torque developed and current draw when the voltage is adjusted to the specified voltage. Lock test (Standard): Voltage / Current 4 V / 980 A max. Torque 23 N⋅m (2.3 kg-m, 17 ft-lb) min.
Page 939 SERVICE PROCEDURE 1. Starter 6) Remove shaft assembly and overrunning clutch as a unit. CAUTION: Record the direction of lever before removing. G6M0036 7) Remove overrunning clutch from shaft assembly as fol- lows: (1) Remove stopper from ring by lightly tapping a fit tool placed on stopper.
Page 940 SERVICE PROCEDURE 1. Starter 4) Armature short-circuit test Check armature for short-circuit by placing it on growler tester. Hold a hacksaw blade against armature core while slowly rotating armature. A short-circuited armature will cause the blade to vibrate and to be attracted to core. If the hacksaw blade is attracted or vibrates, the armature, which is short-circuited, must be replaced or repaired.
Page 941 SERVICE PROCEDURE 1. Starter 4. BRUSH AND BRUSH HOLDER 1) Brush length Measure the brush length and replace if it exceeds the service limit. Replace if abnormal wear or cracks are noticed. Brush length: Standard 17.0 mm (0.669 in) Service limit 11.5 mm (0.453 in) G6M0042 2) Brush movement...
Page 942 SERVICE PROCEDURE 1. Starter E: ASSEMBLY Assembly is in the reverse order of disassembly proce- dures. Observe the following: 1) Carefully assemble all parts in the order of assembly and occasionally inspect nothing has been overlooked. 2) Apply grease to the following parts during assembly. ¼...
Page 943: Generator
SERVICE PROCEDURE 2. Generator 2. Generator A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. G6M0095 2) Disconnect connector and terminal from generator. G2M0088 3) Remove V-belt cover. 4) Remove front side V-belt. G2M0089 5) Remove bolts which install generator onto bracket. G2M0090 6) Installation is in the reverse order of removal.
Page 944 SERVICE PROCEDURE 2. Generator B: DISASSEMBLY 1) Remove the four through-bolts. Then insert the tip of a flat-head screwdriver into the gap between the stator core and front bracket. Pry then apart to disassemble. G6M0065 2) Hold rotor with a vise and remove pulley nut. G6M0066 CAUTION: When holding rotor with vise, insert aluminum plates...
Page 945 SERVICE PROCEDURE 2. Generator 5) Remove the brushes by unsoldering at the pigtails. G6M0070 6) Remove the nut and insulating bushing at terminal B. Remove rectifier. G6M0071 C: INSPECTION AND REPAIR 1. DIODE CAUTION: Never use a megger tester (measuring use for high voltage) or any other similar measure for this test;...
Page 946 SERVICE PROCEDURE 2. Generator 3) Checking trio diode Check the trio diode using a circuit tester. It is in good condition if continuity exists only in one direction. G6M0074 2. ROTOR 1) Slip ring surface Inspect slip rings for contamination or any roughness of the sliding surface.
Page 947 SERVICE PROCEDURE 2. Generator 5) Ball bearing (rear side) (1) Check rear ball bearing. Replace if it is noisy or if rotor does not turn smoothly. (2) The rear bearing can be removed by using com- mon bearing puller. G6M0077 3.
Page 948 SERVICE PROCEDURE 2. Generator 5. BEARING (FRONT SIDE) 1) Check front ball bearing. If resistance is felt while rotating, or if abnormal noise is heard, replace the ball bearing. 2) Replacing front bearing (1) Remove front bearing retainer. (2) Closely install a fit tool on the bearing inner race. Press the bearing down out of front bracket with a hand press or vise.
Page 949: Spark Plug
SERVICE PROCEDURE 3. Spark Plug 3. Spark Plug A: REMOVAL AND INSTALLATION CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: NGK BKR6E-11 1) Remove spark plug cords by pulling boot, not cord itself. 2) Remove spark plugs.
Page 950 SERVICE PROCEDURE 3. Spark Plug 2) Carbon fouled Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in city, weak ignition, too rich fuel mixture, dirty air cleaner, etc. It is advisable to replace with plugs having hotter heat range.
Page 951: Ignition Coil
SERVICE PROCEDURE 4. Ignition Coil 4. Ignition Coil A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. 2) Disconnect connector from ignition coil. 3) Remove ignition coil. 4) Installation is in the reverse order of removal. CAUTION: Be sure to connect wires to their proper positions. Failure to do so will damage unit.
Page 952: Spark Plug Cord
SERVICE PROCEDURE 5. Spark Plug Cord - 6. Ignitor 5. Spark Plug Cord A: INSPECTION Check for: 1) Damage to cords, deformation, burning or rust forma- tion of terminals. 2) Resistance values of cords. Resistance value: kΩ Length: mm (in) #1 cord 4.95 —...
Page 953: Starter
DIAGNOSTICS 1. Starter 1. Starter Trouble Probable cause Magnet switch poor contact or discontinuity Magnet switch does not operate. of pull-in coil circuit (no clicks are heard.) Improper sliding of magnet switch plunger Poor contact of magnet switch’s main con- tact point Layer short of armature Starter does not start.
Page 954: Generator
DIAGNOSTICS 2. Generator 2. Generator Turn ignition switch ON (engine OFF). Check if charge bulb Disconnect generator comes on. body harness connector. Turn ignition switch to Check if charge bulb Replace charge bulb. “START.” (engine starts.) comes on when terminal (L) of body harness connector is grounded.
Page 955 ¼ To avoid rendering the Airbag system inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all maintenance must be performed by an authorized SUBARU dealer. ¼ Improper maintenance, including incorrect removal and installation of the Airbag system, can lead to personal injury caused by unintentional activation of the Air- bag system.
Page 956: Body Electrical
SPECIFICATIONS AND SERVICE DATA 1. Body Electrical 1. Body Electrical Type MT model: 55D23L (MF) AT model: 75D23L (MF) Battery Reverse capacity MT model: 100 minutes AT model: 120 minutes Capacity Cold cranking ampere MT model: 430 amperes AT model: 520 amperes Speedometer Eddy current type Temperature gauge...
Page 957: Precaution
SERVICE PROCEDURE 1. Precaution - 2. Battery 1. Precaution ¼ Before disassembling or reassembling parts, always disconnect battery ground cable. When repairing radio, control units, etc. which are provided with memory functions, record memory contents before disconnecting battery ground cable. Otherwise, these contents are cancelled upon disconnection.
Page 958: Battery
SERVICE PROCEDURE 2. Battery B: INSPECTION 1. BATTERY 1) External parts Check for the existence of dirt or cracks on the battery case, top cover, vent plugs, and terminal posts. If necessary, clean with water and wipe with a dry cloth. Apply a thin coat of grease on the terminal posts to prevent corrosion.
Page 959 SERVICE PROCEDURE 2. Battery 3) Specific gravity of electrolyte Measure specific gravity of electrolyte using a hydrometer and a thermometer. Specific gravity varies with temperature of electrolyte so that it must be corrected at 20°C (68°F) using the follow- ing Equation: = St + 0.0007 x (t −...
Page 960 SERVICE PROCEDURE 2. Battery 2. QUICK CHARGING Quick charging is a method in which the battery is charged in a short period of time with a relatively large current by using a quick charger. Since a large current flow raises electrolyte temperature, the battery is subject to damage if the large current is used for prolonged time.
Page 961: Ignition Key Switch
SERVICE PROCEDURE 3. Ignition Key Switch - 4. Lighting 3. Ignition Key Switch 1) Remove screws, separate upper column cover and lower column cover. 2) Remove knee protector. 3) Remove meter visor. G6M0104 4) Disconnect ignition switch connector from body har- ness.
Page 962: Lighting
SERVICE PROCEDURE 4. Lighting 1) Look at the beam angle gauge (vertical movement). The bubble on the gauge should not deviate from the cen- ter of the gauge. G6M0106 2) Look at the beam angle gauge (horizontal movement). The center mark (the red line on the inner scale) should not deviate from the red line on the outer case.
Page 963 SERVICE PROCEDURE 4. Lighting CAUTION: ¼ Do not pry rear combination light forcefully as this may scratch vehicle body. ¼ Remove all traces of adhesive tape from body before installation. ¼ Attach butyl rubber tape to back of rear combination light before installing rear combination light on body for sealing purposes.
Page 964 SERVICE PROCEDURE 4. Lighting 2) Remove screws which secure lighting switch, wiper and washer switch. Remove both switches. Assembly is in the reverse order of disassembly. G6M0109 D: INSPECTION 1. COMBINATION SWITCH (ON-CAR) 1) Remove instrument panel lower cover. 2) Remove lower column cover. 3) Unfasten holddown clip which secures harness, and disconnect connectors from body harness.
Page 965 SERVICE PROCEDURE 4. Lighting Move combination switch to respective positions and check continuity between terminals as indicated in the following tables. LIGHTING SWITCH Terminal (Wire color) c-1 (W) c-2 (W) c-3 (R) Switch position Tail Head PARKING SWITCH Terminal (Wire color) c-10 (R) c-11 (RG) c-9 (RW)
Page 966 SERVICE PROCEDURE 4. Lighting 3. TAIL AND ILLUMINATION RELAY Check continuity between terminals (indicated in table below) when terminal (3) is connected to battery and ter- minal (1) is grounded. Between terminals (2) When current flows. Continuity exists. and (4) Between terminals (2) Continuity does not and (4)
Page 967: Front Wiper And Washer
SERVICE PROCEDURE 4. Lighting - 5. Front Wiper and Washer Check continuity between terminals (indicated in table below) when terminal (1) is connected to battery and ter- minal (2) is grounded. Between terminals (3) Continuity does not and (5) exist. When current flows.
Page 968 SERVICE PROCEDURE 5. Front Wiper and Washer 2. WIPER ARM 1) Open front hood. 2) Remove cap. Remove the nut which secure wiper arm, and remove wiper arm. Tightening torque: 10 — 18 N⋅m (1.0 — 1.8 kg-m, 7 — 13 ft-lb) G6M0118 3.
Page 969 SERVICE PROCEDURE 5. Front Wiper and Washer 5) Remove wiper link from service hole in front panel. G6M0121 C: INSPECTION 1. FRONT WIPER AND WASHER SWITCH Set wiper switch to each position and check continuity between terminals (indicated in table below). Wiper switch Terminal (Wire color) d-9 (Y)
Page 970: Rear Wiper And Washer
SERVICE PROCEDURE 5. Front Wiper and Washer - 6. Rear Wiper and Washer 2) Check wiper motor operation at high speed. Connect battery wiper motor. Check wiper motor for proper operation at high speed. G6M0123 3) Check wiper motor for proper stoppage. Connect battery to wiper motor.
Page 971 SERVICE PROCEDURE 6. Rear Wiper and Washer B: REMOVAL AND INSTALLATION 1. BLADE Pull out blade from arm while pushing up clip. G6M0117 2. WIPER ARM 1) Remove head cover. 2) Remove nut and wiper arm. Tightening torque: 4.4 — 7.4 N⋅m (0.45 — 0.75 kg-m, 3.3 — 5.4 ft-lb) G6M0128 3.
Page 972 SERVICE PROCEDURE 6. Rear Wiper and Washer 4. WASHER TANK 1) Remove rear quarter trim. <Ref. to 5-2.> 2) Disconnect washer hose and connector. 3) Remove attaching bolts. Tightening torque: 4.4 — 7.4 N⋅m (0.45 — 0.75 kg-m, 3.3 — 5.4 ft-lb) G6M0022 C: INSPECTION 1.
Page 973 SERVICE PROCEDURE 6. Rear Wiper and Washer 2) Check wiper motor for proper stoppage. After operating wiper motor, disconnect battery from wiper motor. G6M0132 3) Reconnect battery and ensure that wiper motor stops at “AUTO STOP” after it has been operated. G6M0133 3.
Page 974: Rear Window Defogger
SERVICE PROCEDURE 7. Rear Window Defogger 7. Rear Window Defogger A: INSPECTION 1. HEAT WIRES 1) Start the engine so that battery is being charged. 2) Turn defogger switch ON. 3) Check each heat wire at its center position for discon- tinuity by setting direct current voltmeter.
Page 975: Combination Meter
SERVICE PROCEDURE 8. Combination Meter 8. Combination Meter A: REMOVAL AND INSTALLATION 1) Move steering wheel down. 2) Remove screws which secure visor and remove visor. 3) Disconnect switch connectors. G6M0098 4) Remove screws which secure combination meter, and pull combination meter out. 5) Disconnect connector and speedometer cable from back of combination meter.
Page 976: Cruise Control
SERVICE PROCEDURE 9. Cruise Control 9. Cruise Control A: ADJUSTMENT G6M0016...
Page 977 SERVICE PROCEDURE 9. Cruise Control B: REMOVAL AND INSTALLATION 1. ACTUATOR 1) Remove air intake duct. Remove the nut which secures control cable end to throttle cam, and remove control cable end. 2) Remove clip bands from control cable. G6M0017 3) Disconnect cruise control hose from intake manifold.
Page 978 SERVICE PROCEDURE 9. Cruise Control C: DRIVING TESTS Conduct road tests by selecting a smooth, flat road or use free rollers as road test simulation. 1. MAIN SWITCH 1) Turn ignition switch ON. 2) Check that indicator light comes on when main switch is pressed (ON).
Page 979: Radio
SERVICE PROCEDURE 10. Radio 10. Radio A: REMOVAL AND INSTALLATION 1. RADIO BODY 1) Remove cup holder. 2) Remove AT cover (AT model). 3) Remove screws which secure center panel. Remove center panel. G6M0100 4) Remove fitting screws, and slightly pull radio out of instrument panel.
Page 980 BRAKES SUPPLEMENTAL RESTRAINT SYSTEM This portion of the service manual has been prepared to provide SUBARU service personnel with the neces- sary information and data for the correct maintenance BODY ELECTRICAL SYSTEM and repair of SUBARU vehicles. The diagnostics relating to the Electronic Control Sys- tem which is made up of various electronic compo- nents (ECM’s etc.) are explained in this manual.
Page 981 Providing appropriate service and repair is a matter of great importance in the serviceman’s safety maintenance and safe operation, function and performance which the SUBARU vehicle possesses. ¼ In case the replacement of parts or replenishment of consumables is required, genuine SUBARU parts whose parts numbers are designated or their equivalents must be utilized. ¼...
Page 982 How to use this manual ¼ This Service Manual is divided into four volumes by section so that it can be used with ease at work. Refer to the Table of Contents, select and use the necessary section. ¼ GENERAL INFORMATION SECTION ¼...
Page 983 ¼ The Title Index No. is indicated on the top left (or right) side of the page as the book is opened. This is useful for retrieving the necessary portion. (Example of usage) Refer to 3 - 2 [ T 5 A 0 ] Small title (Sub-section) Medium title (Section) Large title (Heading)
Page 984 ¼ In this manual, the following symbols are used. Circuit tester Voltage measurement Circuit tester Resistance measurement The arrow indicates that insertion of the probe or numbering of the connector pins is made from the side indicated. The arrow indicates that insertion of the probe or numbering of the connector pins is made from the side indicated.
Page 985 Basic checks DISCONNECTING CONNECTORS ¼ To disconnect a locking connector, first re-lease ¼ Always hold the connector itself. the lock, then pull the connector off. CAUTION: <Unlock by pulling the locking tab> Don’t pull the harness. ¼ Insert a connector by pushing it all the way in. If the connector is equipped with a locking device, <Unlock by pushing the locking tab>...
Page 986 CHECKING FOR POOR CONTACT ON PLUG-IN CONNECTORS Poor contact Poor contact is frequently caused by corroded terminals, dirt, foreign substances, weak contact points between male and female connectors, etc. Quite often a plug with poor contact will work perfectly again after it has been pulled off and reconnected.
Page 987 Diagnosis and checking prodecdure using instruments USING A CIRCUIT TESTER ¼ Voltage ckeck (range set to DC V) Connect the positive probe to the terminal to be tested, and the negative probe to body ground (or the ground terminal of the ECM) J3-1012 ¼...
Page 988 USING A SUBARU SELECT MONITOR With this testing procedure the defective component can be determined by directly monitoring input/output signals of the ECM or the trouble codes. Features ¼ A variety of data can be checked without movements from the drivers seat, passenger’s seat or from outside the vehicle.
Page 989 TABLE OF CONTENTS Fuel Injection System Automatic Transmission and Differential DIAGNOSTICS SECTION Brakes Supplemental Restraint System Body Electrical System (For Cruise Control)
Page 990 FUEL INJECTION SYSTEM Page T DIAGNOSTICS ................2 1. Supplemental Restraint System “Airbag” ..........2 2. Precautions ....................2 3. Pre-inspection ....................4 4. Electrical Unit Location ................6 5. Diagnostics Chart for On-board Diagnosis System.........10 6. Control Module I/O Signal ...............16 7. Diagnostics Chart for Engine Starting Failure .........18 8.
Page 991: Supplemental Restraint System "Airbag
FUEL INJECTION SYSTEM 1. Supplemental Restraint System “Airbag” - 2. Precautions 1. Supplemental Restraint System “Airbag” Airbag system wiring harness is routed near the engine control module (ECM), main relay and fuel pump relay. CAUTION: ¼ All Airbag system wiring harness and connectors are colored yellow.
Page 992 FUEL INJECTION SYSTEM 2. Precautions 4) Before removing ECM from the located position, dis- connect two cables on battery. ¼ Otherwise, the ECM may be damaged. 5) The connectors to each sensor in the engine compart- ment and the harness connectors on the engine side and body side are all designed to be waterproof.
Page 993: Pre-Inspection
FUEL INJECTION SYSTEM 3. Pre-inspection 3. Pre-inspection Before performing diagnostics, check the following items which might affect engine problems: 1. POWER SUPPLY 1) Measure battery voltage and specific gravity of electro- lyte. Standard voltage: 12 V Specific gravity: Above 1.260 2) Check the condition of the main and other fuses, and harnesses and connectors.
Page 994 FUEL INJECTION SYSTEM 3. Pre-inspection 4. FUEL PRESSURE 1) Release fuel pressure <Ref. to 2-8 [W1A0].> 2) Connect fuel pressure gauge between fuel filter and hose, and measure fuel pressure at idling. <Ref. to 2-8 [W2A0].> Fuel pressure: 177 — 206 kPa (1.8 — 2.1 kg/cm , 26 —...
Page 995: Electrical Unit Location
FUEL INJECTION SYSTEM 4. Electrical Unit Location 4. Electrical Unit Location 1. SENSOR AND SOLENOID VALVE G2M0442 Mass air flow sensor Recirculation gas temperature sensor (California) Engine coolant temperature sensor EGR valve Air suction solenoid valve (California) EGR solenoid valve Throttle position sensor Camshaft position sensor Idle air control solenoid valve...
Page 996 FUEL INJECTION SYSTEM 4. Electrical Unit Location G2M0304 G2M0406 G2M0560 G2M0561 G2M0562 G2M0563 G2M0564 G2M0565 G2M0566 G2M0567...
Page 997 FUEL INJECTION SYSTEM 4. Electrical Unit Location 2. MODULE AND RELAY G2M0443 Inhibitor switch Fuel pump relay Starter Fuel pump Read memory connector Test mode connector Main relay Data link connector...
Page 998 FUEL INJECTION SYSTEM 4. Electrical Unit Location G3M0699 G2M0435 G2M0568 G2M0569 G2M0449...
Page 999: Diagnostics Chart For On-Board Diagnosis System
FUEL INJECTION SYSTEM 5. Diagnostics Chart for On-board Diagnosis System 5. Diagnostics Chart for On-board Diagnosis System A: BASIC DIAGNOSTICS PROCEDURE Trouble occurs. Engine does not start. 6. Diagnostics for Engine Starting Failure [T700]** Trouble code designated.* D-CHECK MODE No trouble code designated.
Page 1000 FUEL INJECTION SYSTEM 5. Diagnostics Chart for On-board Diagnosis System B: TROUBLE CODE 1. HOW TO READ TROUBLE CODE The malfunction indicator lamp flashes the code corre- sponding to the faulty parts. The long segment (1.3 sec- onds ON) indicates a “ten”, and the short segment (0.2 seconds ON) signifies “one”.

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