Subaru FORESTER 1999 Service Manual
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Subaru FORESTER 1999 Service Manual

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Table of Contents

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1999 FORESTER 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
G802ABE2

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Summary of Contents for Subaru FORESTER 1999

  • 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 All right reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of FUJI HEAVY INDUSTRIES LTD., TOKYO JAPAN. SUBARU, are trademarks of FUJI HEAVY INDUSTRIES LTD. © Copyright 1998 FUJI HEAVY INDUSTRIES LTD.
  • Page 3 ¼ 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.
  • Page 4 FOREWORD SERVICE PROCEDURE [W200] 2. How to Use this Manual 2. 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...
  • Page 5 FOREWORD SERVICE PROCEDURE [W200] 2. How to Use this Manual 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. H0M0010...
  • Page 6 FOREWORD SERVICE PROCEDURE [W200] 2. How to Use this Manual ¼ In this manual, the following symbols are used. Selective part Replacement part Should be lubricated with oil. S0M0001 Should be lubricated with grease. S0M0002 Sealing point S0M0003 Tightening torque S0M0004 ¼...

  • Page 7: Table Of Contents

    FOREWORD SERVICE PROCEDURE [W300] 3. Table of contents 3. Table of Contents 2-1 Emission Control System and Vacuum Fitting 2-2 On-Car Services 2-3 Engine 2-4 Engine Lubrication System 2-5 Engine Cooling System ENGINE SECTION 2-7 Fuel Injection System 2-8 Fuel System 2-9 Exhaust System 2-10 Clutch 2-11 Engine and Transmission Mounting System...
  • Page 8 FOREWORD SERVICE PROCEDURE MEMO:...

  • Page 9: Emission Control System And Vacuum Fitting

    EMISSION CONTROL SYSTEM AND VACUUM FITTING Page SERVICE PROCEDURE ...................2 Front and Rear Catalytic Converter Assembly ...........2 Canister .......................5 Purge Control Solenoid Valve ..............6 Fuel Tank Pressure Sensor.................7 Pressure Control Solenoid Valve ..............9 Main Fuel Level Sensor ................10 Sub Fuel Level Sensor................12 Air Filter .....................13 Vent Valve ....................14 Shut Valve ....................16...

  • Page 10: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Front and Rear Catalytic Converter Assembly 1. Front and Rear Catalytic 5) Lift-up the vehicle. 6) Remove under cover. Converter Assembly A: REMOVAL 1) Set the vehicle on the lift. 2) Disconnect battery ground cable. S2M0012 7) Disconnect rear oxygen sensor connector.
  • Page 11 SERVICE PROCEDURE [W1B0] 1. Front and Rear Catalytic Converter Assembly 10) Remove front and rear catalytic converter 2) Install front and rear catalytic converter assem- assembly from hanger bracket. bly. Temporarily tighten bolt which installs center CAUTION: exhaust pipe to hanger bracket. ¼...
  • Page 12 SERVICE PROCEDURE [W1B0] 1. Front and Rear Catalytic Converter Assembly 5) Tighten bolt which holds front and rear catalytic 10) Install air intake duct and air cleaner upper converter assembly to hanger bracket. cover. <Ref. to 2-7 [W1A0].> Tightening torque: 24 ±...

  • Page 13: Canister

    SERVICE PROCEDURE [W2A0] 2. Canister 2. Canister 5) Installation is in the reverse order of removal. Tightening torque: A: REMOVAL AND INSTALLATION 22.5 ± 7 N·m (2.3 ± 0.7 kg-m, 16.6 ± 5.1 ft-lb) 1) Lift-up the vehicle. 2) Loosen two clamps which hold two canister hoses.

  • Page 14: Purge Control Solenoid Valve

    SERVICE PROCEDURE [W3A0] 3. Purge Control Solenoid Valve 3. Purge Control Solenoid 4) Remove bolt which installs purge control sole- noid valve to intake manifold. Valve A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S2M0055 5) Take out purge control solenoid valve. 6) Disconnect connector from purge control sole- noid valve.

  • Page 15: Fuel Tank Pressure Sensor

    SERVICE PROCEDURE [W4A0] 4. Fuel Tank Pressure Sensor 4. Fuel Tank Pressure Sensor 8) Installation is in the reverse order of removal. Tightening torque: A: REMOVAL AND INSTALLATION 15.7 ± 1.5 N·m (1.6 ± 0.15 kg-m, 11.6 ± 1.1 ft-lb) 1) Set the vehicle on the lift.
  • Page 16 SERVICE PROCEDURE [W4A0] 4. Fuel Tank Pressure Sensor 7) Remove protector cover. 11) Move clip, and disconnect pressure hose from fuel tank. S2M1153 B2M1778 8) Disconnect connector from fuel tank pressure 12) Disconnect pressure hose from fuel tank pres- sensor. sure sensor.

  • Page 17: Pressure Control Solenoid Valve

    SERVICE PROCEDURE [W5A0] 5. Pressure Control Solenoid Valve 5. Pressure Control Solenoid 5) Remove bolt which installs pressure control solenoid valve holding bracket on body. Valve A: REMOVAL AND INSTALLATION 1) Set the vehicle on the lift. 2) Disconnect battery ground cable. H2M2530 6) Disconnect connector from pressure control solenoid valve.

  • Page 18: Main Fuel Level Sensor

    SERVICE PROCEDURE [W6A0] 6. Main Fuel Level Sensor 6. Main Fuel Level Sensor 10) Disconnect vacuum hose from pressure con- trol solenoid valve. A: REMOVAL 1) Release fuel pressure. <Ref. to 2-2 [W9B0].> 2) Open fuel flap lid, and remove fuel filler cap. B2M1785 11) Installation is in the reverse order of removal.
  • Page 19 SERVICE PROCEDURE [W6B0] 6. Main Fuel Level Sensor 6) Disconnect connector from fuel pump. 12) Remove bolt which installs fuel level sensor on mounting bracket. S2M0172 H2M3206 7) Move clips, and then disconnect fuel delivery hose (A), return hose (B) and jet pump hose (C). B: INSTALLATION 8) Disconnect quick connector, and then discon- nect fuel delivery hose (A).

  • Page 20: Sub Fuel Level Sensor

    SERVICE PROCEDURE [W7A0] 7. Sub Fuel Level Sensor 7. Sub Fuel Level Sensor 5) Remove bolts which install sub fuel level sensor on fuel tank. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S2M0152 6) Remove sub fuel level sensor. G6M0095 2) Remove the floor box located just behind the rear seats.

  • Page 21: Air Filter

    SERVICE PROCEDURE [W8A0] 8. Air Filter 8. Air Filter 6) Disconnect evaporation hoses (A) from joint pipes. A: REMOVAL AND INSTALLATION 1) Set the vehicle on the lift. 2) Disconnect battery ground cable. S2M0876A 7) Remove nut which installs air filter and drain valve brackets on body, and remove them as a G6M0095 unit.

  • Page 22: Vent Valve

    SERVICE PROCEDURE [W9A0] 9. Vent Valve 9. Vent Valve 9) Installation is in the reverse order of removal. Tightening torque: A: REMOVAL AND INSTALLATION 22.5 ± 7 N·m (2.3 ± 0.7 kg-m, 16.6 ± 5.1 ft-lb) 1) Set the vehicle on the lift. 2) Release fuel pressure.
  • Page 23 SERVICE PROCEDURE [W9A0] 9. Vent Valve 7) Remove protector cover. 10) Installation is in the reverse order of removal. CAUTION: Replace rubber seat with a new one. Tightening torque: T: 4.4 ± 1.5 N·m (0.45 ± 0.15 kg-m, 3.3 ± 1.1 ft-lb S2M1153 8) Move clips, and disconnect hoses from vent...

  • Page 24: Shut Valve

    SERVICE PROCEDURE [W10A0] 10. Shut Valve 10. Shut Valve 7) Disconnect evaporation hoses from shut valve. A: REMOVAL AND INSTALLATION 1) Set the vehicle on the lift. 2) Release fuel pressure. <Ref. to 2-2 [W9B0].> 3) Open fuel flap lid, and remove fuel filler cap. B2M1796 8) Remove shut valve from fuel filler pipe.

  • Page 25: Drain Valve

    SERVICE PROCEDURE [W11A0] 11. Drain Valve 11. Drain Valve 7) Remove bolt which installs air filter and drain valve brackets on body. A: REMOVAL AND INSTALLATION 1) Set the vehicle on the lift. 2) Disconnect battery ground cable. B2M1790 8) Move air filter to upper side, and remove drain valve with bracket.
  • Page 26 SERVICE PROCEDURE MEMO:...

  • Page 27: On-Car Services

    ON-CAR SERVICES Page SERVICE PROCEDURE ...................2 Foreword .....................2 Ignition Timing .....................2 Engine Idle Speed..................3 Engine Compression ...................4 Intake Manifold Vacuum................5 Engine Oil Pressure ..................5 Valve Clearance ..................7 Engine Coolant ..................11 Fuel......................12...

  • Page 28: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Foreword 1. Foreword 2. Ignition Timing A: GENERAL A: MEASUREMENT This chapter describes major inspection and ser- CAUTION: vice procedures for the engine mounted on the After warming-up, engine becomes very hot. body. For procedures not found in this chapter, Be careful not to burn yourself during mea- refer to the service procedure section in the appli- surement.

  • Page 29: Engine Idle Speed

    (2) Connect SUBARU SELECT MONITOR to NOTE: the data link connector. ¼ When using the OBD-II general scan tool, care- (3) Turn igintion switch to ON, and SUBARU fully read its operation manual. ¼ This ignition system provides simultaneous igni- SELECT MONITOR switch to ON.

  • Page 30: Engine Compression

    SERVICE PROCEDURE [W4A0] 4. Engine Compression 4. Engine Compression 11) Perform at least two measurements per cylinder, and make sure that the values are correct. A: MEASUREMENT Compression (350 rpm and fully open CAUTION: throttle): After warming-up, engine becomes very hot. Standard;...

  • Page 31: Intake Manifold Vacuum

    SERVICE PROCEDURE [W6A0] 6. Engine Oil Pressure 5. Intake Manifold Vacuum 3) Keep the engine at the idle speed and read the vacuum gauge indication. A: MEASUREMENT By observing the gauge needle movement, the internal condition of the engine can be diagnosed 1) Warm-up the engine.
  • Page 32 SERVICE PROCEDURE [W6A0] 6. Engine Oil Pressure (2) Remove V-belt cover 5) Connect oil pressure gauge hose to cylinder block. 6) Connect battery ground cable. S2M0896 (3) Loosen lock bolt and slider bolt, and remove G6M0095 front side V-belt. 7) Start the engine, and measure oil pressure. G2M0286 S2M0242 (4) Remove generator lock bolt.

  • Page 33: Valve Clearance

    SERVICE PROCEDURE [W7A0] 7. Valve Clearance 7. Valve Clearance 6) When inspecting #1 and #3 cylinders: (1) Disconnect connector from mass air flow A: INSPECTION sensor. CAUTION: Inspection and adjustment of valve clearance should be performed while engine is cold. 1) Set the vehicle onto the lift.
  • Page 34 SERVICE PROCEDURE [W7A0] 7. Valve Clearance (7) Disconnect spark plug cords from spark (14) Remove rocker cover bolts, then remove plugs (#1 and #3 cylinders). rocker cover (RH). B2M2014 B2M2017 (8) Disconnect blow-by hose from rocker cover 7) When inspecting #2 and #4 cylinders: (RH).
  • Page 35 SERVICE PROCEDURE [W7A0] 7. Valve Clearance (6) Disconnect spark plug cords from spark 8) Set #1 cylinder piston to top dead center of plugs (#2 and #4 cylinders). compression stroke by rotating crankshaft pulley clockwise. NOTE: When arrow mark on camshaft sprocket (LH) comes exactly to the top, #1 cylinder piston is brought to the top dead center of the compression stroke.
  • Page 36 SERVICE PROCEDURE [W7B0] 7. Valve Clearance NOTE: 2) Adjust the #1 cylinder valve clearance. ¼ Be sure to set cylinder pistons to their respective (1) Loosen the valve rocker nut and screw. top dead centers on the compression stroke before (2) Place suitable thickness gauge.

  • Page 37: Engine Coolant

    SERVICE PROCEDURE [W8B0] 8. Engine Coolant 8. Engine Coolant 6) Similar to adjustment procedures used for #1 cylinder, adjust #2, #3 and #4 cylinder valve clear- A: DRAINING OF ENGINE ances. COOLANT NOTE: ¼ Be sure to set cylinder pistons to their respective 1) Lift-up the vehicle.

  • Page 38: Fuel

    SERVICE PROCEDURE [W8C0] 9. Fuel 9. Fuel C: CHECKING OF COOLING SYSTEM A: PRECAUTIONS 1) Remove radiator cap, top off radiator, and WARNING: attach tester to radiator in place of cap. ¼ Place “No fire” signs near the working area. ¼...
  • Page 39 SERVICE PROCEDURE [W9C0] 9. Fuel 5) Remove access hole lid. 11) Drain fuel from fuel tank by using a hand pump. WARNING: Do not use a motor pump when draining fuel. S2M0246 6) Disconnect connector from fuel pump. S2M0163 12) Remove fuel sub meter unit. <Ref. to 2-8 [W8A0].>...
  • Page 40 SERVICE PROCEDURE [W9D0] 9. Fuel 14) After draining fuel, reinstall fuel pump and fuel 4) Connect connector to fuel pump relay. sub meter unit. Tighten nuts of fuel pump in alphabetical sequence shown in figure to specified torque. Tightening torque: 4.4 ±...
  • Page 41 ENGINE Page SPECIFICATIONS AND SERVICE DATA............2 Engine ......................2 COMPONENT PARTS ..................6 Timing Belt ....................6 Cylinder Head and Camshaft..............7 Cylinder Head and Valve Assembly............8 Cylinder Block .....................9 Crankshaft and Piston................10 Valve Rocker Assembly ................11 SERVICE PROCEDURE .................12 General Precautions..................12 Timing Belt ....................13 Valve Rocker Assembly................25 Camshaft ....................31 Cylinder Head....................39...

  • Page 42: Engine

    SPECIFICATIONS AND SERVICE DATA [S1A0] 1. Engine 1. Engine A: SPECIFICATIONS Model 2500 cc Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke Type gasoline engine Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder Bore × Stroke 99.5 × 79.0 (3.917 × 3.110) mm (in) Displacement (cu in)
  • Page 43 SPECIFICATIONS AND SERVICE DATA [S1B0] 1. Engine Cylinder Surface warpage limit 0.05 mm (0.0020 in) head Surface grinding limit 0.3 mm (0.012 in) Standard height 127.5 mm (5.02 in) Refacing angle 90° 1.0 mm (0.039 in) Intake Valve Limit 1.7 mm (0.067 in) Contacting width 1.4 mm...
  • Page 44 SPECIFICATIONS AND SERVICE DATA [S1B0] 1. Engine 0.20 — 0.35 mm (0.0079 — 0.0138 in) Top ring Limit 1.0 mm (0.039 in) 0.37 — 0.52 mm (0.0146 — 0.0205 in) Piston ring gap Second ring Limit 1.0 mm (0.039 in) 0.20 —...
  • Page 45 SPECIFICATIONS AND SERVICE DATA [S1B0] 1. Engine 1.998 — 2.011 mm (0.0787 — 0.0792 in) 0.03 mm (0.0012 2.017 — 2.020 mm (0.0794 — 0.0795 in) in) US #1, #3 0.05 mm (0.0020 2.027 — 2.030 mm (0.0798 — 0.0799 in) in) US 0.25 mm (0.0098 2.127 —...

  • Page 46: Component Parts

    COMPONENT PARTS [C100] 1. Timing Belt 1. Timing Belt S2M1004A (1) Belt cover No. 2 (RH) (9) Automatic belt tension adjuster Tightening torque: N·m (kg-m, ft-lb) (2) Timing belt guide (MT vehicles ASSY 5 ± 1 (0.5 ± 0.1, 3.6 ± 0.7) only) (10) Belt idler No.

  • Page 47: Cylinder Head And Camshaft

    COMPONENT PARTS [C200] 2. Cylinder Head and Camshaft 2. Cylinder Head and Camshaft B2M1954A (1) Rocker cover (RH) (10) Cylinder head gasket Tightening torque: N·m (kg-m, ft-lb) (2) Intake valve rocker ASSY (11) Cylinder head (LH) <Ref. to 2-3 [W5E1].> (3) Exhaust valve rocker ASSY (12) Camshaft (LH) 5 ±...

  • Page 48: Cylinder Head And Valve Assembly

    COMPONENT PARTS [C300] 3. Cylinder Head and Valve Assembly 3. Cylinder Head and Valve Assembly B2M1955A (1) Exhaust valve (5) Intake valve oil seal (9) Exhaust valve guide (2) Intake valve (6) Valve spring (10) Exhaust valve spring seat (3) Intake valve guide (7) Retainer (11) Exhaust valve oil seal (4) Intake valve spring seat...

  • Page 49: Cylinder Block

    COMPONENT PARTS [C400] 4. Cylinder Block 4. Cylinder Block B2M1957A (1) Oil pressure switch (12) Cylinder block (LH) Tightening torque: N·m (kg-m, ft-lb) (2) Cylinder block (RH) (13) Water pump 5 (0.5, 3.6) (3) Service hole plug (14) Baffle plate 6.4 (0.65, 4.7) (4) Gasket (15) Oil filter connector...

  • Page 50: Crankshaft And Piston

    COMPONENT PARTS [C500] 5. Crankshaft and Piston 5. Crankshaft and Piston B2M1958A (1) Flywheel (MT) (9) Piston pin (17) Crankshaft bearing #1, #3 (2) Bell bearing (MT) (10) Circlip (18) Crankshaft bearing #2, #4 (3) Reinforcement (AT) (11) Connecting rod bolt (19) Crankshaft bearing #5 (4) Drive plate (AT) (12) Connecting rod...

  • Page 51: Valve Rocker Assembly

    COMPONENT PARTS [C600] 6. Valve Rocker Assembly 6. Valve Rocker Assembly B2M1956A (1) Intake valve rocker arm (6) Intake rocker shaft Tightening torque: N·m (kg-m, ft-lb) (2) Valve rocker nut (7) Exhaust rocker shaft 5 ± 1 (0.5 ± 0.1, 3.6 ± 0.7) (3) Valve rocker adjust screw (8) Exhaust valve rocker arm 10 ±...
  • Page 52 SERVICE PROCEDURE [W100] 1. General Precautions 1. General Precautions 2) All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pis- 1) Before disassembling engine, place it on ST3. tons and bearings. ST1 498457000 ENGINE STAND ADAPTER 3) Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to ST2 498457100 ENGINE STAND ADAPTER...
  • Page 53 SERVICE PROCEDURE [W2A1] 2. Timing Belt 2. Timing Belt A: REMOVAL 1. CRANKSHAFT PULLEY AND BELT COVER S2M1005A (1) Front side V-belt (3) Crankshaft pulley bolt (6) Front belt cover (2) Rear side V-belt (With A/C (4) Crankshaft pulley model) (5) Belt cover (LH) 1) Remove A/C belt.
  • Page 54 SERVICE PROCEDURE [W2A2] 2. Timing Belt 5) Remove belt cover (LH). 6) Remove front belt cover. B2M2587A 2. TIMING BELT B2M2588B (a) Alignment mark (2) Belt idler (No. 2) (1) Timing belt guide (MT vehicles (3) Belt idler No. 2 only) (4) Timing belt 1) Remove timing belt guide.

  • Page 55: Service Procedure

    SERVICE PROCEDURE [W2A2] 2. Timing Belt 2) If alignment mark (a) and/or arrow mark (which (2) Using white paint, put alignment and/or indicates rotation direction) on timing belt fade arrow marks on timing belts in relation to the away, put new marks before removing timing belt sprockets.
  • Page 56 SERVICE PROCEDURE [W2A3] 2. Timing Belt 3. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY B2M2595B (1) Belt idler (No. 1) (2) Automatic belt tension adjuster ASSY 1) Remove belt idler (No. 1). 2) Remove automatic belt tension adjuster assem- bly.
  • Page 57 SERVICE PROCEDURE [W2A4] 2. Timing Belt 4. CAMSHAFT AND CRANKSHAFT SPROCKET B2M2598B (1) Camshaft sprocket No. 2 (3) Crankshaft sprocket (5) Belt cover No. 2 (RH) (2) Camshaft sprocket No. 1 (4) Belt cover No. 2 (LH) (6) Tensioner bracket 1) Remove camshaft sprocket No.

  • Page 58: Timing Belt

    SERVICE PROCEDURE [W2B1] 2. Timing Belt 6) Remove tensioner bracket. (1) Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. (2) With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kg, 66 lb) to it.
  • Page 59 SERVICE PROCEDURE [W2C1] 2. Timing Belt 5. CAMSHAFT AND CRANKSHAFT 2) Make sure there is no free play between sprocket and key. SPROCKET 3) Check crankshaft sprocket notch for sensor for 1) Check sprocket teeth for abnormal wear and damage and contamination of foreign matter. scratches.
  • Page 60 SERVICE PROCEDURE [W2C2] 2. Timing Belt 4) Install crankshaft sprocket. 6) Install camshaft sprocket No. 2. To lock camshaft, use ST. ST 499207100 CAMSHAFT SPROCKET WRENCH CAUTION: Do not confuse left and right side camshaft sprockets during installation. The camshaft sprocket No.
  • Page 61 SERVICE PROCEDURE [W2C2] 2. Timing Belt ¼ Do not use a lateral type vise. 2) Install automatic belt tension adjuster assem- ¼ Push adjuster rod vertically. bly. ¼ Be sure to slowly move the adjuster rod down applying a pressure of 294 N (30 kg, 66 lb).
  • Page 62 SERVICE PROCEDURE [W2C3] 2. Timing Belt 3. TIMING BELT B2M2588A (a) Alignment mark (4) Timing belt guide (MT vehicles Tightening torque: N·m (kg-m, ft-lb) (1) Timing belt only) 9.8 ± 1.0 (1.0 ± 0.1, 7.2 ± 0.7) (2) Belt idler No. 2 39 ±...
  • Page 63 SERVICE PROCEDURE [W2C3] 2. Timing Belt 2) Install belt idler No. 2. (2) Check and adjust clearance between timing 3) Install belt idler (No. 2). belt and timing belt guide. Clearance: 1.0 ± 0.5 mm (0.039 ± 0.020 in) S2M1008 4) After ensuring that the marks on timing belt and camshaft sprockets are aligned, remove stopper S2M0297...
  • Page 64 SERVICE PROCEDURE [W2C4] 2. Timing Belt 4. CRANKSHAFT PULLEY AND BELT COVER S2M1005B (1) Front belt cover (5) Rear side V-belt (With A/C Tightening torque: N·m (kg-m, ft-lb) (2) Belt cover (LH) model) 5 ± 1 (0.5 ± 0.1, 3.6 ± 0.7) (3) Crankshaft pulley (6) Front side V-belt 177 ±...

  • Page 65: Valve Rocker Assembly

    SERVICE PROCEDURE [W3A0] 3. Valve Rocker Assembly (1) Replace the crankshaft pulley bolts and 7) Install A/C belt. (With A/C model) clean them. Crankshaft pulley bolt: 12369AA011 (2) Clean the crankshaft thread using an air gun. (3) Tighten the bolts temporarily with tightening torque of 44 N·m (4.5 kg-m, 33 ft-lb).
  • Page 66 SERVICE PROCEDURE [W3A0] 3. Valve Rocker Assembly 1) Disconnect PCV hose and remove rocker cover. 2) Removal of valve rocker assembly (1) Remove bolts (a) through (b) in alphabetical sequence. CAUTION: Leave two or three threads of bolt (a) engaged to retain valve rocker assembly.
  • Page 67 SERVICE PROCEDURE [W3B0] 3. Valve Rocker Assembly B: DISASSEMBLY B2M2607A (1) Bolt (4) Intake valve rocker arm (7) Exhaust valve rocker arm (2) Intake valve rocker shaft (5) Spring (8) Valve rocker nut (3) Rocker shaft support (6) Exhaust valve rocker shaft (9) Valve rocker adjust screw 1) Remove bolts which secure rocker shaft.
  • Page 68 SERVICE PROCEDURE [W3C1] 3. Valve Rocker Assembly C: INSPECTION 2) Measure inside diameter of rocker shaft sup- port and outside diameter of valve rocker shaft, 1. VALVE ROCKER ARM and determine the difference between the two (= oil clearance). 1) Measure inside diameter of valve rocker arm and outside diameter of valve rocker shaft, and Clearance between support and shaft: determine the difference between the two (= oil...
  • Page 69 SERVICE PROCEDURE [W3D0] 3. Valve Rocker Assembly D: ASSEMBLY B2M2607B (1) Valve rocker adjust screw (5) Rocker shaft support Tightening torque: N·m (kg-m, ft-lb) (2) Valve rocker nut (6) Intake valve rocker shaft 5 ± 1 (0.5 ± 0.1, 3.6 ± 0.7) (3) Intake valve rocker arm (7) Exhaust valve rocker arm (4) Spring...
  • Page 70 SERVICE PROCEDURE [W3E0] 3. Valve Rocker Assembly E: INSTALLATION B2M2604B (1) Spark plug pipe gasket (4) Rocker cover Tightening torque: N·m (kg-m, ft-lb) (2) Intake valve rocker ASSY 5 ± 1 (0.5 ± 0.1, 3.6 ± 0.7) (3) Exhaust valve rocker ASSY 25 ±...

  • Page 71: Camshaft

    SERVICE PROCEDURE [W4A2] 4. Camshaft 4. Camshaft A: REMOVAL 1. RELATED PARTS Remove timing belt, camshaft sprockets and related parts. <Ref. to 2-3 [W2A0].> 2. CAMSHAFT (LH) B2M2610A (1) Bolt (3) Camshaft cap (5) Oil seal (2) Oil level gauge guide (4) Camshaft (LH) (6) Plug 1) Remove camshaft position sensor.
  • Page 72 SERVICE PROCEDURE [W4A3] 4. Camshaft (3) Equally loosen bolts (c) through (j) all the (5) Remove camshaft cap. way in alphabetical sequence. B2M2613 B2M2612A 6) Remove camshaft (LH). (4) Remove bolts (k) through (p) in alphabetical 7) Remove oil seal. sequence using ST.
  • Page 73 SERVICE PROCEDURE [W4B1] 4. Camshaft (1) Remove valve rocker assembly RH. (5) Remove camshaft cap. <Ref. to 2-3 [W3A0].> B2M2613 B2M2615 2) Remove camshaft (RH). 3) Remove oil seal. (2) Remove bolts (a) through (b) in alphabetical 4) Remove plug from rear side of camshaft (RH). sequence.
  • Page 74 SERVICE PROCEDURE [W4B2] 4. Camshaft 3) Measure outside diameter of camshaft journal clearance). If oil clearance exceeds specifications, and inside diameter of cylinder head journal, and replace camshaft or cylinder head as necessary. determine the difference between the two (= oil Unit: mm (in) Standard 0.055 —...
  • Page 75 SERVICE PROCEDURE [W4C1] 4. Camshaft C: INSTALLATION 1. CAMSHAFT (LH) B2M2610B (1) Camshaft (LH) (3) Plug (5) Oil level gauge guide (2) Camshaft cap (4) Oil seal (6) Bolt 1) Apply a coat of engine oil to camshaft journals NOTE: and install camshaft (LH).
  • Page 76 SERVICE PROCEDURE [W4C1] 4. Camshaft (3) Install valve rocker assembly. (6) Tighten bolts (o) through (v) in alphabetical sequence. <Ref. to 2-3 [W3E0].> Tightening torque: 10 ± 2 N·m (1.0 ± 0.2 kg-m, 7.2 ± 1.4 ft-lb) B2M2606 (4) Tighten bolts (a) through (h) in alphabetical B2M2621D sequence.
  • Page 77 SERVICE PROCEDURE [W4C2] 4. Camshaft 2. CAMSHAFT (RH) B2M2614A (1) Camshaft support (RH) (3) Camshaft (RH) (5) Plug (2) O-ring (4) Oil seal 1) Apply a coat of engine oil to camshaft journals NOTE: and install camshaft (RH). Apply 3 mm (0.12 in) dia. liquid gasket along the 2) Install camshaft cap.
  • Page 78 SERVICE PROCEDURE [W4C2] 4. Camshaft (3) Install valve rocker assembly. (6) Tighten bolts (o) through (v) in alphabetical <Ref. to 2-3 [W3E0].> sequence. Tightening torque: 10 ± 2 N·m (1.0 ± 0.2 kg-m, 7.2 ± 1.4 ft-lb) B2M2615 (4) Tighten bolts (a) through (h) in alphabetical B2M2621D sequence.

  • Page 79: Cylinder Head

    SERVICE PROCEDURE [W5A2] 5. Cylinder Head 5. Cylinder Head 3. RELATED PARTS Install timing belt, camshaft sprockets and related A: REMOVAL parts. 1. RELATED PARTS <Ref. to 2-3 [W2C0].> 1) Release fuel pressure. <Ref. to 2-2 [W9B0].> 2) Drain engine coolant. <Ref. to 2-2 [W8A0].> 3) Remove V-belt(s).
  • Page 80 SERVICE PROCEDURE [W5A2] 5. Cylinder Head 4) Remove cylinder head bolts in alphabetical 7) Remove cylinder head gasket. sequence shown in figure. CAUTION: CAUTION: Do not scratch the mating surface of cylinder Leave bolts (a) and (c) engaged by three or four head and cylinder block.
  • Page 81 SERVICE PROCEDURE [W5B0] 5. Cylinder Head B: DISASSEMBLY B2M2629A (1) Valve rocker ASSY (6) Spark plug pipe gasket (11) Valve spring seat (2) Camshaft cap (7) Retainer key (12) Valve guide (3) Camshaft (8) Retainer (13) Valve (4) Oil seal (9) Valve spring (5) Plug (10) Oil seal...
  • Page 82 SERVICE PROCEDURE [W5C1] 5. Cylinder Head C: INSPECTION 2. VALVE SEAT Inspect intake and exhaust valve seats, and cor- 1. CYLINDER HEAD rect the contact surfaces with valve seat cutter if 1) Make sure that no crack or other damage they are defective or when valve guides are exists.
  • Page 83 SERVICE PROCEDURE [W5C3] 5. Cylinder Head 3. VALVE GUIDE 2) If the clearance between valve guide and stem exceeds the specification, replace guide as fol- 1) Check the clearance between valve guide and lows: stem. The clearance can be checked by measur- (1) Place cylinder head on ST1 with the com- ing the outside diameter of valve stem and the bustion chamber upward so that valve guides...
  • Page 84 SERVICE PROCEDURE [W5C3] 5. Cylinder Head (5) Put new valve guide, coated with sufficient (7) Ream the inside of valve guide with ST. oil, in cylinder, and insert ST1 into valve guide. Gently rotate the reamer clockwise while press- Press in until the valve guide upper end is flush ing it lightly into valve guide, and return it also with the upper surface of ST2.
  • Page 85 SERVICE PROCEDURE [W5C5] 5. Cylinder Head 4. INTAKE AND EXHAUST VALVE 5. VALVE SPRING 1) Inspect the flange and stem of valve, and 1) Check valve springs for damage, free length, replace if damaged, worn, or deformed, or if “H” is and tension.
  • Page 86 SERVICE PROCEDURE [W5C6] 5. Cylinder Head 6. INTAKE AND EXHAUST VALVE OIL SEAL Replace oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced.
  • Page 87 SERVICE PROCEDURE [W5D0] 5. Cylinder Head D: ASSEMBLY B2M2629B (1) Valve (6) Retainer (11) Plug (2) Valve guide (7) Retainer key (12) Camshaft cap (3) Valve spirng seat (8) Spark plug gasket (13) Valve rocker ASSY (4) Oil seal (9) Camshaft (5) Valve spring (10) Oil seal 1) Installation of valve spring and valve...
  • Page 88 SERVICE PROCEDURE [W5E1] 5. Cylinder Head (5) Compress valve spring and fit valve spring (6) After installing, tap valve spring retainers retainer key. lightly with wooden hammer for better seating. 2) Install plug. 3) Install camshaft, camshaft cap and valve rocker assembly.
  • Page 89 SERVICE PROCEDURE [W5E2] 5. Cylinder Head 2) Tighten cylinder head bolts. 2. RELATED PARTS (1) Apply a coat of engine oil to washers and CAUTION: bolt threads. Be careful not to scratch the mating surface of (2) Tighten all bolts to 29 N·m (3.0 kg-m, 22 cylinder block and oil pump.

  • Page 90: Cylinder Block

    SERVICE PROCEDURE [W6A1] 6. Cylinder Block 6. Cylinder Block A: REMOVAL 1. RELATED PARTS 1) Remove timing belt, camshaft sprockets and related parts. <Ref. to 2-3 [W2A0].> 2) Remove cylinder heads. <Ref. to 2-3 [W5A0].> 3) Remove water pipe. <Ref. to 2-5 [W7A0].> B2M2638...
  • Page 91 SERVICE PROCEDURE [W6A2] 6. Cylinder Block 2. OIL PUMP AND WATER PUMP S2M0304B (1) Clutch housing cover (MT (5) Water by-pass pipe (10) Baffle plate vehicles only) (6) Water pump (11) Oil filter (2) Flywheel (MT vehicles only) (7) Oil pump (12) Water by-pass pipe (AT vehicles (3) Drive plate (AT vehicles only) (8) Oil pan...
  • Page 92 SERVICE PROCEDURE [W6A2] 6. Cylinder Block 1) Remove clutch housing cover (MT vehicles 7) Remove oil pump from cylinder block. only). Use a flat-bladed screwdriver as shown in figure 2) Remove flywheel (MT vehicles only) or drive when removing oil pump. plate (AT vehicles only).
  • Page 93 SERVICE PROCEDURE [W6B1] 6. Cylinder Block 12) Remove oil filter using ST. 13) Remove oil cooler (AT vehicles only). ST 498187300 OIL FILTER WRENCH B2M2611A S2M0123A B: DISASSEMBLY 1. PISTON PIN AND CYLINDER BLOCK CONNECTING BOLT B2M1180A (1) Service hole plug (3) Circlip (5) Service hole cover (2) Gasket...
  • Page 94 SERVICE PROCEDURE [W6B1] 6. Cylinder Block 1) Remove service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)]. B2M2620 2) Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston circlip through service hole of #1 and #2 cylinders.
  • Page 95 SERVICE PROCEDURE [W6B2] 6. Cylinder Block 2. CYLINDER BLOCK B2M2408A (1) Cylinder block (3) Crankshaft (5) Piston (2) Rear oil seal (4) Crankshaft bearing 1) Set up cylinder block so that #1 and #3 cylin- 5) Remove crankshaft bearings from cylinder ders are on the upper side, then remove cylinder block using hammer handle.
  • Page 96 SERVICE PROCEDURE [W6B3] 6. Cylinder Block 3. CRANKSHAFT AND PISTON B2M1320I (1) Connecting rod cap (3) Top ring (5) Oil ring (2) Connecting rod bearing (4) Second ring (6) Circlip 1) Remove connecting rod cap. 2) Check the oil passages for clogging. 2) Remove connecting rod bearing.
  • Page 97 SERVICE PROCEDURE [W6C2] 6. Cylinder Block 2. CYLINDER AND PISTON 2) How to measure the inner diameter of each cylinder 1) The cylinder bore size is stamped on the cylin- Measure the inner diameter of each cylinder in der block’s front upper surface. both the thrust and piston pin directions at the CAUTION: heights shown in the figure, using a cylinder bore...
  • Page 98 SERVICE PROCEDURE [W6C3] 6. Cylinder Block 4) How to measure the outer diameter of each (2) If the cylinder inner diameter exceeds the piston limit after boring and honing, replace the crank- Measure the outer diameter of each piston at the case.
  • Page 99 SERVICE PROCEDURE [W6C5] 6. Cylinder Block 4) Check circlip installation groove on the piston 2) Squarely place piston ring and oil ring in for burr. If necessary, remove burr from the groove cylinder, and measure the piston ring gap with a so that piston pin can lightly move.
  • Page 100 SERVICE PROCEDURE [W6C5] 6. Cylinder Block 2) Check for bend or twist using a connecting rod size or undersize as necessary. (See the table aligner. Replace connecting rod if the bend or twist below.) exceeds the limit. Connecting rod oil clearance: Standard Limit of bend or twist per 100 mm (3.94 in) in 0.020 —...
  • Page 101 SERVICE PROCEDURE [W6C6] 6. Cylinder Block 7) Replacement procedure is as follows. 3) Inspect the crank journal and crank pin for wear. If not to specifications, replace bearing with (1) Remove bushing from connecting rod with an undersize one, and replace or recondition ST and press.
  • Page 102 SERVICE PROCEDURE [W6C6] 6. Cylinder Block Unit: mm (in) Crank journal diameter Crank pin diameter #1, #3 #2, #4, #5 59.992 — 60.008 59.992 — 60.008 51.984 — 52.000 Journal O.D. (2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472) Standard Bearing size 1.998 —...
  • Page 103 SERVICE PROCEDURE [W6D1] 6. Cylinder Block D: ASSEMBLY 1. CRANKSHAFT AND PISTON B2M1320J (1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kg-m, ft-lb) (2) Connecting rod (6) Top ring 44 ± 2 (4.5 ± 0.2, 32.5 ± 1.4) (3) Connecting rod cap (7) Circlip (4) Oil ring...
  • Page 104 SERVICE PROCEDURE [W6D1] 6. Cylinder Block (4) Position the upper rail gap at (C) or (D) in 5) Install circlip. the figure. Install circlips in piston holes located opposite ser- vice holes in cylinder block, when positioning all pistons in the corresponding cylinders. CAUTION: Use new circlips.
  • Page 105 SERVICE PROCEDURE [W6D2] 6. Cylinder Block 2. CYLINDER BLOCK B2M2407A (1) Crankshaft bearing (4) Rear oil seal Tightening torque: N·m (kg-m, ft-lb) (2) Crankshaft 25 ± 2 (2.5 ± 0.2, 18.1 ± 1.4) (3) Cylinder block 47 ± 3 (4.8 ± 0.3, 34.7 ± 2.2) 1) Install ST to cylinder block, then install crank- 3) Apply fluid packing to the mating surface of #1 shaft bearings.
  • Page 106 SERVICE PROCEDURE [W6D2] 6. Cylinder Block 4) Temporarily tighten 10 mm cylinder block con- 7) Install rear oil seal using ST1 and ST2. necting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE figure. ST2 499587200 OIL SEAL INSTALLER B2M0088D G2M0186 5) Tighten 10 mm cylinder block connecting bolts...
  • Page 107 SERVICE PROCEDURE [W6D3] 6. Cylinder Block 3. PISTON AND PISTON PIN (#1 AND #2) B2M1322E (1) Piston (4) Gasket Tightening torque: N·m (kg-m, ft-lb) (2) Piston pin (5) Service hole plug 69 ± 7 (7.0 ± 0.7, 50.6 ± 5.1) (3) Circlip 1) Installing piston 2) Installing piston pin...
  • Page 108 SERVICE PROCEDURE [W6D3] 6. Cylinder Block (3) Install circlip. (5) Install service hole plug and gasket. CAUTION: CAUTION: Use new circlips. Use a new gasket. G2M0190 B2M2620 (4) Apply fluid packing around the service hole plug. Fluid packing: THREE BOND 1215 or equivalent B2M2625...
  • Page 109 SERVICE PROCEDURE [W6D4] 6. Cylinder Block 4. PISTON AND PISTON PIN (#3 AND #4) B2M1323E (1) Piston (5) Service hole plug Tightening torque: N·m (kg-m, ft-lb) (2) Piston pin (6) Service hole cover 6.4 (0.65, 4.7) (3) Circlip 69 ± 7 (7.0 ± 0.7, 50.6 ± 5.1) (4) Gasket Turn cylinder block so that #3 and #4 cylinders face upward.
  • Page 110 SERVICE PROCEDURE [W6E1] 6. Cylinder Block E: INSTALLATION 1. OIL PUMP AND WATER PUMP S2M0304A (1) Baffle plate (9) Water pump Tightening torque: N·m (kg-m, ft-lb) (2) Oil strainer (10) Water by-pass pipe 5 (0.5, 3.6) (3) Oil pan (11) Oil cooler (AT vehicles only) 6.4 (0.65, 4.7) (4) Oil separater cover (12) Water by-pass pipe (AT vehicles...
  • Page 111 SERVICE PROCEDURE [W6E1] 6. Cylinder Block 1) Install baffle plate. 6) Install flywheel or drive plate. 2) Install oil strainer and O-ring To lock crankshaft, use ST. 3) Install oil strainer stay. ST 498497100 CRANKSHAFT STOPPER 4) Apply fluid packing to matching surfaces and install oil pan.
  • Page 112 SERVICE PROCEDURE [W6E2] 6. Cylinder Block (2) Apply fluid packing to matching surface of 11) Install oil cooler (AT vehicles only). oil pump. Fluid packing: THREE BOND 1215 or equivalent S2M0739A (3) Apply a coat of engine oil to the inside of the oil seal.
  • Page 113 SERVICE PROCEDURE [W6E2] 6. Cylinder Block 2) Install timing belt and camshaft sprocket. 3) Install water pipe. <Ref. to 2-5 [W7B0].> <Ref. to 2-3 [W2C0].> 4) Install intake manifold. <Ref. to 2-7 [W5D0].>...

  • Page 114: Engine Trouble In General

    DIAGNOSTICS [K100] 1. Engine Trouble in General 1. Engine Trouble in General NOTE: “RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”) A — Very often B — Sometimes C —...
  • Page 115 DIAGNOSTICS [K100] 1. Engine Trouble in General TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 4) Engine stalls after initial Fuel injection system <Ref. to 2-7 [T600].> combustion. ¼ Intake system ¼ Loosened or cracked intake uct ¼ Loosened or cracked PCV hose ¼...
  • Page 116 DIAGNOSTICS [K100] 1. Engine Trouble in General TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK ¼ Fuel injection system <Ref. to 2-7 [T600].> 3. Low output, hesitation and poor acceleration ¼ Intake system ¼ Loosened or cracked intake duct ¼ Loosened or cracked PCV hose ¼...
  • Page 117 DIAGNOSTICS [K100] 1. Engine Trouble in General TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 5. Engine does not return to Fuel injection system <Ref. to 2-7 [T600].> idle. ¼ Intake system ¼ Loosened or cracked vacuum hose ¼ Others ¼ Stuck or damaged throttle valve ¼...
  • Page 118 DIAGNOSTICS [K100] 1. Engine Trouble in General TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK ¼ Fuel injection system <Ref. to 2-7 [T600].> 10. Excessive fuel consump- tion ¼ Intake system ¼ Dirty air cleaner element ¼ Belt ¼ Defective timing ¼...

  • Page 119: Engine Noise

    DIAGNOSTICS [K200] 2. Engine Noise 2. Engine Noise Type of sound Condition Possible cause ¼ Valve mechanism is defective. ¼ Incorrect valve clearance Sound increases as engine ¼ Worn valve rocker Regular clicking sound speed increases. ¼ Worn camshaft ¼ Broken valve spring ¼...
  • Page 120 DIAGNOSTICS MEMO:...

  • Page 121: Engine Lubrication System

    ENGINE LUBRICATION SYSTEM Page SPECIFICATIONS AND SERVICE DATA............2 Specifications ....................2 COMPONENT PARTS ..................3 Lubrication System..................3 SERVICE PROCEDURE ...................4 Oil Pump......................4 Oil Pan and Oil Strainer ................8 Oil Pressure Switch...................13 Oil Cooler (AT Vehicles Only) ..............15 DIAGNOSTICS....................18 Engine Lubrication System Trouble in General ........18...

  • Page 122: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Specifications 1. Specifications Lubrication method Forced lubrication Pump type Trochoid type Inner rotor Number of teeth Outer rotor Outer rotor diameter × thickness 78 × 10 mm (3.07 × 0.39 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 123: Component Parts

    COMPONENT PARTS [C100] 1. Lubrication System 1. Lubrication System S2M0943A (1) Plug (16) Gasket (AT vehicles) (31) Gasket (2) Washer (17) Oil cooler connector (MT (32) Oil level gauge guide (3) Relief valve spring vehicles) (33) Oil pan (34) Oil level gauge (4) Relief valve (18) Gasket (MT vehicles) (5) Oil seal...
  • Page 124 SERVICE PROCEDURE [W1A0] 1. Oil Pump 1. Oil Pump 6) Remove water pipe and hoses between oil cooler and water pump. (AT vehicles only) A: REMOVAL 1) Disconnect battery ground cable. S2M0112 7) Remove radiator. <Ref. to 2-5 [W3A0].> G6M0095 2) Lift-up the vehicle.

  • Page 125: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Oil Pump 11) Remove V-belts. <Ref. to 1-5 [G2A0].> 15) Remove timing belt guide. (MT vehicles only) G2M0286 S2M0115 12) Remove rear side V-belt tensioner. 16) Remove crankshaft sprocket. S2M0113 S2M0116 13) Remove crankshaft pulley using ST. 17) Remove bolts which install oil pump onto cyl- ST 49997700 CRANKSHAFT PULLEY inder block.
  • Page 126 SERVICE PROCEDURE [W1B0] 1. Oil Pump B: DISASSEMBLY C: INSPECTION Remove screws which secure oil pump cover and 1. TIP CLEARANCE disassemble oil pump. Measure the tip clearance of rotors. If the clear- Inscribe alignment marks on inner and outer rotors ance exceeds the limit, replace rotors as a so that they can be replaced in their original posi- matched set.
  • Page 127 SERVICE PROCEDURE [W1D0] 1. Oil Pump 3. SIDE CLEARANCE D: ASSEMBLY Measure clearance between oil pump inner rotor 1) Install front oil seal using ST. and pump cover. If the clearance exceeds the limit, ST 499587100 OIL SEAL INSTALLER replace rotor or pump body. CAUTION: Side clearance: Use a new oil seal.

  • Page 128: Oil Pan And Oil Strainer

    SERVICE PROCEDURE [W1E0] 2. Oil Pan and Oil Strainer 2. Oil Pan and Oil Strainer E: INSTALLATION Installation is in the reverse order of removal. A: REMOVAL Observe the following: 1) Disconnect battery ground cable. 1) Apply fluid packing to matching surfaces of oil pump.
  • Page 129 SERVICE PROCEDURE [W2A0] 2. Oil Pan and Oil Strainer 5) Remove radiator upper bracket. 9) Drain engine oil. Set container under the vehicle, and remove drain plug from oil pan. S2M0932 6) Support engine with a lifting device and wire G2M0066 ropes.
  • Page 130 SERVICE PROCEDURE [W2B0] 2. Oil Pan and Oil Strainer (3) Remove front and center exhaust pipe 14) Insert oil pan cutter blade between cylinder assembly from hanger bracket. block-to-oil pan clearance. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter.
  • Page 131 SERVICE PROCEDURE [W2C0] 2. Oil Pan and Oil Strainer 2) Install oil strainer onto baffle plate. 5) Lower engine onto front crossmember. 6) Tighten nuts which install front cushion rubber CAUTION: onto front crossmember. Replace O-ring with a new one. Tightening torque: Tightening torque: 69 ±...
  • Page 132 SERVICE PROCEDURE [W2C0] 2. Oil Pan and Oil Strainer (4) Tighten bolt which installs front and center 10) Lower the vehicle. exhaust pipe assembly on bracket. CAUTION: Tightening torque: At this time, lower lifting device and release 24 ± 3 N·m (2.4 ± 0.3 kg-m, 17.4 ± 2.2 ft-lb) steel cables.

  • Page 133: Oil Pressure Switch

    SERVICE PROCEDURE [W3A0] 3. Oil Pressure Switch 3. Oil Pressure Switch 14) Install radiator upper brackets. Tightening torque: A: REMOVAL 18 ± 5 N·m (1.8 ± 0.5 kg-m, 13 ± 4 ft-lb) 1) Remove alternator from bracket. (1) Disconnect connector and terminal from generator.
  • Page 134 SERVICE PROCEDURE [W3B0] 3. Oil Pressure Switch 2) Disconnect terminal from oil pressure switch. 2) 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) G2M0091 3) Remove oil pressure switch. S2M0119 3) Connect terminal of oil pressure switch.

  • Page 135: Oil Cooler (At Vehicles Only)

    SERVICE PROCEDURE [W4A0] 4. Oil Cooler (AT Vehicles Only) 4. Oil Cooler (AT Vehicles 7) Connect connector and terminal to generator. Only) A: REMOVAL 1) Lift-up the vehicle. 2) Remove under cover. S2M0941 S2M0012 3) Drain engine coolant completely. <Ref. to 2-2 [W8A0].>...
  • Page 136 SERVICE PROCEDURE [W4B0] 4. Oil Cooler (AT Vehicles Only) 5) Disconnect water hose from oil cooler. B: INSPECTION 1) Check that coolant passages are not clogged using air blow method. 2) Check mating surfaces of cylinder block, O-ring groove and oil filter for damage. C: INSTALLATION 1) Install oil cooler on cylinder block with connec- tor pipe.
  • Page 137 SERVICE PROCEDURE [W4C0] 4. Oil Cooler (AT Vehicles Only) 3) Install water hose to oil cooler. 4) Check the amount of engine oil. If necessary, fill engine oil. <Ref. to 1-5 [G4A0].> 5) Fill engine coolant. <Ref. to 2-2 [W8B0].> S2M0112...

  • Page 138: Engine Lubrication System Trouble In General

    DIAGNOSTICS [K100] 1. Engine Lubrication System Trouble in General 1. Engine Lubrication System Trouble in General NOTE: 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...

  • Page 139: Engine Cooling System

    ENGINE COOLING SYSTEM Page SPECIFICATIONS AND SERVICE DATA............2 Specifications ....................2 Service Data....................2 COMPONENT PARTS ..................3 Water Pump ....................3 Radiator and Radiator Fan................4 Water Pipe....................5 SERVICE PROCEDURE ...................6 Water Pump ....................6 Thermostat....................11 Radiator .....................13 Radiator Cap .....................16 Radiator Main Fan Motor ................17 Radiator Sub Fan Motor................19 Water Pipe....................20 Reservoir Tank ..................22...

  • Page 140: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Specifications 1. Specifications Electric fan + Forced engine coolant circula- Cooling system tion system MT: Approx. 6.0 (6.3, 5.3) Total engine coolant capacity (US qt, Imp qt) AT: Approx. 6.2 (6.6, 5.5) Type Centrifugal impeller type Discharge (5.3 US gal, 4.4 Imp gal)/min.
  • Page 141 COMPONENT PARTS [C100] 1. Water Pump 1. Water Pump S2M0010A (1) Water by-pass hose A (AT (6) Heater hose Tightening torque: N·m (kg-m, ft-lb) vehicles) (7) Thermostat First (2) Water by-pass pipe (AT vehicles) (8) Gasket +0.4 +2.9 (1.0 , 7.2 −0 −0 −0...

  • Page 142: Ccomponent Parts

    COMPONENT PARTS [C200] 2. Radiator and Radiator Fan 2. Radiator and Radiator Fan S2M0890A (1) Radiator lower cushion (13) Main fan shroud (21) ATF inlet hose B (AT vehicles (2) Radiator (14) Radiator main fan only) (3) Radiator upper cushion (15) Radiator main fan motor (22) Radiator outlet hose (4) Radiator upper bracket...

  • Page 143: Water Pipe

    COMPONENT PARTS [C300] 3. Water Pipe 3. Water Pipe B2M1189A (1) Engine coolant temperature sen- (3) Water pipe Tightening torque: N·m (kg-m, ft-lb) (4) O-ring 6.4 ± 0.5 (0.65 ± 0.05, 4.7 ± 0.4) (2) Engine coolant temperature (5) By-pass hose gauge...
  • Page 144 SERVICE PROCEDURE [W1A0] 1. Water Pump 1. Water Pump 5) Disconnect connectors from radiator main fan (A) and sub fan (B) motors. A: REMOVAL 1) Disconnect ground cable from the battery. S2M0893A 6) Remove bolt which installs water by-pass pipe of oil cooler onto oil pump.
  • Page 145 SERVICE PROCEDURE [W1A0] 1. Water Pump 11) Remove reservoir tank. 15) Remove automatic belt tension adjuster. S2M0931 H2M2375 12) Remove radiator main fan and sub fan assem- 16) Remove belt idler No. 2. blies. <Ref. to 2-5 [W5A0].> and <Ref. to 2-5 [W6A0].>...

  • Page 146: Service Procedure

    SERVICE PROCEDURE [W1B0] 1. Water Pump 19) Remove left-hand belt cover No. 2. 3) Using a dial gauge, measure impeller runout in thrust direction while rotating the pulley. “Thrust” runout limit: 0.5 mm (0.020 in) B2M2040 20) Remove tensioner bracket. G2M0211 4) Check clearance between impeller and pump case.
  • Page 147 SERVICE PROCEDURE [W1C0] 1. Water Pump Tightening torque: 4) Install left-hand camshaft sprockets by using +0.4 +2.9 N·m (1.0 kg-m, 7.2 ft-lb) −0 −0 −0 ST 4992707100 CAMSHAFT SPROCKET WRENCH Tightening torque: 78 ± 5 N·m (8.0 ± 0.5 kg-m, 57.9 ± 3.6 ft-lb) S2M0023A 2) Install left-hand belt cover No.
  • Page 148 SERVICE PROCEDURE [W1C0] 1. Water Pump 7) Install automatic belt tension adjuster which 11) Install reservoir tank. tension rod is holded with pin. <Ref. to 2-3 [W2C2].> S2M0931 12) Connect over flow hose. H2M2384 8) Install timing belt. <Ref. to 2-3 [W2C0].> S2M0930 13) Lift-up the vehicle.

  • Page 149: Thermostat

    SERVICE PROCEDURE [W2A0] 2. Thermostat 2. Thermostat 17) Connect connectors to radiator main fan (A) and sub fan (B) motors. A: REMOVAL AND INSTALLATION 1) Lift-up the vehicle. 2) Remove under cover. S2M0893A 18) Install under cover. S2M0012 3) Drain engine coolant completely. <Ref. to 2-2 [W8A0].>...
  • Page 150 SERVICE PROCEDURE [W2B0] 2. Thermostat 5) Disconnect radiator outlet hose and water by- B: INSPECTION pass hose B (AT vehicles) from thermostat cover. Replace the thermostat if the valve does not close completely at an ambient temperature or if the fol- lowing test shows unsatisfactory results.

  • Page 151: Radiator

    SERVICE PROCEDURE [W3A0] 3. Radiator 3. Radiator 5) Disconnect connectors of radiator main fan (A) and sub fan (B) motor. A: REMOVAL 1) Disconnect battery ground cable. S2M0893A 6) Disconnect ATF cooler hoses from radiator. (AT G6M0095 vehicles only) 2) Lift-up the vehicle. 3) Remove under cover.
  • Page 152 SERVICE PROCEDURE [W3B0] 3. Radiator 10) Remove reservoir tank. 15) Lift radiator up and away from vehicle. S2M0931 S2M0033 11) Remove V-belt covers. B: INSTALLATION 1) Attach radiator mounting cushions to pins on the lower side of radiator. S2M0896 12) Disconnect radiator inlet hose from radiator. S2M0944 2) Install radiator while fitting radiator pins to cush- ions.
  • Page 153 SERVICE PROCEDURE [W3B0] 3. Radiator 3) Install radiator brackets and tighten bolts. 8) Connect connectors to radiator main fan motor and sub fan motor. Tightening torque: 18 ± 5 N·m (1.8 ± 0.5 kg-m, 13.0 ± 3.6 ft-lb) S2M0893 S2M0932 9) Connect radiator outlet hose.

  • Page 154: Radiator Cap

    SERVICE PROCEDURE [W4A0] 4. Radiator Cap 4. Radiator Cap 13) Connect battery ground cable. A: INSPECTION 1) Attach radiator cap to tester. G6M0095 14) Fill coolant. <Ref. to 2-2 [W8B0].> G2M0223 2) Increase pressure until tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for five to six sec- onds.

  • Page 155: Radiator Main Fan Motor

    SERVICE PROCEDURE [W5A0] 5. Radiator Main Fan Motor 5. Radiator Main Fan Motor 7) Disconnect over flow nose. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S2M0930 8) Remove reservoir tank. G6M0095 2) Lift-up the vehicle. 3) Remove under cover. S2M0931 9) Remove radiator main fan motor assembly.
  • Page 156 SERVICE PROCEDURE [W5B0] 5. Radiator Main Fan Motor 10) Installation is in the reverse order of removal. 2) Remove nut which holds fan itself onto fan motor and shroud assembly. NOTE: When the main fan motor assembly cannot be installed as is, loosen the sub fan motor assembly securing bolts to install it.

  • Page 157: Radiator Sub Fan Motor

    SERVICE PROCEDURE [W6B0] 6. Radiator Sub Fan Motor 6. Radiator Sub Fan Motor 7) Remove bolts which hold sub fan shroud to radiator. A: REMOVAL AND INSTALLATION 8) Remove radiator sub fan motor assembly. 1) Disconnect battery ground cable. S2M0935 G6M0095 9) Installation is in the reverse order of removal.

  • Page 158: Water Pipe

    SERVICE PROCEDURE [W7A0] 7. Water Pipe 7. Water Pipe 2) Remove nut which holds fan itself onto fan motor and shroud assembly. A: REMOVAL 1) Release fuel pressure. <Ref. to 2-2 [W9B0].> 2) Disconnect ground cable from the battery. S2M0939 3) Remove bolts which install fan motor onto shroud.
  • Page 159 SERVICE PROCEDURE [W7B0] 7. Water Pipe 5) Disconnect heater inlet hose. B: INSTALLATION 1) Install water pipe on cylinder block. Tightening torque: 6.4 ± 0.5 N·m (0.65 ± 0.05 kg-m, 4.7 ± 0.4 ft-lb) CAUTION: Use a new O-ring. B2M0138 6) Disconnect radiator inlet hose from water pipe.

  • Page 160: Reservoir Tank

    SERVICE PROCEDURE [W8A0] 8. Reservoir Tank 8. Reservoir Tank 3) Remove reservoir tank. A: REMOVAL AND INSTALLATION 1) Disconnect over flow hose from radiator filler neck position. S2M0931 4) Installation is in the reverse order of removal. Tightening torque: 4.9 ± 1.5 N·m (0.50 ± 0.15 kg-m, 3.6 ± 1.1 ft-lb) S2M0930 2) Remove bolts which install reservoir tank onto radiator main fan shroud.

  • Page 161: Engine Cooling System Trouble In General

    DIAGNOSTICS [K100] 1. Engine Cooling System Trouble in General 1. Engine Cooling System Trouble in General Trouble 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.
  • Page 162 DIAGNOSTICS MEMO:...

  • Page 163: Fuel Injection System

    FUEL INJECTION SYSTEM Page COMPONENT PARTS ..................2 Intake Manifold ....................2 Air Intake System ..................4 Air Cleaner ....................5 Crankshaft Position, Camshaft Position and Knock Sensors.....6 SERVICE PROCEDURE ...................7 Air Cleaner Case and Air Intake Duct............7 Air Intake Chamber ..................8 Mass Air Flow Sensor .................9 Throttle Body .....................10 Intake Manifold ..................12 Engine Coolant Temperature Sensor............23...
  • Page 164 COMPONENT PARTS [C100] 1. Intake Manifold 1. Intake Manifold S2M1116A...

  • Page 165: Component Parts

    COMPONENT PARTS [C100] 1. Intake Manifold (1) Intake manifold gasket LH (12) Purge control solenoid valve (20) Bracket (For Canada spec. (2) Intake manifold gasket RH (13) Nipple vehicles) (3) Fuel injector pipe (14) Pressure sensor (21) Intake manifold (4) O-ring A (15) Pressure sources switching sole- (5) O-ring B noid valve...

  • Page 166: Air Intake System

    COMPONENT PARTS [C200] 2. Air Intake System 2. Air Intake System S2M1117A (1) Gasket (7) Air intake chamber Tightening torque: N·m (kg-m, ft-lb) (2) Throttle position sensor (8) Stay LH (MT vehicles) 2.2 ± 0.2 (0.22 ± 0.02, 1.6 ± 0.1) (3) Throttle body (9) Stay LH (AT vehicles) 4.9 ±...

  • Page 167: Air Cleaner

    COMPONENT PARTS [C300] 3. Air Cleaner 3. Air Cleaner S2M1151A (1) Mass air flow sensor bracket (7) Clip Tightening torque: N·m (kg-m, ft-lb) (2) Mass air flow sensor ASSY (8) Air cleaner case 33 ± 10 (3.4 ± 1.0, 25 ± 7) (3) Air cleaner upper cover (9) Cushion rubber 7.4 ±...

  • Page 168: Crankshaft Position, Camshaft Position And Knock Sensors

    COMPONENT PARTS [C400] 4. Crankshaft Position, Camshaft Position and Knock Sensors 4. Crankshaft Position, Camshaft Position and Knock Sensors B2M2282A (1) Crankangle position sensor Tightening torque: N·m (kg-m, ft-lb) (2) Knock sensor 6.4 ± 0.5 (0.65 ± 0.05, 4.7 ± 0.4) (3) Camshaft position sensor 23.5 ±...

  • Page 169: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Air Cleaner Case and Air Intake Duct 1. Air Cleaner Case and Air 4) Remove two clips of air cleaner upper cover. Intake Duct A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. B2M2289 5) Remove air intake duct and air cleaner upper cover as a unit.

  • Page 170: Air Intake Chamber

    SERVICE PROCEDURE [W2A0] 2. Air Intake Chamber 2. Air Intake Chamber 8) Installation is in the reverse order of removal. CAUTION: A: REMOVAL AND INSTALLATION Before installing air cleaner upper cover, align holes with protruding portions of air cleaner 1) Loosen clamps which connect air intake cham- lower case, then secure upper cover to lower ber to throttle body and air intake duct.

  • Page 171: Mass Air Flow Sensor

    SERVICE PROCEDURE [W3A0] 3. Mass Air Flow Sensor 3. Mass Air Flow Sensor 5) Remove air intake duct and air cleaner upper cover as a unit. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. B2M2020 6) Loosen clamp which connects air intake duct to G6M0095 mass air flow sensor.

  • Page 172: Throttle Body

    SERVICE PROCEDURE [W4A0] 4. Throttle Body 4. Throttle Body 8) Installation is in the reverse order of removal. Tightening torque: A: REMOVAL AND INSTALLATION 7.4 ± 2.0 N·m (0.75 ± 0.2 kg-m, 5.4 ± 1.4 ft-lb) 1) Disconnect battery ground cable. CAUTION: Before installing air cleaner upper cover, align holes with protruding portions of air cleaner...
  • Page 173 SERVICE PROCEDURE [W4A0] 4. Throttle Body 4) Disconnect blow-by hose and air hoses, and 9) Disconnect engine coolant hoses from throttle remove air intake chamber. body. B2M2304 B2M2301 10) Remove bolts which install throttle body to 5) Disconnect accelerator cable (A). intake manifold.

  • Page 174: Intake Manifold

    SERVICE PROCEDURE [W5A0] 5. Intake Manifold 5. Intake Manifold 6) Loosen clamp which connects air intake cham- ber to throttle body. A: REMOVAL 1) Release fuel pressure. <Ref. to 2-2 [W9B0].> 2) Open fuel flap lid, and remove fuel filler cap. S2M1001 7) Remove bolts which install air intake chamber on stays.
  • Page 175 SERVICE PROCEDURE [W5A0] 5. Intake Manifold 11) Disconnect accelerator cable (A). (3) Remove bolts which secure power steering 12) Disconnect cruise control cable (B). (With pipe brackets to intake manifold. cruise control model) NOTE: Do not disconnect power steering hose. B2M2302A S2M1013 13) Disconnect vacuum hoses from pressure...
  • Page 176 SERVICE PROCEDURE [W5A0] 5. Intake Manifold 15) Disconnect spark plug cords from ignition coil 20) Remove air intake chamber stay RH, engine and ignitor assembly. harness bracket from transmission housing, and disconnect engine harness connectors from bulk- head harness connectors. B2M2312 16) Disconnect PCV hose (A) and pressure regu- B2M2315...
  • Page 177 SERVICE PROCEDURE [W5B0] 5. Intake Manifold 24) Disconnect connector from crankshaft position 28) Remove intake manifold. sensor. B2M0160 B2M1252A B: DISASSEMBLY 25) Disconnect connector from oil pressure switch. 1) Remove engine ground terminal from intake manifold. B2M1253A 26) Disconnect fuel hoses from fuel pipes. B2M2779 WARNING: 2) Disconnect connector from ignition coil and...
  • Page 178 SERVICE PROCEDURE [W5B0] 5. Intake Manifold 4) Disconnect connectors from throttle position 9) Remove purge control solenoid valve. sensor (A) and idle air control solenoid valve (B). B2M2350A B2M2357A 10) Remove bolts which install injector pipe on 5) Remove throttle body. intake manifold.
  • Page 179 SERVICE PROCEDURE [W5C0] 5. Intake Manifold 13) Remove bolts which hold fuel pipes on the left C: ASSEMBLY side of intake manifold. 1) Assemble fuel pipes, etc. to intake manifold. B2M2786 B2M2356A 14) Remove two bolts which install fuel pipes on Pressure regulator intake manifold.
  • Page 180 SERVICE PROCEDURE [W5C0] 5. Intake Manifold 4) Tighten two bolts which install fuel pipes on the 7) Tighten bolts which install injector pipe on left side of intake manifold. intake manifold. Tightening torque: Tightening torque: 4.9 ± 0.5 N·m (0.5 ± 0.05 kg-m, 3.6 ± 0.4 ft-lb) 4.9 ±...
  • Page 181 SERVICE PROCEDURE [W5D0] 5. Intake Manifold 12) Assemble throttle body to intake manifold. 16) Install engine ground terminal to intake mani- fold. CAUTION: Replace gasket with a new one. Tightening torque: 18.6 ± 1.5 N·m (1.9 ± 0.15 kg-m, 13.7 ± 1.1 Tightening torque: ft-lb) 22 ±...
  • Page 182 SERVICE PROCEDURE [W5D0] 5. Intake Manifold 3) Connect connector to oil pressure switch. 7) Connect connectors to engine coolant tempera- ture sensor. B2M1253A S2M1118 4) Connect connector to crankshaft position sen- sor. 8) Install air intake chamber stay RH and engine harness bracket, and connect engine harness con- nectors to bulkhead connectors.
  • Page 183 SERVICE PROCEDURE [W5D0] 5. Intake Manifold 11) Connect PCV hose (A) and vacuum hose (B) (2) Install power steering pipe brackets on the to intake manifold. right side of intake manifold. H2M2440A S2M1013 12) Connect spark plug cords to ignition coil and (3) Install power steering pump drive V-belt.
  • Page 184 SERVICE PROCEDURE [W5D0] 5. Intake Manifold 15) Install air cleaner element. 18) Connect connector to mass air flow sensor. 16) Install air cleaner upper cover, air intake duct and air intake chamber as a unit. B2M2018 19) Connect connector to fuel pump relay. S2M0940 CAUTION: Before installing air cleaner upper cover, align...

  • Page 185: Engine Coolant Temperature Sensor

    SERVICE PROCEDURE [W6A0] 6. Engine Coolant Temperature Sensor 6. Engine Coolant Temperature 4) Remove two clips of air cleaner upper cover. Sensor A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. B2M2289 5) Remove air intake duct and air cleaner upper cover as a unit.

  • Page 186: Crankshaft Position Sensor

    SERVICE PROCEDURE [W7A0] 7. Crankshaft Position Sensor 7. Crankshaft Position Sensor 4) Installation is in the reverse order of removal. Tightening torque: A: REMOVAL AND INSTALLATION 6.4 ± 0.5 N·m (0.65 ± 0.05 kg-m, 4.7 ± 0.4 ft-lb) 1) Disconnect battery ground cable. G2M0408 G6M0095 2) Remove bolt which install crankshaft position...

  • Page 187: Camshaft Position Sensor

    SERVICE PROCEDURE [W8A0] 8. Camshaft Position Sensor 8. Camshaft Position Sensor 4) Remove bolt which installs camshaft position sensor support to camshaft cap LH. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. B2M2321 5) Remove camshaft position sensor and cam- shaft position sensor support as a unit.

  • Page 188: Knock Sensor

    SERVICE PROCEDURE [W9A0] 9. Knock Sensor 9. Knock Sensor 4) Remove knock sensor from cylinder block. A: REMOVAL 1) Disconnect battery ground cable from battery ground terminal. B2M2316 B: INSTALLATION 1) Install knock sensor to cylinder block. G6M0095 Tightening torque: 2) Remove air intake chamber.

  • Page 189: Front Oxygen Sensor

    4) Disconnect connector from front oxygen sen- sor. B2M1979 5) Lift-up the vehicle. 6) Apply SUBARU CRC or its equivalent to threaded portion of front oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003)
  • Page 190 SERVICE PROCEDURE [W10B0] 10. Front Oxygen Sensor 7) Remove front oxygen sensor. 2) Install front oxygen sensor. Tightening torque: CAUTION: 21 ± 3 N·m (2.1 ± 0.3 kg-m, 15.2 ± 2.2 ft-lb) When removing, do not force front oxygen sen- sor in an unnatural way especially when exhaust pipe is cold, otherwise it will damage exhaust pipe.

  • Page 191: Rear Oxygen Sensor

    Tightening torque: 21 ± 3 N·m (2.1 ± 0.3 kg-m, 15.2 ± 2.2 ft-lb) B2M0335 4) Apply SUBARU CRC or its equivalent to threaded portion of rear oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove rear oxygen sensor.

  • Page 192: Throttle Position Sensor

    SERVICE PROCEDURE [W12A0] 12. Throttle Position Sensor 12. Throttle Position Sensor 5) Connect battery ground cable. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. G6M0095 G6M0095 2) Disconnect connector from throttle position sensor. B2M2303 3) Remove throttle position sensor holding screws, and remove throttle position sensor itself.
  • Page 193 For detailed operation procedures, refer to the B: ADJUSTMENT Subaru Select Monitor Operation Manual. 1) Turn ignition switch to OFF. (1) Insert the cartridge to Subaru Select Moni- 2) Loosen throttle position sensor holding screws. tor. <Ref. to 1-6 [G1100].> B2M2761 S2M0286A 3) When using voltage meter;...

  • Page 194: Pressure Sensor

    SERVICE PROCEDURE [W13A0] 13. Pressure Sensor 13. Pressure Sensor (8) Adjust throttle position sensor to the proper position to match with the following specifica- A: REMOVAL AND INSTALLATION tions. Condition: Throttle fully closed 1) Disconnect battery ground cable. Throttle opening angle 0.00% Throttle sensor voltage 0.50 V G6M0095 2) Disconnect connector from pressure sensor.

  • Page 195: Idle Air Control Solenoid Valve

    SERVICE PROCEDURE [W14A0] 14. Idle Air Control Solenoid Valve 14. Idle Air Control Solenoid 4) Installation is in the reverse order of removal. CAUTION: Valve Replace gasket with a new one. A: REMOVAL AND INSTALLATION Tightening torque: 6.0 ± 0.8 N·m (0.61 ± 0.08 kg-m, 4.4 ± 0.6 ft-lb) 1) Disconnect battery ground cable.

  • Page 196: Pressure Sources Switching Solenoid Valve

    SERVICE PROCEDURE [W15A0] 15. Pressure Sources Switching Solenoid Valve 15. Pressure Sources 16. Fuel Injector Switching Solenoid Valve A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION 1. RH SIDE 1) Disconnect battery ground cable. 1) Release fuel pressure. <Ref. to 2-2 [W9B0].> 2) Open fuel flap lid, and remove fuel filler cap.
  • Page 197 SERVICE PROCEDURE [W16A1] 16. Fuel Injector (2) Remove air intake duct and air cleaner (3) Remove bolts which secure power steering upper cover as a unit, and remove air cleaner pipe brackets to intake manifold. element. <Ref. to 2-7 [W1A0].> S2M1013 B2M2020 (4) Remove bolts which install power steering...
  • Page 198 SERVICE PROCEDURE [W16A2] 16. Fuel Injector 8) Disconnect connector from fuel injector. 11) Installation is in the reverse order of removal. CAUTION: Always use new o-rings and insulators. Tightening torque: 19 ± 2 N·m (1.9 ± 0.2 kg-m, 13.7 ± 1.4 ft-lb) B2M2365 9) Remove bolts which install injector pipe to intake manifold.
  • Page 199 SERVICE PROCEDURE [W16A2] 16. Fuel Injector 3) Disconnect battery ground cable. 8) Move washer tank, and secure it away from working area. G6M0095 B2M2023 4) Disconnect connector from front window washer motor. 9) Remove spark plug cords from spark plugs (#1 5) Disconnect connector from rear gate glass and #3 cylinders).
  • Page 200 SERVICE PROCEDURE [W16A2] 16. Fuel Injector 12) Remove bolts which hold fuel pipes on the left 15) Installation is in the reverse order of removal. side of intake manifold. CAUTION: Always use new o-rings and insulators. Tightening torque: 19 ± 2 N·m (1.9 ± 0.2 kg-m, 13.7 ± 1.4 ft-lb) B2M2786 13) Remove bolts which install injector pipe to intake manifold.

  • Page 201: Engine Control Module

    SERVICE PROCEDURE [W17A0] 17. Engine Control Module 17. Engine Control Module 5) Remove nuts which hold ECM to bracket. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. B2M2368 6) Remove clip from bracket. G6M0095 2) Remove side sill front cover. <Ref.

  • Page 202: Main Relay

    SERVICE PROCEDURE [W18A0] 18. Main Relay 18. Main Relay 4) Remove main relay from mounting bracket. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S2M0137A 5) Installation is in the reverse order of removal. G6M0095 2) Remove bolt which holds bracket of main relay and fuel pump relay.

  • Page 203: Fuel Pump Relay

    SERVICE PROCEDURE [W19A0] 19. Fuel Pump Relay 19. Fuel Pump Relay 3) Remove fuel pump relay from mounting bracket. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S2M0138 4) Installation is in the reverse order of removal. G6M0095 2) Disconnect connector from fuel pump relay. S2M0093A...
  • Page 204 SERVICE PROCEDURE MEMO:...

  • Page 205: Fuel System

    FUEL SYSTEM Page SPECIFICATIONS AND SERVICE DATA............2 Specifications ....................2 COMPONENT PARTS ..................4 Fuel Tank.....................4 Fuel Line......................6 SERVICE PROCEDURE ...................8 Fuel Tank.....................8 Fuel Filler Pipe ..................13 Fuel Filter ....................18 Fuel Pump ....................19 Fuel Meter Unit..................20 Fuel Delivery, Return and Evaporation Lines ...........22 Roll Over Valve ..................24 Fuel Sub Meter Unit ..................25 Fuel Cut Valve...................26...

  • Page 206: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Specifications 1. Specifications Capacity (15.9 US gal, 13.2 Imp gal) Fuel tank Location Under rear seat Type Impeller Discharge pressure 299.1 kPa (3.05 kg/cm , 43.4 psi) Fuel pump More than 65 (17.2 US gal, 14.3 Imp gal)/h Discharge flow [12 V at 300 kPa (3.06 kg/cm , 43.5 psi)]...
  • Page 207 SPECIFICATIONS AND SERVICE DATA [S100] 1. Specifications MEMO:...
  • Page 208 COMPONENT PARTS [C100] 1. Fuel Tank 1. Fuel Tank S2M0877A...

  • Page 209: Component Parts

    COMPONENT PARTS [C100] 1. Fuel Tank (1) Heat seated cover (15) Evaporation hose C (29) Jet pump filter (2) Fuel tank band (16) Evaporation hose B (30) Fuel sub meter unit (3) Protector LH (17) Evaporation hose D (31) Protector cover (4) Protector RH (18) Evaporation hose E (32) Vent valve hose...

  • Page 210: Fuel Line

    COMPONENT PARTS [C200] 2. Fuel Line 2. Fuel Line S2M1114A...
  • Page 211 COMPONENT PARTS [C200] 2. Fuel Line (1) Clamp (19) Canister hose A (37) Shut valve (2) Fuel delivery hose A (20) Air filter hose A (38) Packing (3) Fuel filter bracket (21) Drain valve hose (39) Ring A (4) Fuel filter holder (22) Air filter hose B (40) Ring B (5) Fuel filter cup...
  • Page 212 SERVICE PROCEDURE [W1A0] 1. Fuel Tank 1. Fuel Tank 6) Remove rear seat cushion, and turn up cover. <Ref. to 5-3 [W2A0].> A: REMOVAL 1) Set the vehicle on the lift. 2) Release fuel pressure. <Ref. to 2-2 [W9B0].> 3) Open fuel flap lid, and remove fuel filler cap. S2M0064 7) Disconnect connector of fuel tank cord from rear harness.

  • Page 213: Service Procedure

    S2M0157 (3) Remove bracket from rubber cushion, and remove exhaust pipe. NOTE: To facilitate the removal of parts, apply a coat of SUBARU CRC5-56 (Part No. 004301003). <Ref. to 2-9 [W2A0].> 12) Remove muffler assembly. <Ref. to 2-9 [W3A0].> NOTE:...
  • Page 214 SERVICE PROCEDURE [W1A0] 1. Fuel Tank 19) Remove bolts which hold parking brake cable 22) Loosen clamp, and disconnect fuel filler hose holding bracket. (A) and air vent hose (B) from fuel filler pipe and air vent pipe. S2M0191 S2M0193A 20) Remove rear differential assembly.
  • Page 215 SERVICE PROCEDURE [W1B0] 1. Fuel Tank B: INSTALLATION 6) Install rear crossmember. <Ref. [W10C0].> 1) While a helper holds fuel tank, push fuel tank harness into access hole with grommet. 2) Set fuel tank, and temporary tighten bolts for installing fuel tank bands. G4M0545 7) Install rear differential assembly.
  • Page 216 SERVICE PROCEDURE [W1B0] 1. Fuel Tank 10) Connect hose to joint pipe. 13) Install bolts which hold parking brake holding bracket. Tightening torque: 1.4 ± 0.3 N·m (0.14 ± 0.03 kg-m, 1.0 ± 0.2 ft-lb) S2M0191 S2M0880 14) Install heat sealed cover. 11) Connect evaporation hose to canister, and hold them with clamp.

  • Page 217: Fuel Filler Pipe

    SERVICE PROCEDURE [W2A0] 2. Fuel Filler Pipe 2. Fuel Filler Pipe 17) Lower the vehicle. 18) Connect connectors to fuel tank harness, and A: REMOVAL plug access hole with grommet. 1) Set the vehicle on the lift. 2) Release fuel pressure. <Ref. to 2-2 [W9B0].> 3) Open fuel flap lid, and remove fuel filler cap.
  • Page 218 SERVICE PROCEDURE [W2A0] 2. Fuel Filler Pipe 7) Remove screws holding packing in place. 13) Disconnect evaporation hoses from pipes. S2M0170 S2M0881 8) Remove wheel nuts of rear right side. 14) Lift-up the vehicle more. 9) Remove wheel nuts of rear right side. 15) Remove two evaporation hoses from clip.
  • Page 219 SERVICE PROCEDURE [W2C0] 2. Fuel Filler Pipe 18) Remove fuel filler pipe to under side of 3) Disconnect evaporation hose from fuel filler vehicle. pipe. B2M1756 B2M1760 4) Disconnect evaporation hoses from shut valve. B: DISASSEMBLY 1) Move clip, and disconnect evaporation hose from joint pipe.
  • Page 220 SERVICE PROCEDURE [W2D0] 2. Fuel Filler Pipe 2) Connect evaporation hoses to shut valve. 2) Connect fuel filler pipe into fuel filler hose. B2M1761 B2M1757 3) Connect evaporation hose to fuel filler pipe. 3) Lower the vehicle. 4) Temporarily tighten screws which install fuel filler pipe on filler lid open.
  • Page 221 SERVICE PROCEDURE [W2D0] 2. Fuel Filler Pipe 8) Install two evaporation hoses to clip. 13) Tighten screws which install fuel filler pipe on filler lid open. B2M1753 S2M0170 9) Connect evaporation hose to joint pipe. 14) Install fuel filler cap. 15) Install rear right wheel.

  • Page 222: Fuel Filter

    SERVICE PROCEDURE [W3A0] 3. Fuel Filter 3. Fuel Filter C: INSTALLATION CAUTION: A: REMOVAL ¼ If fuel hoses are damaged at the connecting 1) Release fuel pressure. <Ref. to 2-2 [W9B0].> portion, replace it with a new one. ¼ If clamps are badly damaged, replace with 2) Disconnect battery ground cable.

  • Page 223: Fuel Pump

    SERVICE PROCEDURE [W4B0] 4. Fuel Pump 4. Fuel Pump 7) Remove nuts which install fuel pump assembly onto fuel tank. A: REMOVAL 1) Release fuel pressure. <Ref. to 2-2 [W9B0].> 2) Remove fuel filler cap. 3) Disconnect battery ground cable. S2M0061 8) Take off fuel pump from fuel tank.

  • Page 224: Fuel Meter Unit

    SERVICE PROCEDURE [W4C0] 5. Fuel Meter Unit 5. Fuel Meter Unit C: INSTALLATION Installation is in the reverse order of removal. Do A: REMOVAL the following: NOTE: 1) Always use new gaskets. Fuel meter unit is built in fuel pump assembly. 2) Ensure sealing portion is free from fuel or for- eign particles before installation.
  • Page 225 SERVICE PROCEDURE [W5B0] 5. Fuel Meter Unit 5) Move clips, and then disconnect fuel return B: INSTALLATION hose (B) and jet pump hose (C). Installation is in the reverse order of removal. Do 6) Disconnect quick connector, and then discon- the following: nect fuel delivery hose (A).

  • Page 226: Fuel Delivery, Return And Evaporation Lines

    SERVICE PROCEDURE [W6A0] 6. Fuel Delivery, Return and Evaporation Lines 6. Fuel Delivery, Return and 2) Remove fuel filler cap. 3) Remove inner trim, insulator and rear seat. Evaporation Lines 4) Remove fuel delivery pipes and hoses, fuel return pipes and hoses, and evaporation pipes and A: REMOVAL hoses.
  • Page 227 SERVICE PROCEDURE [W6B0] 6. Fuel Delivery, Return and Evaporation Lines B: INSTALLATION Installation is in the reverse order of removal. 1) Connect quick connector on fuel delivery line. CAUTION: ¼ Always use a new retainer. ¼ Make sure that the connected portion is not damaged or has dust.

  • Page 228: Roll Over Valve

    SERVICE PROCEDURE [W7A0] 7. Roll Over Valve 7. Roll Over Valve 3) Connect return hose and evaporation hose to pipe by approx. 15 mm (0.59 in) from hose end. A: REMOVAL AND INSTALLATION Fuel return hose: L = 20 — 25 mm (0.79 — 0.98 in) 1) Lift-up the vehicle.

  • Page 229: Fuel Sub Meter Unit

    SERVICE PROCEDURE [W8A0] 8. Fuel Sub Meter Unit 8. Fuel Sub Meter Unit B: INSPECTION 1) Connect hoses to roll over valve as shown in A: REMOVAL AND INSTALLATION Figure. 1) Disconnect battery ground cable. G2M0374 G6M0095 2) While blowing through open end of hose, tilt valve at least 90°...

  • Page 230: Fuel Cut Valve

    SERVICE PROCEDURE [W9A0] 9. Fuel Cut Valve 9. Fuel Cut Valve 5) Remove bolts which install fuel sub meter unit on fuel tank. A: REMOVAL AND INSTALLATION 1) Remove fuel tank. <Ref. to 2-8 [W1A0].> S2M0152 6) Remove fuel sub meter unit. S2M0169A 2) Remove protect cover.
  • Page 231 SERVICE PROCEDURE [W9A0] 9. Fuel Cut Valve 5) Installation is in the reverse order of removal. Tightening torque: 4.4 ± 1.5 N·m (0.45 ± 0.15 kg-m, 3.3 ± 1.1 ft-lb) G2M0867...

  • Page 232: Fuel System Trouble In General

    DIAGNOSTICS [K100] 1. Fuel System Trouble in General 1. Fuel System Trouble in General Trouble and possible cause Corrective action 1. Insufficient fuel supply to the injector Fuel pump will not operate. Inspect connections, especially ground, and k Defective terminal contact. tighten securely.

  • Page 233: Exhaust System

    EXHAUST SYSTEM Page COMPONENT PARTS ..................2 Exhaust System ..................2 SERVICE PROCEDURE ...................3 Front and Center Exhaust Pipe Assembly..........3 Rear Exhaust Pipe ..................5 Muffler......................6...

  • Page 234: Component Parts

    COMPONENT PARTS [C100] 1. Exhaust System 1. Exhaust System S2M0921A (1) Upper front exhaust pipe cover (11) Spring (25) Front catalytic converter (12) Rear exhaust pipe (26) Lower front catalytic converter (2) Lower front exhaust pipe cover (13) Self-locking nut cover (14) Gasket (27) Upper front catalytic converter...

  • Page 235: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Front and Center Exhaust Pipe Assembly 1. Front and Center Exhaust 5) Separate front and center exhaust pipe assem- bly from rear exhaust pipe. Pipe Assembly WARNING: A: REMOVAL Be careful, exhaust pipe is hot. 1) Disconnect battery ground cable. B2M0055 G6M0095 6) Remove bolts which hold front exhaust pipe...
  • Page 236 SERVICE PROCEDURE [W1B0] 1. Front and Center Exhaust Pipe Assembly 9) Separate front exhaust pipe from front catalytic 4) Tighten bolts which hold front exhaust pipe onto converter and center exhaust pipe assembly. cylinder heads. Tightening torque: 30 ± 5 N·m (3.1 ± 0.5 kg-m, 22.4 ± 3.6 ft-lb) S2M0923 B: INSTALLATION B2M0054...

  • Page 237: Rear Exhaust Pipe

    S2M0922 10) Connect battery ground cable. S2M0157 3) Remove rear exhaust pipe bracket from rubber cushion. NOTE: G6M0095 To facilitate removal, apply a coat of SUBARU CRC or equivalent to pipe bracket in advance. SUBARU CRC (Part No. 004301003) S2M0158...

  • Page 238: Muffler

    Be careful, exhaust pipe is hot. ion. 1) Separate muffler from rear exhaust pipe. NOTE: To facilitate installation, apply a coat of SUBARU CRC or equivalent to mating area of rubber cush- ion in advance. SUBARU CRC (Part No. 004301003) S2M0157 2) Remove left and right rubber cushions.
  • Page 239 CAUTION: NOTE: Replace gasket with a new one. To facilitate removal, apply a coat of SUBARU Tightening torque: CRC or equivalent to mating area of rubber cush- 48 ± 5 N·m (4.9 ± 0.5 kg-m, 35.4 ± 3.6 ft-lb) ion in advance.
  • Page 240 SERVICE PROCEDURE MEMO:...

  • Page 241: Clutch

    2-10 CLUTCH Page SPECIFICATIONS AND SERVICE DATA............2 Clutch System .....................2 COMPONENT PARTS ..................3 Clutch System .....................3 Master Cylinder and Reservoir Tank............4 SERVICE PROCEDURE ...................5 General......................5 On-car Service ....................5 Release Bearing and Lever ................6 Clutch Disc and Cover ................8 Operating Cylinder..................11 Master Cylinder and Reservoir Tank............12 Brake Fluid ....................14 DIAGNOSTICS....................15...

  • Page 242: Specifications And Service Data

    2-10 SPECIFICATIONS AND SERVICE DATA [S100] 1. Clutch System 1. Clutch System 2500 cc Clutch cover Diaphragm set load kg (lb) 580 (1,279) Facing material Woven O.D. × I.D. × thickness mm (in) 225 × 150 × 3.5 (8.86 × 5.91 × 0.138) Spline O.D.

  • Page 243: Component Parts

    2-10 COMPONENT PARTS [C100] 1. Clutch System 1. Clutch System S2M0910A (1) Operating cylinder (10) Lever (19) Flywheel (2) Washer (11) Clutch release lever sealing (3) Clutch hose (12) Retainer spring Tightening torque: N·m (kg-m, ft-lb) 15.7 ± 1.5 (1.6 ± 0.15, 11.6 ± 1.1) (4) Bracket (13) Pivot 18 ±...

  • Page 244: Master Cylinder And Reservoir Tank

    2-10 COMPONENT PARTS [C200] 2. Master Cylinder and Reservoir Tank 2. Master Cylinder and Reservoir Tank S2M0911A (1) Reservoir cap (5) Master cylinder (9) Push rod (2) Reservoir tank (6) Seat (10) Piston stop ring (3) Oil seal (7) Return spring (4) Straight pin (8) Piston...

  • Page 245: Service Procedure

    2-10 SERVICE PROCEDURE [W2A0] 2. On-car Service 1. General 2. On-car Service A: PRECAUTION A: ADJUSTMENT When servicing clutch system, pay attention to the NOTE: following items. Bleed air from oil line with the help of a co-worker. 1) Check fluid level using a scale on outside of 1) Remove air chamber.

  • Page 246: Release Bearing And Lever

    2-10 SERVICE PROCEDURE [W3A0] 3. Release Bearing and Lever 3. Release Bearing and Lever 5) Tighten air bleeder. Tightening torque: A: REMOVAL T: 18 ± 3 N·m (1.8 ± 0.3 kg-m, 13.0 ± 2.2 ft-lb) 1) Remove transmission assembly from vehicle body.
  • Page 247 2-10 SERVICE PROCEDURE [W3C0] 3. Release Bearing and Lever 5) Remove release lever retainer spring from 2. RELEASE LEVER release lever pivot with a screwdriver by accessing 1) Check lever pivot portion and the point of con- it through clutch housing release lever hole. Then tact with release bearing case for wear.

  • Page 248: Clutch Disc And Cover

    2-10 SERVICE PROCEDURE [W4A0] 4. Clutch Disc and Cover 4. Clutch Disc and Cover 1) While pushing release lever to pivot and twist- ing it to both sides, fit retainer spring onto the con- A: REMOVAL stricted portion of pivot. NOTE: 1) Install ST on flywheel.
  • Page 249 2-10 SERVICE PROCEDURE [W4B2] 4. Clutch Disc and Cover B: INSPECTION 4) Deflection on facing If deflection exceeds the specified value at the 1. CLUTCH DISC outer circumference of facing, repair or replace. 1) Facing wear Limit for deflection: Measure the depth of rivet head from the surface 1.0 mm (0.039 in) at R = 107 mm (4.21 in) of facing.
  • Page 250 2-10 SERVICE PROCEDURE [W4B3] 4. Clutch Disc and Cover 3) Damaged or worn disc contact surface of pres- 2) Tighten the flywheel attaching bolts to the sure plate. specified torque. 4) Loose strap plate setting bolt. NOTE: 5) Worn diaphragm sliding surface. Tighten flywheel installing bolts gradually.

  • Page 251: Operating Cylinder

    2-10 SERVICE PROCEDURE [W5A0] 5. Operating Cylinder 4) Install clutch cover on flywheel and tighten bolts 5. Operating Cylinder to the specified torque. A: REMOVAL AND INSTALLATION NOTE: ¼ When installing the clutch cover on the flywheel, 1) Remove air chamber. position the clutch cover so that there is a gap of 120°...

  • Page 252: Master Cylinder And Reservoir Tank

    2-10 SERVICE PROCEDURE [W6A0] 6. Master Cylinder and Reservoir Tank 6. Master Cylinder and 4) Installation is in the reverse order of removal. NOTE: Reservoir Tank Before installing operating cylinder, apply grease A: REMOVAL (SUNLIGHT 2: P/N 003602010) to contact point of release lever and operating cylinder.
  • Page 253 2-10 SERVICE PROCEDURE [W6E0] 6. Master Cylinder and Reservoir Tank 2) Remove oil seal. D: ASSEMBLY 1) Apply a coat of grease to the contacting sur- faces of the push rod and piston before installation. Grease: SILICONE GREASE G40M (Part No. 004404003) S2M0916A 3) Move the cylinder boot backward.

  • Page 254: Brake Fluid

    2-10 SERVICE PROCEDURE [W7A0] 7. Brake Fluid 7. Brake Fluid 2) Connect push rod of master cylinder to clutch pedal, and install clevis pin and snap pin. A: REPLACEMENT NOTE: CAUTION: Apply grease to clevis pin. ¼ The FMVSS No. 116, fresh DOT3 or 4 brake fluid must be used.

  • Page 255: Clutch System

    2-10 DIAGNOSTICS [K100] 1. Clutch System 1. Clutch System Symptom Possible cause Corrective 1. Clutch slippage. (a) Clutch facing smeared by oil Replace. It is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms ¼...
  • Page 256 2-10 DIAGNOSTICS [K100] 1. Clutch System Symptom Possible cause Corrective 5. Clutch grabs. (a) Grease or oil on facing Replace clutch disc. When starting the vehicle with the clutch (b) Deteriorated cushioning spring Replace clutch disc. partially engaged, the clutch engages (c) Worn or rusted spline of clutch disc Take off rust, apply grease or replace suddenly and the vehicle jumps instead...
  • Page 257 2-10 DIAGNOSTICS [K1A0] 1. Clutch System A: DIAGNOSTIC DIAGRAM OF CLUTCH DRAG B2M1012B...
  • Page 258 2-10 DIAGNOSTICS MEMO:...

  • Page 259: Engine And Transmission Mounting System

    ENGINE AND TRANSMISSION 2-11 MOUNTING SYSTEM Page COMPONENT PARTS ..................2 Engine Mounting ..................2 Transmission Mounting ................3 SERVICE PROCEDURE ...................5 Engine ......................5 Transmission .....................18...

  • Page 260: Component Parts

    2-11 COMPONENT PARTS [C100] 1. Engine Mounting 1. Engine Mounting B2M1024A (1) Front cushion rubber Tightening torque: N·m (kg-m, ft-lb) (2) Front engine mounting bracket 26 ± 7 (2.7 ± 0.7, 19.5 ± 5.1) 41 ± 10 (4.2 ± 1.0, 30 ± 7) 83 ±...

  • Page 261: Transmission Mounting

    2-11 COMPONENT PARTS [C2A0] 2. Transmission Mounting 2. Transmission Mounting A: MT MODEL S2M0196A (1) Pitching stopper (8) Center crossmember Tightening torque: N·m (kg-m, ft-lb) (2) Spacer (9) Rear plate 33 ± 5 (3.4 ± 0.5, 24.6 ± 3.6) (3) Cushion C (10) Front crossmember 37 ±...
  • Page 262 2-11 COMPONENT PARTS [C2B0] 2. Transmission Mounting B: AT MODEL S2M0197A (1) Pitching stopper Tightening torque: N·m (kg-m, ft-lb) (2) Rear cushion rubber 37 ± 10 (3.8 ± 1.0, 27 ± 7) (3) Crossmember 38 ± 15 (3.9 ± 1.5, 28 ± 11) (4) Stopper 49 ±...
  • Page 263 2-11 SERVICE PROCEDURE [W1B0] 1. Engine 1. Engine 5) Remove under cover. A: GENERAL PRECAUTION (1) Remove or install engine 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 264 2-11 SERVICE PROCEDURE [W1B0] 1. Engine (3) Lower the vehicle. (1) Place and connect the attachment hose to (4) Disconnect ATF cooler hoses from radiator. the refrigerant recycle system. (AT vehicles) (2) Collect refrigerant from A/C system. (3) Disconnect A/C flexible hoses from A/C compressor.

  • Page 265: Service Procedure

    2-11 SERVICE PROCEDURE [W1B0] 1. Engine 10) Remove chamber stay. 11) Disconnect connectors, cables and hoses. ¼ MT vehicles S2M0900 ¼ AT vehicles S2M0901...
  • Page 266 2-11 SERVICE PROCEDURE [W1B0] 1. Engine (1) Disconnect the following connectors and cables. S2M0887E (1) Front oxygen sensor connector (5) A/C compressor connectors (2) Engine harness connectors (With A/C) (3) Engine ground terminal (6) Accelerator cable (4) Alternator connector and termi- (7) Cruise control cable (With cruise control)
  • Page 267 2-11 SERVICE PROCEDURE [W1B0] 1. Engine B2M1979B B2M0019F S2M0201B B2M1291F B2M2295B...
  • Page 268 2-11 SERVICE PROCEDURE [W1B0] 1. Engine (2) Disconnect the following hoses. S2M0887F (1) Brake booster vacuum hose (2) Heater inlet and outlet hose (3) Cruise control vacuum hose...
  • Page 269 2-11 SERVICE PROCEDURE [W1B0] 1. Engine B2M2776A S2M0902A S2M0203A 12) Remove power steering pump from bracket. (3) Remove bolts which install power steering (1) Loosen lock bolt and slider bolt, and remove pump from bracket. front side V-belt. S2M0086 G2M0286 (4) Place power steering pump on the right side (2) Remove power steering pump bracket.
  • Page 270 2-11 SERVICE PROCEDURE [W1B0] 1. Engine 13) Remove front exhaust pipe and center (5) Remove bolt which installs center exhaust exhaust pipe. pipe on hunger bracket. (1) Lift-up the vehicle. (2) Disconnect connector from rear oxygen sensor. S2M0206 (6) Take off front and center exhaust pipes. CAUTION: B2M0335 Exhaust pipe will drop when all bolts are...
  • Page 271 2-11 SERVICE PROCEDURE [W1B0] 1. Engine (3) Remove bolts which hold torque converter 19) Support engine with a lifting device and wire to drive plate. ropes. S2M0207 G2M0297 (4) Remove other bolts while rotating the 20) Support transmission with a garage jack. engine using ST.
  • Page 272 2-11 SERVICE PROCEDURE [W1C0] 1. Engine (4) Slowly move engine away from engine 2) Tighten bolts which hold upper side of transmis- compartment. sion to engine. CAUTION: Tightening torque: 50 ± 4 N·m (5.1 ± 0.4 kg-m, 36.9 ± 2.9 ft-lb) Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc.
  • Page 273 2-11 SERVICE PROCEDURE [W1C0] 1. Engine (2) Tighten other bolts while rotating the engine (3) Install front side V-belt, and adjust it. by using ST. <Ref. to 1-5 [G200].> ST 499977100 CRANK PULLEY WRENCH CAUTION: Be careful not to drop bolts into torque con- verter housing.
  • Page 274 2-11 SERVICE PROCEDURE [W1C0] 1. Engine (2) Heater inlet and outlet hoses 16) Install A/C flexible hoses. (With A/C) (3) Brake booster vacuum hose <Ref. to 4-7 [W16A0].> (4) Cruise control vacuum hose CAUTION: 13) Connect the following connectors. Use new O-rings. (1) Engine ground terminal Tightening torque: (2) Engine harness connectors...
  • Page 275 2-11 SERVICE PROCEDURE [W1C0] 1. Engine (3) Install radiator brackets and tighten bolts. (7) Connect radiator fan motor connector. Tightening torque: 12 ± 3 N·m (1.2 ± 0.3 kg-m, 8.7 ± 2.2 ft-lb) S2M0893 (8) Install V-belt covers. S2M0905 (4) Connect radiator inlet hose. S2M0896 18) Install battery in the vehicle, and connect cables.

  • Page 276: Transmission

    2-11 SERVICE PROCEDURE [W2A0] 2. Transmission 2. Transmission 4) Remove chamber stay. ¼ MT vehicles A: GENERAL PRECAUTION (1) Remove or install transmission in an area where chain hoists, lifting devices, etc. are avail- able 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 277 2-11 SERVICE PROCEDURE [W2B0] 2. Transmission (4) Neutral position switch connector (MT 7) Remove pitching stopper. vehicles) (5) Back-up light switch connector vehicles) S2M0126 8) Separate torque converter from drive plate. (AT vehicles) B2M0337 (1) Remove service hole plug. (6) Vehicle speed sensor (MT vehicles) (2) Remove bolts which hold torque converter to drive plate.
  • Page 278 2-11 SERVICE PROCEDURE [W2B0] 2. Transmission 10) Remove operating cylinder. (MT vehicles) (2) Remove nuts which install front exhaust pipe onto engine. B2M1179B S2M0205 11) Set ST. ST 41099AA020 ENGINE SUPPORT ASSY (3) Disconnect connector from rear oxygen sensor. NOTE: Also is available Part No.
  • Page 279 2-11 SERVICE PROCEDURE [W2B0] 2. Transmission (7) Remove rear exhaust pipe. 14) Drain ATF to remove ATF drain plug. (AT vehicles) CAUTION: When removing exhaust pipes, be careful each exhaust pipe does not drop out. B3M1036A Front differential oil drain plug S2M0158 ATF drain plug (8) Remove heat shield cover of rear exhaust...
  • Page 280 2-11 SERVICE PROCEDURE [W2B0] 2. Transmission (3) Remove bolts which hold center bearing 18) Remove shift selector cable. (AT vehicles) onto body. (1) Disconnect shift selector cable from selec- tor lever. CAUTION: (2) Remove cable bracket from body. Be careful not to drop propeller shaft. S3M0013A S2M0219 19) Remove bolts which install stabilizer clamps...
  • Page 281 2-11 SERVICE PROCEDURE [W2B0] 2. Transmission (2) Lower transverse link. 23) Remove transmission rear crossmember. ¼ MT vehicles (3) Remove spring pins and separate front drive shafts from each side of the transmission. CAUTION: Discard removing spring pin. Replace with a new one.
  • Page 282 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission ¼ AT vehicles C: INSTALLATION Tightening torque: 1) Install ST to torque converter clutch case. (AT T1: 37 ± 10 N·m (3.8 ± 1.0 kg-m, 27 ± 7 ft-lb) vehicles) T2: 69 ± 15 N·m (7.0 ± 1.5 kg-m, 51 ± 11 ft-lb) ST 498277200 STOPPER SET S2M0221A H2M1961A...
  • Page 283 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission 7) Install torque converter to drive plate. (AT 10) Install pitching stopper. vehicles) Tightening torque: (1) Tighten bolts which hold torque converter to T1: 57 ± 10 N·m (5.8 ± 1.0 kg-m, 42 ± 7 ft-lb) drive plate.
  • Page 284 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission 12) Install stabilizer clamps onto front crossmem- 15) Install ATF level gauge guide, and ATF cooler ber. hoses onto pipe. (AT vehicles) Tightening torque: 25 ± 4 N·m (2.5 ± 0.4 kg-m, 18.1 ± 2.9 ft-lb) S2M0909A 16) Install propeller shaft.
  • Page 285 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission (1) Install heat shield cover. (5) Install center exhaust pipe to rear exhaust pipe. Tightening torque: 18 ± 5 N·m (1.8 ± 0.5 kg-m, 13.0 ± 3.6 ft-lb) S2M0215 (2) Install rear exhaust pipe to muffler. Tightening torque: B2M0055 48 ±...
  • Page 286 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission 18) Install ATF level gauge. (AT vehicles) (5) Neutral position switch and back-up light switch connector (MT vehicles) S2M0908A B2M0337 19) Connect the following connectors. (1) Transmission harness connectors 20) Install starter. (1) Install starter onto transmission case, and connect connectors and terminals.
  • Page 287 2-11 SERVICE PROCEDURE [W2C0] 2. Transmission 21) Install chamber stay. 22) Install air intake duct and chamber. ¼ MT vehicles S2M0906 S2M0900 23) Connect battery ground cable. ¼ AT vehicles 24) Fill ATF. (AT vehicles) <Ref. to 3-2 [S1A0].> 25) Check selector lever operation. (AT vehicles) <Ref.
  • Page 288 2-11 SERVICE PROCEDURE MEMO:...

  • Page 289: Manual Transmission And Differential

    MANUAL TRANSMISSION AND DIFFERENTIAL Page SPECIFICATIONS AND SERVICE DATA............2 Manual Transmission and Differential............2 Transmission Gear Oil ................2 Transmission Case Assembly ..............2 Drive Pinion Assembly ................3 Reverse Idler Gear..................3 Shifter Fork and Rod...................4 Transfer Case....................4 Extension Assembly ..................5 Front Differential..................5 COMPONENT PARTS ..................6 Transmission Case..................6 Drive Pinion Assembly ................7 Main Shaft Assembly...................8...

  • Page 290: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Manual Transmission and Differential 1. Manual Transmission and Differential Model Item 2500 cc Type 5-forward speeds with synchromesh and 1-reverse 3.545 2.111 1.448 Transmission gear ratio 1.088 0.780 Reverse 3.333 Type of gear Hypoid Front reduction Final gear...

  • Page 291: Drive Pinion Assembly

    SPECIFICATIONS AND SERVICE DATA [S500] 5. Reverse Idler Gear 4. Drive Pinion Assembly 5. Reverse Idler Gear Preload adjustment of thrust bearing Adjustment of reverse idler gear position Starting torque Reverse idler gear to transmission case (LH) wall 0.3 — 0.8 N·m (0.03 — 0.08 kg-m, 0.2 — 0.6 clearance ft-lb) 6.0 —...

  • Page 292: Shifter Fork And Rod

    SPECIFICATIONS AND SERVICE DATA [S600] 6. Shifter Fork and Rod 6. Shifter Fork and Rod 7. Transfer Case Select suitable shifter forks so that both coupling Neutral position adjustment sleeve and reverse driven gear are positioned in Adjustment shim the center of their synchromesh mechanisms. Rod end clearance Part No.

  • Page 293: Extension Assembly

    SPECIFICATIONS AND SERVICE DATA [S900] 9. Front Differential 8. Extension Assembly 9. Front Differential Thrust washer (52 × 61 × t) to ball bearing side Bevel gear to pinion backlash 0.13 — 0.18 mm (0.0051 — 0.0071 in) clearance 0.05 — 0.30 mm (0.0020 — 0.0118 in) Washer (38.1 ×...

  • Page 294: Component Parts

    COMPONENT PARTS [C100] 1. Transmission Case 1. Transmission Case B3M1356A (1) Transmission case ASSY (7) Speedometer shaft (13) Clip (2) Gasket (8) Snap ring (Outer) (3) Drain plug (9) Oil seal Tightening torque: N·m (kg-m, ft-lb) 44 ± 3 (4.5 ± 0.3, 32.5 ± 2.2) (4) Snap ring (Outer) (10) Oil level gauge (5) Speedometer driven gear...

  • Page 295: Drive Pinion Assembly

    COMPONENT PARTS [C200] 2. Drive Pinion Assembly 2. Drive Pinion Assembly S3M0423A (1) Drive pinion shaft (15) Baulk ring (29) Lock nut (2) Roller bearing (16) 1st-2nd synchronizer hub (30) Washer (3) Washer (17) Insert key (31) Thrust bearing (4) Thrust bearing (18) Reverse driven gear (32) Differential bevel gear sleeve (5) Needle bearing...

  • Page 296: Main Shaft Assembly

    COMPONENT PARTS [C300] 3. Main Shaft Assembly 3. Main Shaft Assembly S3M0446A (1) Oil seal (14) 4th gear thrust washer (27) Ball bearing (2) Needle bearing (15) Ball bearing (28) Synchro cone stopper (3) Transmission main shaft (16) 5th gear thrust washer (29) Snap ring (4) Needle bearing (17) 5th needle bearing race...

  • Page 297: Shifter Fork And Shifter Rod

    COMPONENT PARTS [C400] 4. Shifter Fork and Shifter Rod 4. Shifter Fork and Shifter Rod S3M0427A (1) Shifter arm (9) Ball (17) Snap ring (Outer) (2) 5th shifter fork (10) 3rd-4th fork rod (18) Reverse fork rod arm (3) Straight pin (11) Interlock plunger (19) Reverse shifter lever (4) Washer...

  • Page 298: Transfer Case And Extension

    COMPONENT PARTS [C500] 5. Transfer Case and Extension 5. Transfer Case and Extension B3M1358A (1) Oil guide (16) O-ring (31) Ball bearing (2) Gasket (17) Adjusting select shim (32) Gasket (3) Transfer case (18) Reverse check sleeve (33) Extension (4) Ball (19) Gasket (34) Oil seal (5) Reverse accent spring...

  • Page 299: Front Differential

    COMPONENT PARTS [C600] 6. Front Differential 6. Front Differential B3M0521B (1) Drive pinion shaft (8) Snap ring (Outer) (15) Retainer lock plate (2) Hypoid driven gear (9) Roller bearing (3) Pinion shaft (10) Differential case Tightening torque: N·m (kg-m, ft-lb) 25 ±...
  • Page 300 SERVICE PROCEDURE [W1A0] 1. General ¼ Bearings that fail to turn smoothly or make 1. General abnormal noise when turned after gear oil lubrica- A: PRECAUTIONS tion. ¼ The ball bearing on the rear side of the drive 1) Clean oil, grease, dirt and dust from transmis- pinion shaft should be checked for smooth rotation sion.

  • Page 301: Service Procedure

    SERVICE PROCEDURE [W1B0] 1. General ¼ When the ring inner surface is abnormally or 9) Differential gear partially worn down. Repair or replace the differential gear in the follow- ¼ If the gap between the end faces of the ring and ing cases: ¼...

  • Page 302: Transmission Case

    SERVICE PROCEDURE [W2A1] 2. Transmission Case 2. Transmission Case A: DISASSEMBLY 1. SEPARATION OF TRANSMISSION S3M0190A (1) Operating cylinder (5) Main shaft rear plate (9) Main shaft ASSY (2) Release lever (6) Bolt (10) Front differential (3) Release bearing (7) Transmission case (4) Release lever sealing (8) Drive pinion ASSY 1) Remove clutch release lever.
  • Page 303 SERVICE PROCEDURE [W2A1] 2. Transmission Case 4) Remove main shaft rear plate. 7) Remove drive pinion shaft assembly from left side transmission case. NOTE: Use a hammer handle, etc. to remove if too tight. S3M0100B 5) Put vinyl tape around splines of right and left axle drive shafts to prevent damage to oil seals.
  • Page 304 SERVICE PROCEDURE [W2A2] 2. Transmission Case 2. TRANSMISSION CASE S3M0432A (1) Straight pin (7) 3rd-4th fork rod (13) Reverse idler gear (2) 5th shifter fork (8) 3rd-4th shifter fork (14) Washer (3) Checking ball plug (9) 1st-2nd fork rod (15) Snap ring (4) Gasket (10) 1st-2nd shifter fork (16) Reverse fork rod arm...
  • Page 305 SERVICE PROCEDURE [W2A2] 2. Transmission Case 3) Drive out straight pin, and pull out 3-4 fork rod 6) Remove outer snap ring, and pull out reverse and shifter fork. shifter rod arm from reverse fork rod. Then take out ball, spring and interlock plunger from rod. NOTE: And then remove rod.
  • Page 306 SERVICE PROCEDURE [W2B1] 2. Transmission Case B: ASSEMBLY 1. TRANSMISSION CASE S3M0432C (1) Reverse shifter lever (9) Checking ball spring (17) 3rd-4th shifter fork (2) Reverse idler gear (10) Washer (18) 5th shifter fork (3) Reverse idler gear shaft (11) Checking ball plug (4) Straight pin (12) Washer Tightening torque: N·m (kg-m, ft-lb)
  • Page 307 SERVICE PROCEDURE [W2B1] 2. Transmission Case 2) Install reverse shifter lever, reverse idler gear 5) Move reverse shifter rod toward REV side. and reverse idler gear shaft, and secure with Adjust clearance between reverse idler gear and straight pin. transmission case wall, using reverse shifter lever. Clearance A: NOTE: 6.0 —...
  • Page 308 SERVICE PROCEDURE [W2B1] 2. Transmission Case 8) Align the holes in rod and fork, and drive 13) Position balls, checking ball springs and gas- straight pin (6 × 22) into these holes using ST. kets into 3-4 and 1-2 rod holes, and install plugs. ST 398791700 STRAIGHT PIN REMOVER CAUTION: CAUTION:...
  • Page 309 SERVICE PROCEDURE [W2B2] 2. Transmission Case 2. COMBINATION OF TRANSMISSION CASE S3M0190B (1) Differential ASSY (8) Differential side retainer Tightening torque: N·m (kg-m, ft-lb) (2) Drive pinion shim (9) O-ring 25 (2.5, 18) (3) Drive pinion ASSY (10) Oil seal 29 ±...
  • Page 310 SERVICE PROCEDURE [W2B2] 2. Transmission Case 3) Inspection and adjustment of ST 7) Select one to three shims from the next table for the value determined as described above and take NOTE: a shim thickness which is closest to the said value. ¼...
  • Page 311 SERVICE PROCEDURE [W2B2] 2. Transmission Case NOTE: 1st driven gear to reverse driven gear ¼ Align the end face of seal with surface A of left Clearance (a): 9.5 mm (0.374 in) side transmission main case when installing oil Reverse driven gear to 2nd driven gear seal.
  • Page 312 SERVICE PROCEDURE [W2B2] 2. Transmission Case 5th driven gear to coupling sleeve 14) Tighten 17 bolts with bracket, clip, etc. as Clearance (a): 9.3 mm (0.366 in) shown in the figure. NOTE: ¼ Insert bolts from the bottom and tighten nuts at the top.
  • Page 313 SERVICE PROCEDURE [W2B2] 2. Transmission Case 16) Backlash adjustment of hypoid gear and pre- 19) Remove weight and screw in retainer without load adjustment of roller bearing O-ring on the upper side and stop at the point where slight resistance is felt. NOTE: NOTE: Support drive pinion assembly with ST.
  • Page 314 SERVICE PROCEDURE [W2B2] 2. Transmission Case ¼ Tooth contact is correct. 24) Set ST1 and ST2. Insert the needle through transmission oil drain plug hole so that the needle comes in contact with the tooth surface at a right angle and check the backlash. ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE ST3 498255400 PLATE...
  • Page 315 SERVICE PROCEDURE [W2B2] 2. Transmission Case ¼ The drive pinion shim selected before is too 27) Selecting of main shaft rear plate thick. Reduce its thickness. Using ST, measure the amount (A) of ball bearing protrusion from transmission main case surface and select the proper plate in the following table: ST 498147000 DEPTH GAUGE NOTE:...

  • Page 316: Drive Pinion Assembly

    SERVICE PROCEDURE [W3A1] 3. Drive Pinion Assembly 3) Remove roller bearing and washer (33 × 50 × 3. Drive Pinion Assembly 5) using ST and press. A: DISASSEMBLY CAUTION: Do not reuse roller bearing. 1. DRIVE PINION SHAFT ST 498077000 REMOVER 1) Straighten lock nut at staked portion.
  • Page 317 SERVICE PROCEDURE [W3B1] 3. Drive Pinion Assembly 4) Remove roller bearing (42 × 74 × 40), 3rd-4th 7) Remove 1st driven gear, 2nd gear bushing, driven gear using ST1 and ST2. gear and hub using ST1 and ST2. ST1 499757002 SNAP RING PRESS NOTE: ST2 899714110 REMOVER Replace gear and hub if necessary.
  • Page 318 SERVICE PROCEDURE [W3B2] 3. Drive Pinion Assembly 3) Install 2nd driven gear bushing onto driven shaft using ST1, ST2 and press. ST1 499277200 INSTALLER ST2 499587000 INSTALLER CAUTION: ¼ Attach a cloth to the end of driven shaft to prevent damage. ¼...
  • Page 319 SERVICE PROCEDURE [W3B2] 3. Drive Pinion Assembly 5) After installing key on driven shaft, install 3rd- 7) Position woodruff key in groove on the rear of 4th driven gear using ST and press. driven shaft. Install 5th driven gear onto drive shaft using ST and press.
  • Page 320 SERVICE PROCEDURE [W3B3] 3. Drive Pinion Assembly 3. DRIVE PINION SHAFT 4) Install drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting 1) Install roller bearing onto drive pinion. washer No. 1 and differential bevel gear sleeve in NOTE: that order.
  • Page 321 SERVICE PROCEDURE [W3C1] 3. Drive Pinion Assembly C: ADJUSTMENT 3) After removing ST2, measure starting torque using torque driver. 1. THRUST BEARING PRELOAD ST1 899884100 HOLDER ST3 899988608 SOCKET WRENCH (27) 1) After completing the preceding steps 1) through 3), select adjusting washer No. 2 so that dimension Starting torque: (H) is zero through visual check.

  • Page 322: Main Shaft Assembly

    SERVICE PROCEDURE [W4A0] 4. Main Shaft Assembly 4. Main Shaft Assembly 5) If specified starting torque range cannot be obtained when a No. 1 adjusting washer is used, A: DISASSEMBLY then select a suitable No. 2 adjusting washer from those listed in the following table. Repeat steps 1) 1) Put vinyl tape around main shaft splines to pro- through 4) to adjust starting torque.
  • Page 323 SERVICE PROCEDURE [W4A0] 4. Main Shaft Assembly 4) Remove snap ring and synchro cone stopper 6) Using ST1 and ST2, remove the rest of parts. from 5th-Rev sleeve and hub assembly. NOTE: Replace sleeve and hub with new ones. Do not attempt to disassemble because they must engage specified point.
  • Page 324 SERVICE PROCEDURE [W4B0] 4. Main Shaft Assembly 4) Install baulk ring, needle bearing (32 × 30 × B: ASSEMBLY 25.7), 4th drive gear and 4th gear thrust washer to 1) Assemble sleeve and hub assembly for 3rd-4th transmission main shaft. and, 5th synchronizing.
  • Page 325 SERVICE PROCEDURE [W4B0] 4. Main Shaft Assembly 6) Using ST1 and ST2, install the 5th gear thrust 9) Install synchro cone stopper and snap ring to washer and 5th needle bearing race onto the rear 5th-Rev sleeve and hub assembly. section of transmission main shaft.

  • Page 326: Transfer Case And Extension

    SERVICE PROCEDURE [W5A0] 5. Transfer Case and Extension 5. Transfer Case and Extension 2) Remove transfer driven gear and center differ- ential as a set. A: REMOVAL 1) Remove back-up light switch and neutral switch. B3M1375A 3) Remove thrust washer. 2.
  • Page 327 SERVICE PROCEDURE [W5B4] 5. Transfer Case and Extension 3. EXTENSION 4. REVERSE CHECK SLEEVE 1) Remove transfer drive gear assembly. 1) Using a standard screwdriver, remove snap ring. NOTE: Replace snap ring with a new one if deformed or weakened. B3M1380 2) Remove shift bracket.
  • Page 328 SERVICE PROCEDURE [W5B5] 5. Transfer Case and Extension 5. TRANSFER DRIVEN GEAR 2) Using ST, install oil seal to extension case. CAUTION: 1) Using ST, remove ball bearing from transfer Use new oil seal. driven gear. ST 498077000 REMOVER ST 498057300 INSTALLER 3) Install shift bracket to extension case.
  • Page 329 SERVICE PROCEDURE [W5C3] 5. Transfer Case and Extension 2. REVERSE CHECK SLEEVE CAUTION: ¼ Make sure the cutout section of reverse 1) Install return spring (1st-2nd), return spring cap, accent shaft is aligned with the opening in reverse accent shaft, check cam, return spring and reverse check sleeve.
  • Page 330 SERVICE PROCEDURE [W5C4] 5. Transfer Case and Extension 2) Install reverse check sleeve assembly to trans- 2) Install ball bearing to transfer driven gear. fer case. CAUTION: Tightening torque: Do not apply pressure in excess of 10 kN (1 ton, 6.4 ±...
  • Page 331 SERVICE PROCEDURE [W5C5] 5. Transfer Case and Extension 3) Measure depth “X”. 8) Measure depth “T” between extension case and transfer drive gear. ST 398643600 GAUGE B3M1406A 4) Calculate space “Y” using the following equa- B3M1395A tion: Y = X − W + 0.24 mm (0.0094 in) [Thickness of gasket] 9) Calculate space “U”...
  • Page 332 SERVICE PROCEDURE [W5D0] 5. Transfer Case and Extension D: INSTALLATION E: ADJUSTMENT 1) Install shifter arm to transfer case. 1. 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 333: Front Differential

    SERVICE PROCEDURE [W6A0] 6. Front Differential 6. Front Differential 2. REVERSE CHECK PLATE ADJUSTMENT A: DISASSEMBLY 1) Shift shifter arm to “5th” and then to reverse to see if reverse check mechanism operates properly. 1) Remove right and left snap rings from 2) Also check to see if arm returns to neutral when differential, and then remove two axle drive shafts.
  • Page 334 SERVICE PROCEDURE [W6B0] 6. Front Differential 4) Pull out pinion shaft, and remove differential 2) Measure backlash between bevel gear and pin- bevel pinion and gear and washer. ion. If it is not within specifications, install a suitable washer to adjust it. NOTE: Be sure the pinion gear tooth contacts adjacent gear teeth during measurement.
  • Page 335 SERVICE PROCEDURE [W6B0] 6. Front Differential 4) Install roller bearing (40 × 80 × 19.75) to differ- 6) Position drive axle shaft in differential case and ential case. hold it with outer snap ring (28). Using a thickness gauge, measure clearance between the shaft and CAUTION: case is within specifications.

  • Page 336: Center Differential

    SERVICE PROCEDURE [W7A0] 7. Center Differential 7. Center Differential 2) Install ball bearing to center differential assem- bly. A: DISASSEMBLY AND ASSEMBLY CAUTION: 1) Remove ball bearing using ST. Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

  • Page 337: Manual Transmission

    DIAGNOSTICS [K100] 1. Manual Transmission 1. Manual Transmission Symptom Possible cause Remedy 1. Gears are difficult to intermesh. (a) Worn, damaged or burred chamfer of Replace. NOTE: internal spline of sleeve and reverse The cause for difficulty in shifting gears driven gear can be classified into two kinds: one is malfunction of the gear shift system and...

  • Page 338: Differential

    DIAGNOSTICS [K200] 2. Differential 2. Differential Symptom Possible cause Remedy 1. Broken differential (case, gear, (a) Insufficient or improper oil Disassemble differential and replace bro- bearing, etc.) ken components and at the same time NOTE: check other components for any trouble, Abnormal noise will develop and finally it and replace if necessary.

  • Page 339: Automatic Transmission And Differential

    AUTOMATIC TRANSMISSION AND DIFFERENTIAL Page SPECIFICATIONS AND SERVICE DATA............2 Automatic Transmission and Differential ...........2 COMPONENT PARTS ..................15 Torque Converter Clutch and Case ............15 Oil Pump....................16 Transmission Case and Control Device............18 Control Valve and Harness Routing............20 High Clutch and Reverse Clutch...............21 Planetary Gear and 2-4 Brake ..............22 Low Clutch and Low &...
  • Page 340 SPECIFICATIONS AND SERVICE DATA [S1A0] 1. Automatic Transmission and Differential 1. Automatic Transmission and Differential A: SPECIFICATIONS Type Symmetric, 3 element, single stage, 2 phase torque converter Stall torque ratio 1.9 — 2.1 Torque converter Nominal diameter 246 mm (9.69 in) clutch Stall speed (at sea level) 2,200 —...
  • Page 341 SPECIFICATIONS AND SERVICE DATA [S1A0] 1. Automatic Transmission and Differential Transmission in neutral, output mem- P (Park) ber immovable, and engine start possible Transmission in R (Reverse) reverse for backing Transmission in N (Neutral) neutral, and engine start possible Automatic gear change D (Drive) ←...

  • Page 342: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S1A0] 1. Automatic Transmission and Differential Final gear ratio Front drive 4.444 (40/9) Lubrication oil Final reduction H3M1235A Oil capacity Front drive (1.3 US qt, 1.1 Imp qt) ATF cooling system Radiation capacity 4.630 kW (3,981 kcal/h, 15,797 BTU/h)
  • Page 343 SPECIFICATIONS AND SERVICE DATA [S1A0] 1. Automatic Transmission and Differential MEMO:...
  • Page 344 SPECIFICATIONS AND SERVICE DATA [S1B0] 1. Automatic Transmission and Differential B: ADJUSTING PARTS B3M1015A...
  • Page 345 SPECIFICATIONS AND SERVICE DATA [S1B0] 1. Automatic Transmission and Differential Part Name Part Number Dimension mm (in) Application 15008AA060 11.37 — 11.38 (0.4476 — 0.4480) Adjusting side clearance of oil Rotor (Oil pump) 15008AA070 11.38 — 11.39 (0.4480 — 0.4484) pump 15008AA080 11.39 —...
  • Page 346 SPECIFICATIONS AND SERVICE DATA [S1B0] 1. Automatic Transmission and Differential Part Name Part Number Dimension mm (in) Application 31451AA050 0.150 (0.0059) 31451AA060 0.175 (0.0069) 31451AA070 0.200 (0.0079) Drive pinion shim Adjusting drive pinion shim 31451AA080 0.225 (0.0089) 31451AA090 0.250 (0.0098) 31451AA100 0.275 (0.0108)
  • Page 347 SPECIFICATIONS AND SERVICE DATA [S1B0] 1. Automatic Transmission and Differential MEMO:...
  • Page 348 SPECIFICATIONS AND SERVICE DATA [S1C0] 1. Automatic Transmission and Differential C: LOCATION AND INSTALLING DIRECTION OF THRUST NEEDLE BEARING S3M0220A...
  • Page 349 SPECIFICATIONS AND SERVICE DATA [S1D1] 1. Automatic Transmission and Differential Inside diameter Outside diameter Dimension Part Name Part Number Application mm (in) mm (in) mm (in) 806528050 4.11 (0.1618) 806528060 4.3 (0.169) Thrust needle 806528070 4.5 (0.177) Adjusting total 28.5 (1.122) 48 (1.89) bearing 806528080...
  • Page 350 SPECIFICATIONS AND SERVICE DATA [S1D2] 1. Automatic Transmission and Differential 2. TRANSMISSION CASE (LH SIDE) B3M0988A (1) Oil cooler outlet pressure (3) Oil cooler inlet pressure (5) 2-4 brake pressure (2) Low & reverse brake pressure (4) Low clutch pressure 3.
  • Page 351 SPECIFICATIONS AND SERVICE DATA [S1D5] 1. Automatic Transmission and Differential 4. OIL PUMP COVER B3M0990A (1) High clutch pressure (3) Front lubricating hole (5) Reverse clutch pressure (2) Lock-up release pressure (4) Lock-up apply pressure 5. OIL PUMP HOUSING B3M0991A (1) Oil pump outlet pressure (4) High clutch pressure (7) Reverse clutch pressure...
  • Page 352 SPECIFICATIONS AND SERVICE DATA [S1D6] 1. Automatic Transmission and Differential 6. TRANSMISSION CASE B3M0992A (1) Oil pump inlet port (5) Lock-up release pressure (9) Pilot pressure (2) Reverse clutch pressure (6) High clutch pressure (10) Low & reverse brake pressure (3) Oil pump outlet port (7) Oil cooler outlet pressure (11) Low clutch pressure...

  • Page 353: Component Parts

    COMPONENT PARTS [C100] 1. Torque Converter Clutch and Case 1. Torque Converter Clutch and Case B3M0918A (1) Pitching stopper bracket (9) Oil drain pipe Tightening torque: N·m (kg-m, ft-lb) (2) O-ring (10) Input shaft 18 ± 5 (1.8 ± 0.5, 13.0 ± 3.6) (3) Differential oil level gauge (11) O-ring 41 ±...

  • Page 354: Oil Pump

    COMPONENT PARTS [C200] 2. Oil Pump 2. Oil Pump B3M0876A (1) Oil pump rotor (12) O-ring Tightening torque: N·m (kg-m, ft-lb) (2) Oil pump cover (13) Test plug 7 ± 1 (0.7 ± 0.1, 5.1 ± 0.7) (3) Seal ring (14) Stud bolt 13 ±...
  • Page 355 COMPONENT PARTS [C200] 2. Oil Pump MEMO:...

  • Page 356: Transmission Case And Control Device

    COMPONENT PARTS [C300] 3. Transmission Case and Control Device 3. Transmission Case and Control Device B3M0878A...
  • Page 357 COMPONENT PARTS [C300] 3. Transmission Case and Control Device (1) Oil level gauge (20) Oil filter stud bolt (39) Nipple (2) Oil charger pipe (21) Drain plug (40) Air breather hose (3) O-ring (22) Gasket (41) Transmission case (4) Transfer valve plate (23) Oil pan (42) Plate ASSY (5) Transfer valve ASSY...

  • Page 358: Control Valve And Harness Routing

    COMPONENT PARTS [C400] 4. Control Valve and Harness Routing 4. Control Valve and Harness Routing B3M0928A (1) Stay (12) Accumulator spring (24) ATF temperature sensor (2) Transmission harness (13) Side plate (25) Duty solenoid A (Line pressure) (3) O-ring (14) Separate plate (26) Low clutch timing solenoid (4) O-ring (15) Middle valve body...

  • Page 359: High Clutch And Reverse Clutch

    COMPONENT PARTS [C500] 5. High Clutch and Reverse Clutch 5. High Clutch and Reverse Clutch S3M0221A (1) High clutch drum (8) Spring retainer (15) Dish plate (2) Lip seal (9) Cover (16) Driven plate (3) Lathe cut seal ring (10) Snap ring (17) Drive plate (4) Reverse clutch piston (11) Driven plate...

  • Page 360: Planetary Gear And 2-4 Brake

    COMPONENT PARTS [C600] 6. Planetary Gear and 2-4 Brake 6. Planetary Gear and 2-4 Brake B3M1178A (1) Thrust needle bearing (10) Washer (19) Snap ring (2) Front sun gear (11) Thrust needle bearing (20) Spring retainer (3) Thrust needle bearing (12) Rear internal gear (21) 2-4 brake piston (4) Snap ring...

  • Page 361: Low Clutch And Low & Reverse Brake

    COMPONENT PARTS [C700] 7. Low Clutch and Low & Reverse Brake 7. Low Clutch and Low & Reverse Brake B3M1017A (1) Retaining plate (12) Needle bearing (23) Snap ring (2) Drive plate (13) Snap ring (Inner) (24) Retaining plate (3) Driven plate (14) One-way clutch (25) Leaf spring (4) Dish plate...

  • Page 362: Reduction Gear

    COMPONENT PARTS [C800] 8. Reduction Gear 8. Reduction Gear S3M0222A (1) Seal ring (6) Snap ring Tightening torque: N·m (kg-m, ft-lb) (2) Ball bearing (7) Ball bearing 100 ± 5 (10.2 ± 0.5, 73.8 ± 3.6) (3) Reduction drive gear (8) Reduction driven gear (4) Reduction drive shaft (9) Washer...

  • Page 363: Differential Case

    COMPONENT PARTS [C900] 9. Differential Case 9. Differential Case B3M1019A (1) Crown gear (8) O-ring (15) Differential bevel gear (2) Pinion shaft (9) Differential side retainer (3) Differential case (RH) (10) Circlip Tightening torque: N·m (kg-m, ft-lb) 25 ± 2 (2.5 ± 0.2, 18.1 ± 1.4) (4) Straight pin (11) Lock plate 62 ±...

  • Page 364: Transfer And Extension

    COMPONENT PARTS [C1000] 10. Transfer and Extension 10. Transfer and Extension H3M1811A (1) Thrust needle bearing (11) Transfer clutch piston (21) Test plug (2) Needle bearing (12) Rear drive shaft (22) O-ring (3) Snap ring (13) Ball bearing (23) Clip (4) Pressure plate (14) Seal ring (5) Drive plate...
  • Page 365 SERVICE PROCEDURE [W1B1] 1. General 1. General the parts immediately after the cleaning without exposure to the air for a while. Besides in case A: PRECAUTION of washing rubber parts, perform the job quickly not to dip them into the washing fluid for long When disassembling or assembling the automatic time.
  • Page 366 SERVICE PROCEDURE [W1B2] 1. General range (above the center between upper and lower 3. OIL LEAKAGE marks). When the transmission is hot, the level It is difficult to accurately determine the precise should be above the center of upper and lower position of a oil leak, since the surrounding area marks, and when it is cold, the level should be also becomes wet with oil.

  • Page 367: Service Procedure

    SERVICE PROCEDURE [W1B3] 1. General 3) Oil pump housing 5) Extension case ¼ Oil pump housing (Defective casting) ¼ Extension case (Defective casting) ¼ O-ring on the vehicle speed sensor 1 (Rear) ¼ O-ring on the test plugs ¼ Rear drive shaft oil seal ¼...

  • Page 368: Inhibitor Switch

    SERVICE PROCEDURE [W2A0] 2. Inhibitor Switch 2. Inhibitor Switch 4) Check if there is continuity at equal points when the select lever is turned 1.5° in both directions A: INSPECTION from the N range. If there is continuity in one direction and the conti- When driving condition or starter motor operation nuity in the other or if there is continuity at unequal is erroneous, first check the shift linkage for...
  • Page 369 SERVICE PROCEDURE [W2D0] 2. Inhibitor Switch C: REMOVAL 7) Remove bolts. 1) Move select lever to neutral position. 2) Remove air intake chamber and duct. <Ref. to 2-7 [W1A0].> and <Ref. to 2-7 [W2A0].> 3) Disconnect inhibitor switch connector. B3M1031A 8) Move range select lever to parking position (left side).
  • Page 370 SERVICE PROCEDURE [W2D0] 2. Inhibitor Switch 2) Move range select lever to neutral position. 7) Install front exhaust pipe. <Ref. to 2-9 [W1B0].> 8) Connect inhibitor switch connector. 3) Using ST, tighten bolts of inhibitor switch. <Ref. to 3-2 [W2B0].> ST 499267300 STOPPER PIN B3M1028A 9) Install air intake chamber and duct.

  • Page 371: Sensor (In Transmission)

    SERVICE PROCEDURE [W3A0] 3. Sensor (in transmission) 3. Sensor (in transmission) 3) Check each sensor, solenoid and ground sys- tem for short circuits. A: INSPECTION 1) Remove air intake chamber and duct. 2) Disconnect transmission connector. S3M0039A S2M0212A B3M1035A (A) Torque converter turbine speed (E) Duty solenoid A (Line pressure) (J) Shift solenoid 2 sensor...

  • Page 372: Shift Solenoid, Duty Solenoid And Valve

    SERVICE PROCEDURE [W3A1] 4. Shift Solenoid, Duty Solenoid and Valve 1. EVALUATION 4. Shift Solenoid, Duty Solenoid and Valve NOTE: If part is faulty, its resistance value will be different A: REMOVAL from the standard value indicated above. 1) Clean transmission exterior. Part name Terminal Resistance (Ω)
  • Page 373 SERVICE PROCEDURE [W4B0] 4. Shift Solenoid, Duty Solenoid and Valve 5) Remove control valve body. B: INSTALLATION CAUTION: 1) Install 7 solenoids and ATF temperature sensor. When removing control valve body, be careful Tightening torque: not to interfere with transfer duty solenoid C T: 8 ±...
  • Page 374 SERVICE PROCEDURE [W4B0] 4. Shift Solenoid, Duty Solenoid and Valve 3) Install valve body to transmission case. 4) Connect harness connectors at 8 places. (1) Temporarily tighten the valve body on the Connect connectors of same color, and secure transmission case. connectors to valve body using clips.

  • Page 375: Duty Solenoid C And Transfer Valve Body

    SERVICE PROCEDURE [W5A0] 5. Duty Solenoid C and Transfer Valve Body 7) Add ATF and check level. 5. Duty Solenoid C and Transfer Valve Body A: REMOVAL 1) Remove air intake duct and chamber. <Ref. to 2-7 [W1A0].> and <Ref. to 2-7 [W2A0].> B3M1020A S6M0007 2) Remove pitching stopper.
  • Page 376 SERVICE PROCEDURE [W5A0] 5. Duty Solenoid C and Transfer Valve Body 4) Remove front exhaust pipe. 7) Remove vehicle speed sensor 1 (rear). Disconnect oxygen sensor connector, and remove front and center exhaust pipe. <Ref. to 2-9 [W1A0].> B3M1043 8) Remove extension and gasket. (1) Remove select cable nut.
  • Page 377 SERVICE PROCEDURE [W5B0] 5. Duty Solenoid C and Transfer Valve Body 9) Disconnect duty solenoid C (transfer) connec- 2) Install extension case to transmission case. tor. (1) Tighten 11 bolts. 10) Remove duty solenoid C (transfer) and trans- Tightening torque: fer valve body.
  • Page 378 SERVICE PROCEDURE [W5B0] 5. Duty Solenoid C and Transfer Valve Body 5) Install propeller shaft. 9) Install pitching stopper. <Ref. to 3-4 [W1E0].> Tightening torque: T1: 49 ± 5 N·m (5.0 ± 0.5 kg-m, 36.2 ± 3.6 ft-lb) NOTE: T2: 57 ± 10 N·m (5.8 ± 1.0 kg-m, 42 ± 7 ft-lb) Align matching marks on propeller shaft and rear differential coupling.
  • Page 379 SERVICE PROCEDURE [W5B0] 5. Duty Solenoid C and Transfer Valve Body MEMO:...

  • Page 380: Road Test

    SERVICE PROCEDURE [W6A1] 6. Road Test 6. Road Test 2. SHIFT PATTERNS Check “kick-down”. A: INSPECTION ← ← ← D range: 1st → → → 1. GENERAL PRECAUTION ← ← 3rd ← 4th 3 range: 1st → → Road tests should be conducted to properly diag- 2 range: 2nd ←...

  • Page 381: Stall Test

    SERVICE PROCEDURE [W7A1] 7. Stall Test G3M0322 3. ENGINE BRAKE OPERATION 7. Stall Test Engine brake operation: A: MEASUREMENT D range → 4th gear 3 range → 3rd gear 1. GENERAL INFORMATION 2 range → 2nd gear The stall test is of extreme importance in diagnos- 1 range →...
  • Page 382 SERVICE PROCEDURE [W7A2] 7. Stall Test 2. TEST METHODS 6) When the engine speed is stabilized, read that speed quickly and release the accelerator pedal. 1) Preparations before test: 7) Shift the select lever to Neutral, and cool down (1) Check that throttle valve opens fully. the engine by idling it for more than one minute.
  • Page 383 SERVICE PROCEDURE [W7A3] 7. Stall Test MEMO:...

  • Page 384: Time Lag Test

    SERVICE PROCEDURE [W8A1] 8. Time Lag Test 8. Time Lag Test 9. Line Pressure Test A: INSPECTION A: MEASUREMENT 1. GENERAL INFORMATION 1. GENERAL INFORMATION If the shift lever is shifted while the engine is idling, If the clutch or the brake shows a sign of slippage there will be a certain time elapse or lag before the or shifting sensation is not correct, the line pres- shock can be felt.
  • Page 385 4) Check for duty ratio changes by opening and closing throttle valve using Subaru Select Monitor. 1) Temporarily attach the ST to a suitable place in (1) Insert the cartridge to Subaru Select Moni- the driver’s compartment, remove the blind plug tor.

  • Page 386: Transfer Clutch Pressure Test

    SERVICE PROCEDURE [W10A1] 10. Transfer Clutch Pressure Test 10. Transfer Clutch Pressure 2. EVALUATION Test NOTE: If oil pressure is not produced or if it does not A: MEASUREMENT change in the AWD mode, the duty solenoid C or transfer valve assembly may be malfunctioning. If 1.

  • Page 387: Overall Transmission

    SERVICE PROCEDURE [W11B1] 11. Overall Transmission 11. Overall Transmission A: SECTIONS THAT CAN BE DETACHED/ASSEMBLED H3M1250A B: DISASSEMBLY 2) Remove the drain plug, and drain differential oil. Tighten the plug temporarily after draining. 1. EXTERNAL PARTS 3) Remove the drain plug, and drain automatic transmission fluid (ATF).
  • Page 388 SERVICE PROCEDURE [W11B1] 11. Overall Transmission 4) Extract the torque converter clutch assembly. 7) Remove harnesses from bracket. NOTE: ¼ Extract the torque converter clutch horizontally. Be careful not to scratch the bushing inside the oil pump shaft. ¼ Note that oil pump shaft also comes out. B3M1054A Transmission harness Inhibitor switch harness...
  • Page 389 SERVICE PROCEDURE [W11B3] 11. Overall Transmission 10) Remove the oil cooler inlet and outlet pipes. (2) Separation of transmission case and exten- sion case sections CAUTION: When removing outlet pipes, be careful not to lose balls and springs used with retaining screws.
  • Page 390 SERVICE PROCEDURE [W11B3] 11. Overall Transmission (3) Using the ST, extract the reduction drive 3) Remove the parking pawl, return spring and gear. shaft. ST 499737100 PULLER SET B3M1062A B3M0953A 4) Loosen the taper roller bearing mounting bolts. 2) Remove transfer valve body and duty solenoid C (Transfer).
  • Page 391 SERVICE PROCEDURE [W11B3] 11. Overall Transmission 6) Remove the oil pan. 9) Remove vehicle speed sensor 2 (front) and torque converter turbine speed sensor. NOTE: Use a scraper to remove oil pan. B3M1066A B3M1065A 10) Remove transmission harness. 7) Disconnect the harness connectors for the solenoids, duty solenoids, ATF temperature sensor and the ground cord.
  • Page 392 SERVICE PROCEDURE [W11B3] 11. Overall Transmission 13) Take out the high clutch and reverse clutch 16) Pull out leaf spring. assembly. CAUTION: CAUTION: Be careful not to bend leaf spring during Be careful not to lose thrust needle bearing. removal. NOTE: Remove it while pressing down on lower leaf spring.
  • Page 393 SERVICE PROCEDURE [W11B3] 11. Overall Transmission 19) Take out the thrust needle bearing, planetary 23) Separate 2-4 brake piston and piston retainer. gear assembly and the low clutch assembly. B3M1080A B3M1076A 24) Pull out leaf spring. 20) Remove snap ring. CAUTION: Be careful not to bend leaf spring during removal.
  • Page 394 SERVICE PROCEDURE [W11B3] 11. Overall Transmission 27) Turning the case upside down, take out the 30) Pull off the straight pin of manual lever. one-way clutch inner race, retainer and wave spring. NOTE: After loosening all socket bolts, place the side of the transmission case on the floor.
  • Page 395 SERVICE PROCEDURE [W11B5] 11. Overall Transmission 34) Remove parking support. 4) Remove the differential case assembly. CAUTION: ¼ Remove the seal pipe if it is attached. (Reus- ing is not allowed.) ¼ Be careful not to damage the retainer mount- ing hole of the torque converter clutch case and the speedometer gears.
  • Page 396 SERVICE PROCEDURE [W11C1] 11. Overall Transmission C: ASSEMBLY OF OVERALL 5) Wrap vinyl tape around the splined portion of the axle shaft. TRANSMISSION 1. TORQUE CONVERTER CLUTCH CASE SECTION 1) Check the appearance of each component and clean. CAUTION: Make sure each part is free of harmful cuts, damage and other faults.
  • Page 397 SERVICE PROCEDURE [W11C1] 11. Overall Transmission (2) Tighten four bolts to secure the roller bear- (5) Tighten the LH retainer until contact is felt ing. while rotating the shaft. Then loosen the RH retainer. Keep tightening the LH retainer and Tightening torque: loosening the RH retainer until the pinion shaft 41 ±...
  • Page 398 SERVICE PROCEDURE [W11C1] 11. Overall Transmission (7) Turn the drive pinion several rotations with (8) Apply red lead evenly to the surfaces of ST1 and check to see if the backlash is within three or four teeth of the crown gear. Rotate the the standard value with ST2, ST3, ST4 and drive pinion in the forward and reverse direc- ST5.
  • Page 399 SERVICE PROCEDURE [W11C1] 11. Overall Transmission Checking item Contact pattern Corrective action Tooth contact Tooth contact pattern is slightly shifted toward to under no-load rotation. — [When loaded, contact pattern moves toward heel.] B3M0317A Face contact This may cause noise and chipping at Increase thickness of drive pinion height Backlash is too large.
  • Page 400 SERVICE PROCEDURE [W11C1] 11. Overall Transmission (9) If tooth contact is correct, mark the retainer 11) Attach the O-ring to the oil seal retainer with position and loosen it. After fitting the O-ring, vaseline. Install the seal to the oil pump housing screw in the retainer to the marked position.
  • Page 401 SERVICE PROCEDURE [W11C2] 11. Overall Transmission 13) Apply vaseline to the groove on the oil pump 2) Install parking support to transmission case. cover, and install two (R) seal rings and two (H) Tightening torque: seal rings. 25 ± 2 N·m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-lb) NOTE: ¼...
  • Page 402 SERVICE PROCEDURE [W11C2] 11. Overall Transmission 5) Insert range select lever, and tighten bolt. 8) Install the low and reverse piston. Tightening torque: CAUTION: 6 ± 1 N·m (0.6 ± 0.1 kg-m, 4.3 ± 0.7 ft-lb) ¼ Be careful not to tilt the piston when install- ing.
  • Page 403 SERVICE PROCEDURE [W11C2] 11. Overall Transmission (1) Using a press and ST1, install the needle NOTE: Place transmission case with the front facing up. bearing to the inner race. ST1 398497701 INSTALLER 12) Installation of the low & reverse brake: (1) Install dish plate, driven plates, drive plates, NOTE: and a retaining plate, and secure with a snap...
  • Page 404 SERVICE PROCEDURE [W11C2] 11. Overall Transmission 16) Install 2-4 brake piston and retainer to trans- Available retaining plates mission case. Part No. Thickness mm (in) CAUTION: 31667AA320 4.2 (0.165) Align the hole in the 2-4 brake seal of transmis- 31667AA330 4.5 (0.177) 31667AA340 4.8 (0.189)
  • Page 405 SERVICE PROCEDURE [W11C2] 11. Overall Transmission 19) Install planetary gear and low clutch assembly (3) After all 2-4 brake component parts have to transmission case. been installed, blow in air intermittently and con- Install carefully while rotating the low clutch and firm the operation of the brake.
  • Page 406 SERVICE PROCEDURE [W11C2] 11. Overall Transmission 21) Install leaf spring of 2-4 brake. 24) Install the high clutch hub and thrust needle bearing. NOTE: Attach the thrust needle bearing to the hub with Be careful not to mistake the location of the leaf vaseline and install the hub by correctly engaging spring to be inserted.
  • Page 407 SERVICE PROCEDURE [W11C3] 11. Overall Transmission (2) Using ST, measure the distance from the oil (2) After correctly installing the gasket to the pump housing mating surface to the top surface case mating surface, carefully install the oil of the oil pump cover with thrust needle bearing. pump housing assembly.
  • Page 408 SERVICE PROCEDURE [W11C4] 11. Overall Transmission 2) Install the torque converter clutch case assem- (2) Temporarily tighten the valve body on the bly to the transmission case assembly, and secure transmission case. with six bolts and four nuts. CAUTION: CAUTION: Be sure to engage the manual valve with the When installing, be careful not to damage the manual plate during installation.
  • Page 409 SERVICE PROCEDURE [W11C5] 11. Overall Transmission 3) Connect all connectors. (3) Install the oil pan to the transmission case assembly, and secure with 20 bolts. NOTE: Tighten the bolts evenly. Tightening torque: 4.9 ± 0.5 N·m (0.50 ± 0.05 kg-m, 3.6 ± 0.4 ft-lb) B2M2263C Lock-up duty solenoid (Blue) Low clutch timing solenoid (Gray)
  • Page 410 SERVICE PROCEDURE [W11C6] 11. Overall Transmission 2) Install the transfer clutch assembly to the case. 3) Install transfer valve plate, valve body and duty solenoid C (transfer) to transmission case. CAUTION: Be careful not to damage the seal rings. CAUTION: ¼...
  • Page 411 SERVICE PROCEDURE [W11C6] 11. Overall Transmission 6) Using a plastic hammer, install reduction driven (3) Calculation equation: gear assembly, and tighten drive pinion lock nut. NOTE: NOTE: Add 0.05 mm (0.0020 in) and 0.20 mm (0.0079 in) ¼ Be sure to use a new lock nut and a washer. thick shims to area “T”.
  • Page 412 SERVICE PROCEDURE [W11C7] 11. Overall Transmission 9) Install the vehicle speed sensor 1 (rear). (1) With the select lever set to “N” adjust the inhibitor switch so that the hole of range select Tightening torque: lever is aligned with the inhibitor switch hole 7 ±...
  • Page 413 SERVICE PROCEDURE [W11C7] 11. Overall Transmission 5) Install the oil cooler outlet pipe. 9) Tighten the drain plugs. Tightening torque: CAUTION: Be sure to use a new aluminum washer. Diff. 44 ± 3 N·m (4.5 ± 0.3 kg-m, 32.5 ± 2.2 ft-lb) Tightening torque: 34 ±...
  • Page 414 SERVICE PROCEDURE [W11C7] 11. Overall Transmission (3) Rotate the shaft lightly by hand to engage the splines securely. Dimension A: 2.7 — 2.9 mm (0.106 — 0.114 in) B3M1116A 12) Fill ATF and differential gear oil. NOTE: After filling oil, insert the oil level gauge into the oil inlet.

  • Page 415: Reduction Drive Gear Assembly

    SERVICE PROCEDURE [W12C0] 12. Reduction Drive Gear Assembly 12. Reduction Drive Gear 3) Attach two seal rings. NOTE: Assembly To make subsequent assembly easier, apply vase- A: DISASSEMBLY line to the grooves of the shaft and to the exterior of the seal ring. 1) Take out the seal rings.

  • Page 416: Reduction Driven Gear

    SERVICE PROCEDURE [W13A0] 13. Reduction Driven Gear 13. Reduction Driven Gear 2) Install snap ring to reduction driven gear. A: DISASSEMBLY 1) Remove snap ring from reduction driven gear. B3M1125A B3M1125A 2) Using ST, remove ball bearing from reduction driven gear. ST 498077600 REMOVER B3M1127A B: INSPECTION...
  • Page 417 SERVICE PROCEDURE [W13C0] 13. Reduction Driven Gear MEMO:...

  • Page 418: Control Valve Body

    SERVICE PROCEDURE [W14A0] 14. Control Valve Body 14. Control Valve Body be also handled carefully, as springs may jump out of place when the parts are disassembled or A: PRECAUTION removed. Extreme care should be taken so as not to drop valves on the floor. Before assembling, the The control valve is composed of parts which are parts and valves should be dipped in a container accurately machined to a high degree and should...
  • Page 419 SERVICE PROCEDURE [W14A0] 14. Control Valve Body Wire dia. Average dia. Free length Part name Effective turn mm (in) mm (in) mm (in) 2-4 brake accumulator B spring 1.6 (0.063) 9.3 (0.366) 14.6 47.0 (1.850) (Inlet) 2-4 brake accumulator B spring (Out- 2.3 (0.091) 13.7 (0.539) 8.79...
  • Page 420 SERVICE PROCEDURE [W14B0] 14. Control Valve Body B: DISASSEMBLY CAUTION: ¼ Do not lose the ten (10) steel balls contained 1) Remove oil strainer from lower control valve in the upper valve body and middle valve body. body. ¼ Do not lose strainers contained in the lower valve body.
  • Page 421 SERVICE PROCEDURE [W14D0] 14. Control Valve Body D: ASSEMBLY 4) Install three filters to lower valve body. CAUTION: 1) Install accumulator pistons, valve springs and Pay attention to the location of filters. steel balls to upper valve body. CAUTION: Insert steel balls in their proper positions. B3M1136A 5) Install lower separate plate to lower valve body.

  • Page 422: Oil Pump Assembly

    SERVICE PROCEDURE [W15A0] 15. Oil Pump Assembly 7) Tighten bolts. 15. Oil Pump Assembly Tightening torque: A: DISASSEMBLY 8 ± 1 N·m (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft-lb) 1) Remove the oil seal retainer. Also remove the O-ring and oil seal (air breather). B3M1130A Short bolts B3M1094A...
  • Page 423 SERVICE PROCEDURE [W15C0] 15. Oil Pump Assembly 5) Remove the inner and outer rotor. (3) If depth and/or side clearances are outside specifications, replace rotor assembly. Oil pump rotor assembly Part No. Thickness mm (in) 15008AA060 11.37 — 11.38 (0.4476 — 0.4480) 15008AA070 11.38 —...

  • Page 424: Drive Pinion Shaft

    SERVICE PROCEDURE [W16A0] 16. Drive Pinion Shaft ¼ Install the oil seal retainer and seal rings. After 16. Drive Pinion Shaft adjusting the drive pinion backlash and tooth con- A: DISASSEMBLY tact. 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.
  • Page 425 SERVICE PROCEDURE [W16C0] 16. Drive Pinion Shaft C: ASSEMBLY 4) Tighten the lock washer and lock nut with ST1, ST2 and ST3. 1) Measure dimension “A” of the drive pinion ST1 498937110 HOLDER shaft. ST2 499787100 WRENCH ST 398643600 GAUGE ST3 499787500 ADAPTER Actual tightening torque: 116 ±...
  • Page 426 SERVICE PROCEDURE [W16C0] 16. Drive Pinion Shaft 7) Measure dimension “B” of the drive pinion shaft. ST 398643600 GAUGE B3M0590D 8) Determine the thickness “t” (mm) of the drive pinion shim. NOTE: The number of shims must be three or less. t = 6.5 ±...

  • Page 427: High Clutch And Reverse Clutch

    SERVICE PROCEDURE [W17A0] 17. High Clutch and Reverse Clutch 17. High Clutch and Reverse Clutch A: DISASSEMBLY S3M0221A (1) Reverse clutch drum (8) Spring retainer (15) Dish plate (2) Lip seal (9) Cover (16) Driven plate (3) Lathe cut seal ring (10) Snap ring (17) Drive plate (4) Reverse clutch piston...
  • Page 428 SERVICE PROCEDURE [W17B0] 17. High Clutch and Reverse Clutch 1) Remove the snap ring, and take out the retain- 5) Remove seal rings and lip seal from high clutch piston and reverse clutch piston. ing plate, drive plates, driven plates. B3M1146A B3M1142A 2) Remove snap ring, and take out the retaining...
  • Page 429 SERVICE PROCEDURE [W17C0] 17. High Clutch and Reverse Clutch C: ASSEMBLY S3M0221A (1) Reverse clutch drum (8) Spring retainer (15) Dish plate (2) Lip seal (9) Cover (16) Driven plate (3) Lathe cut seal ring (10) Snap ring (17) Drive plate (4) Reverse clutch piston (11) Driven plate (18) Retaining plate...
  • Page 430 SERVICE PROCEDURE [W17C0] 17. High Clutch and Reverse Clutch 1) Install seal rings and lip seal to high clutch pis- 5) Install ST to high clutch piston. ton and reverse clutch piston. ST 498437000 HIGH CLUTCH PISTON 2) Install high clutch piston to reverse clutch pis- GAUGE ton.
  • Page 431 SERVICE PROCEDURE [W17C0] 17. High Clutch and Reverse Clutch 10) Apply compressed air intermittently to check 12) If specified tolerance limits are exceeded, for operation. select a suitable high clutch retaining plate. High clutch retaining plate Part No. Thickness mm (in) 31567AA710 4.7 (0.185) 31567AA720...
  • Page 432 SERVICE PROCEDURE [W17C0] 17. High Clutch and Reverse Clutch 15) Measure the clearance between the retaining 16) If specified tolerance limits are exceeded, plate and snap ring. select a suitable high clutch retaining plate. CAUTION: Reverse clutch retaining plates Do not press down retaining plate during clear- Part No.

  • Page 433: Low Clutch Drum And Planetary Gear

    SERVICE PROCEDURE [W18A0] 18. Low Clutch Drum and Planetary Gear 18. Low Clutch Drum and Planetary Gear A: DISASSEMBLY B3M1155A (1) Snap ring (10) Washer (19) Low clutch piston (2) Front planetary carrier (11) Retaining plate (20) Lathe cut seal ring (3) Thrust needle bearing (12) Drive plate (21) Low clutch drum...
  • Page 434 SERVICE PROCEDURE [W18A0] 18. Low Clutch Drum and Planetary Gear 1) Remove snap ring from the low clutch drum. 5) Take out rear internal gear. B3M1156A B3M1160A 2) Take out front planetary carrier and thrust 6) Remove the snap ring from the low clutch drum. needle bearing from low clutch drum.
  • Page 435 SERVICE PROCEDURE [W18B0] 18. Low Clutch Drum and Planetary Gear 9) Install the one-way clutch inner race to the low clutch drum, and apply compressed air to remove the low clutch piston. B3M0960A 10) Remove the one-way clutch inner race. 11) Remove the one-way clutch after taking out the snap ring.
  • Page 436 SERVICE PROCEDURE [W18C0] 18. Low Clutch Drum and Planetary Gear C: ASSEMBLY B3M1155A (1) Snap ring (10) Washer (19) Low clutch piston (2) Front planetary carrier (11) Retaining plate (20) Lathe cut seal ring (3) Thrust needle bearing (12) Drive plate (21) Low clutch drum (4) Rear sun gear (13) Driven plate...
  • Page 437 SERVICE PROCEDURE [W18C0] 18. Low Clutch Drum and Planetary Gear 4) Install ST to low clutch drum. 7) Check the low clutch for operation. ST 498437100 LOW CLUTCH PISTON Set the one-way clutch inner race, and apply com- GUIDE pressed air for checking. B3M1167A B3M0960A 5) Set the cover on the piston with a press using...
  • Page 438 SERVICE PROCEDURE [W18C0] 18. Low Clutch Drum and Planetary Gear 9) Install washer to rear internal gear. 12) Install washer to rear planetary carrier. NOTE: Make sure washer tooth is inserted into hole on planetary carrier. B3M1170A 10) Install rear internal gear. B3M1172A 13) Install rear planetary carrier to low clutch drum.
  • Page 439 SERVICE PROCEDURE [W18C0] 18. Low Clutch Drum and Planetary Gear 15) Install rear sun gear. 18) Install snap ring to low clutch drum. NOTE: Pay attention to the orientation of the rear sun gear. B3M1156A 19) Install the needle bearing, and secure with the snap ring.

  • Page 440: Differential Case Assembly

    SERVICE PROCEDURE [W19A0] 19. Differential Case Assembly 19. Differential Case Assembly C: ASSEMBLY 1) Install the washer, differential bevel gear and A: DISASSEMBLY differential bevel pinion in the differential case 1) Using a press and ST, remove the taper roller (RH).

  • Page 441: Transfer Clutch

    SERVICE PROCEDURE [W20A0] 20. Transfer Clutch 4) Measurement of backlash (Selection of washer) 20. Transfer Clutch Measure the gear backlash with ST1 and ST2, and A: DISASSEMBLY insert ST2 through the access window of the case. ST1 498247001 MAGNET BASE 1) Remove the seal ring.
  • Page 442 SERVICE PROCEDURE [W20B0] 20. Transfer Clutch 4) Remove the snap ring with ST1, ST2 and ST3, 2) Install return spring to transfer piston. and take out the return spring and transfer clutch piston seal. ST1 399893600 PLIERS ST2 398673600 COMPRESSOR ST3 398623600 SEAT B3M1177A 3) Install transfer clutch piston seal.
  • Page 443 SERVICE PROCEDURE [W20C0] 20. Transfer Clutch 6) Using ST1 and ST2, install snap ring to rear 9) Check the clearance. drive shaft. NOTE: NOTE: Before measuring clearance, place the same thick- After installing snap ring, remove ST1 and ST2. ness of shim on both sides to prevent pressure plate from tilting.

  • Page 444: Transfer Valve Body

    SERVICE PROCEDURE [W21A0] 21. Transfer Valve Body 11) Coat the seal ring with vaseline, and install it 21. Transfer Valve Body in the seal ring groove of the shaft. A: DISASSEMBLY CAUTION: Do not expand the seal ring excessively when 1) Separate duty solenoid C (transfer) and trans- installing.

  • Page 445: Transmission Control Module

    SERVICE PROCEDURE [W22B0] 22. Transmission Control Module 22. Transmission Control 2) Install TCM to steering support beam. Tightening torque: Module 7.4 ± 2.0 N·m (0.75 ± 0.2 kg-m, 5.4 ± 1.4 ft-lb) A: REMOVAL 1) Disconnect battery ground cable. B3M0443L Transmission control module Pedal bracket G6M0095...

  • Page 446: Dropping Resistor

    SERVICE PROCEDURE [W23A0] 23. Dropping Resistor 23. Dropping Resistor 5) Installation is in the reverse order of removal. Tightening torque: A: REMOVAL AND INSTALLATION 6.4 ± 0.5 N·m (0.65 ± 0.05 kg-m, 4.7 ± 0.4 ft-lb) 1) Disconnect battery ground cable. B3M1408A G6M0095 2) Remove air intake duct.

  • Page 447: Transmission Control System

    TRANSMISSION CONTROL SYSTEM Page COMPONENT PARTS ..................2 Gear Shift Lever ..................2 Select Lever ....................3 SERVICE PROCEDURE ...................4 Gear Shift Lever ..................4 Select Lever ....................7...

  • Page 448: Component Parts

    COMPONENT PARTS [C100] 1. Gear Shift Lever 1. Gear Shift Lever B3M0607B (1) Gear shift knob (11) Bush (Shift lever) Tightening torque: N·m (kg-m, ft-lb) (2) Console boot (12) Cushion rubber 4.4 ± 1.5 (0.45 ± 0.15, 3.3 ± 1.1) (3) Boot plate (13) Bush (Stay rear) 5 (0.51, 3.7)

  • Page 449: Select Lever

    COMPONENT PARTS [C200] 2. Select Lever 2. Select Lever S3M0015A (1) Button A (11) Selector lever upper (21) Shift-lock solenoid (2) Button B (12) Rod (22) Lock arm (3) Spring (button) (13) Indicator light bulb (23) “P” position switch (4) Grip (14) Retainer spring Tightening torque: N·m (kg-m, ft-lb) (5) Indicator cover...
  • Page 450 SERVICE PROCEDURE [W1A0] 1. Gear Shift Lever 1. Gear Shift Lever 6) Remove gearshift lever. A: REMOVAL 1) Remove console box. <Ref. to 5-4 [W1A0].> 2) Remove boot plate from the body. G3M0683 7) Remove the exhaust cover and remove cush- ion rubber from the body.

  • Page 451: Service Procedure

    SERVICE PROCEDURE [W1D0] 1. Gear Shift Lever 3) Remove snap ring, then disconnect gearshift C: INSPECTION lever from stay. Check each parts (Bush, cushion, spacer, boot, 4) Remove boot from gearshift lever. spring, stay and rod etc.) for deformation, damage and wear.
  • Page 452 SERVICE PROCEDURE [W1E0] 1. Gear Shift Lever 3) Mount each parts (Boot, O-ring, bush and 8) Insert the rod into the boot hole. spacer) on the gearshift lever. 9) Connect rod to gearshift lever. CAUTION: Tightening torque: 12 ± 3 N·m (1.2 ± 0.3 kg-m, 8.7 ± 2.2 ft-lb) ¼...

  • Page 453: Select Lever

    SERVICE PROCEDURE [W2A0] 2. Select Lever 5) Connect rod to the joint. 2. Select Lever Tightening torque: A: REMOVAL 18 ± 5 N·m (1.84 ± 0.51 kg-m, 13.3 ± 3.7 ft-lb) 1) Remove the cable. (1) Prior to removal, set lever to “N” position. (2) Remove front exhaust pipe.
  • Page 454 SERVICE PROCEDURE [W2B0] 2. Select Lever 2) Remove console box. <Ref. to 5-4 [W1A0].> 4) Remove shift-lock solenoid and “P” position 3) Disconnect the connectors, then remove the six switch. screws to take out the selector lever assembly from the body. S3M0018A 5) Remove cap and clip, then extract pin.
  • Page 455 SERVICE PROCEDURE [W2E0] 2. Select Lever E: INSTALLATION 9) Adjust the inner cable length. (1) Put connector into contact with nut (A). 1) Mount the selector lever onto the vehicle body. (2) Tighten nut (B). 2) Tighten the six bolts to install the selector lever Tightening torque: to the vehicle body, then connect connectors.
  • Page 456 SERVICE PROCEDURE [W2E0] 2. Select Lever (2) Ensure selector lever moves from “P” to any other position when the brake pedal is depressed with ignition key set at “ON” or “START”.

  • Page 457: Awd System

    AWD SYSTEM Page SPECIFICATIONS AND SERVICE DATA............2 Propeller Shaft.....................2 Rear Differential ..................3 COMPONENT PARTS ..................6 Propeller Shaft.....................6 Rear Differential Assembly................7 Rear Differential Mounting System .............8 SERVICE PROCEDURE ...................9 Propeller Shaft.....................9 Rear Differential ..................12 Rear Differential Front Member ..............30 DIAGNOSTICS....................31 Propeller Shaft...................31 Rear Differential ..................32...
  • Page 458 SPECIFICATIONS AND SERVICE DATA [S1A0] 1. Propeller Shaft 1. Propeller Shaft A: SPECIFICATIONS Front propeller shaft Joint- 580 (22.83) to-joint length: mm (in) 644 (25.35) Rear propeller shaft Joint- 712 (28.03) to-joint length: mm (in) 707 (27.83) Outside dia. of tube 63.5 (2.500) mm (in) 57.0 (2.244)
  • Page 459 SPECIFICATIONS AND SERVICE DATA [S2B0] 2. Rear Differential 2. Rear Differential A: SPECIFICATIONS Hypoid Type of gear Gear ratio (Num- 4.111 (37/9) 4.444 (40/9) ber of gear teeth) Oil capacity (0.8 US qt, 0.7 Imp qt) Rear differential GL-5 gear oil B: IDENTIFICATION When replacing a rear differential assembly, select the correct one according to the following table.
  • Page 460 SPECIFICATIONS AND SERVICE DATA [S2C0] 2. Rear Differential C: ADJUSTING PARTS 19.6 — 28.4 N New bearing (2.0 — 2.9 kg, 4.4 — 6.4 lb) Front and rear bearing preload at com- panion flange bolt hole 8.34 — 16.67 N Used bearing (0.85 —...

  • Page 461: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S2D0] 2. Rear Differential Part No. Thickness 383445201 0.75 — 0.80 mm (0.0295 — 0.0315 in) Side gear thrust washer 383445202 0.80 — 0.85 mm (0.0315 — 0.0335 in) 383445203 0.85 — 0.90 mm (0.0335 — 0.0354 in) Side bearing standard width —...

  • Page 462: Propeller Shaft

    COMPONENT PARTS [C100] 1. Propeller Shaft 1. Propeller Shaft S3M0022A (1) Propeller shaft (AT model) Tightening torque: N·m (kg-m, ft-lb) (2) Propeller shaft (MT model) 31 ± 8 (3.2 ± 0.8, 23.1 ± 5.8) (3) Rear differential 52 ± 5 (5.3 ± 0.5, 38.3 ± 3.6)

  • Page 463: Rear Differential Assembly

    COMPONENT PARTS [C200] 2. Rear Differential Assembly 2. Rear Differential Assembly B3M0130C (1) Pinion crown gear set (14) O-ring (28) Oil drain plug (2) Pinion height adjusting washer (15) Side bearing retainer shim (29) Rear cover (3) Rear bearing (16) Side bearing retainer (30) Differential case (4) Bearing preload adjusting spacer (17) Side oil seal...

  • Page 464: Rear Differential Mounting System

    COMPONENT PARTS [C300] 3. Rear Differential Mounting System 3. Rear Differential Mounting System S3M0023A (1) Plate (8) Dynamic damper (MT vehicles) Tightening torque: N·m (kg-m, ft-lb) (2) Crossmember (9) Differential mount front cover 32 ± 8 (3.3 ± 0.8, 23.9 ± 5.8) (3) Rear bushing (10) Differential front member 40 ±...
  • Page 465 SERVICE PROCEDURE [W1B0] 1. Propeller Shaft 1. Propeller Shaft 4) Center bearing free play While holding propeller shaft near center bearing A: ON-CAR SERVICE with your hand, move it up and down, and left and right to check for any abnormal bearing free play. 1) Joints and connections Check for any looseness of yoke flange connect- ing bolts and center bearing retaining bolts.
  • Page 466 SERVICE PROCEDURE [W1C0] 1. Propeller Shaft 6) Remove differential mount front cover. 9) Remove propeller shaft from transmission. CAUTION: ¼ Be sure not to damage oil seals and the fric- tional surface of sleeve yoke. ¼ Cover the center exhaust pipe with a cloth because ATF or oil may be spilled from transmission, when removing propeller shaft.

  • Page 467: Service Procedure

    SERVICE PROCEDURE [W1E0] 1. Propeller Shaft E: INSTALLATION 4) Install front exhaust cover. NOTE: Be careful not to damage rubber boot (installed at DOJ) while installing propeller shaft. 1) Insert sleeve yoke into transmission and attach center bearing to vehicle body. Tightening torque: 52 ±...
  • Page 468 SERVICE PROCEDURE [W2A1] 2. Rear Differential 2. Rear Differential 8) Extract companion flange with a puller. 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.
  • Page 469 SERVICE PROCEDURE [W2A2] 2. Rear Differential 12) Tighten self-locking nut within the specified 9) Remove the ABS sensor cable clamp from the torque range so that the turning resistance of com- trailing link. panion flange becomes the same as that before replacing oil seal.
  • Page 470 SERVICE PROCEDURE [W2A2] 2. Rear Differential 13) Remove the bolts which secure the front and 15) Secure rear drive shaft to rear crossmember rear lateral link to the rear housing. using wire. G3M0043 G3M1022 14) Remove the DOJ from the rear differential by 16) Remove side oil seal with ST.
  • Page 471 SERVICE PROCEDURE [W2B0] 2. Rear Differential 18) Install ST to rear differential. B: REMOVAL ST 28099PA090 SIDE OIL SEAL PROTEC- 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.

  • Page 472: Propeller Shaft

    SERVICE PROCEDURE [W2B0] 2. Rear Differential 10) Remove propeller shaft. 12) Remove clamps and bracket of parking brake cable. CAUTION: When removing propeller shaft, pay attention not to damage the sliding surfaces of rear drive shaft (extension) spline, oil seal and sleeve yoke.
  • Page 473 SERVICE PROCEDURE [W2C0] 2. Rear Differential 16) Support rear differential with transmission 19) While slowly lowering transmission jack, move jack. rear differential forward and remove front member and rear differential from body. G3M0055 G3M1029 17) Remove self-locking nuts connecting rear dif- ferential to rear crossmember.
  • Page 474 SERVICE PROCEDURE [W2C0] 2. Rear Differential 3) Remove the air breather cap. 6) Pull out differential assembly from differential carrier. NOTE: Do not attempt to replace the air breather cap CAUTION: unless necessary. Be careful not to hit the teeth against the case. G3M1033 G3M1035 4) Remove rear cover by loosening retaining...
  • Page 475 SERVICE PROCEDURE [W2C0] 2. Rear Differential 9) Remove crown gear by loosening crown gear 12) Hold companion flange with ST and remove bolts. drive pinion nut. ST 498427200 FLANGE WRENCH CAUTION: Further disassembling is not allowed. G3M1052 G3M0069 13) Extract the companion flange with a puller. 10) Drive out pinion shaft lock pin from crown gear side.
  • Page 476 SERVICE PROCEDURE [W2D0] 2. Rear Differential 15) Remove rear bearing cone from drive pinion 18) When replacing bearings, tap front bearing cup and rear bearing cup in this order out of case by supporting cone with ST. by using a brass bar. NOTE: Place the replacer so that its center-recessed side faces the pinion gear.
  • Page 477 SERVICE PROCEDURE [W2E0] 2. Rear Differential E: ASSEMBLY (2) Insert ST1 into case with pinion height adjusting washer and rear bearing cone fitted 1) Precautions for assembling onto it. ¼ Assemble in the reverse order of disassembling. CAUTION: ¼ Check and adjust each part during assembly. ¼...
  • Page 478 SERVICE PROCEDURE [W2E0] 2. Rear Differential NOTE: Front and rear bearing preload At this time, install a pinion height adjusting shim For new bearing: which is temporarily selected or the same as that 17.7 — 25.5 N (1.8 — 2.6 kg, 4.0 — 5.7 lb) used before.
  • Page 479 SERVICE PROCEDURE [W2E0] 2. Rear Differential 5) Insert drive pinion into differential carrier, install Pinion height adjusting shim the previously selected bearing preload adjusting Part No. Thickness mm (in) spacer and washer. 383495200 3.09 (0.1217) 383505200 3.12 (0.1228) 383515200 3.15 (0.1240) 383525200 3.18 (0.1252) 383535200...
  • Page 480 SERVICE PROCEDURE [W2E0] 2. Rear Differential 8) Fit a new oil seal with ST. CAUTION: ¼ Apply gear oil on both sides of the washer NOTE: and on the side gear shaft before installing. ¼ Press-fit until end of oil seal is 1 mm (0.04 in) ¼...
  • Page 481 SERVICE PROCEDURE [W2E0] 2. Rear Differential 13) Press side bearing cone onto differential case (4) Align arrow marked on differential carrier with ST1. with that marked on side retainer during instal- ST1 398487700 DRIFT lation. CAUTION: Be careful that side bearing outer race is not damaged by bearing roller.
  • Page 482 SERVICE PROCEDURE [W2E0] 2. Rear Differential (6) Measure the crown gear-to-drive pinion 16) Check the crown gear runout on its back backlash. surface, and make sure pinion and crown gear Set magnet base on differential carrier. Align rotate smoothly. contact point of dial gauge with tooth face of Limit of runout: crown gear, and move crown gear while holding Less than 0.05 mm (0.0020 in)
  • Page 483 SERVICE PROCEDURE [W2E0] 2. Rear Differential (1) Drive pinion height ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE T = To + N − (H x 0.01) − 0.20 (mm) Where: T = Thickness of pinion height adjusting shim (mm) To = Thickness of shim temporarily inserted (mm)
  • Page 484 SERVICE PROCEDURE [W2E0] 2. Rear Differential : Adjusting direction of drive pinion : Adjusting direction of crown gear 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.) B3M0317A...
  • Page 485 SERVICE PROCEDURE [W2F0] 2. Rear Differential 19) Install rear cover and tighten bolts to specified 5) After installation, fill differential carrier with gear oil to the upper plug level. torque. CAUTION: Tightening torque: 29 ± 5 N·m (3.0 ± 0.5 kg-m, 21.7 ± 3.6 ft-lb) Apply fluid packing to plug.

  • Page 486: Rear Differential Front Member

    SERVICE PROCEDURE [W3A0] 3. Rear Differential Front Member 3. Rear Differential Front 2) Insert DOJ of rear drive shaft into rear differen- tial. Member CAUTION: A: REMOVAL Before inserting, replace the differential side oil seal and the circlip at the end of the spline 1) Disconnect ground cable from battery.

  • Page 487: Propeller Shaft

    DIAGNOSTICS [K100] 1. Propeller Shaft 1. Propeller Shaft NOTE: Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper wheel alignment, etc. Symptom Possible cause Remedy 1. Vibration of propeller shaft (1) Worn or damaged universal joint/ Replace.

  • Page 488: Rear Differential

    DIAGNOSTICS [K200] 2. Rear Differential 2. Rear Differential Symptom Possible cause Remedy 1. Oil leakage (1) Worn, scratched, or incorrectly Repair or replace. seated front or side oil seal. Scored, battered, or excessively worn sliding sur- face of companion flange. (2) Clogged or damaged air breather.

  • Page 489: Suspension

    SUSPENSION Page SPECIFICATIONS AND SERVICE DATA............2 Stabilizer......................2 Wheel Alignment ..................2 COMPONENT PARTS ..................3 Front Suspension ..................3 Rear Suspension..................4 SERVICE PROCEDURE ...................5 On-car Service ....................5 Front Transverse Link ................12 Front Ball Joint ..................14 Front Strut ....................16 Front Stabilizer ..................20 Front Crossmember ..................21 Rear Trailing Link ..................23 Lateral Link....................27 Rear Strut ....................31...

  • Page 490: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Stabilizer 1. Stabilizer Bar dia. Model Front Rear 2500 cc 19 mm (0.75 in) 13 mm (0.51 in) 2. Wheel Alignment Camber (tolerance: ±0°30′) −0°15′ Caster (tolerance: ±0°45′) 2°35′ 0±3 mm (0±0.12 in) *1 Toe-in Front Each toe-in angle: 0°±0°09′...

  • Page 491: Component Parts

    COMPONENT PARTS [C100] 1. Front Suspension 1. Front Suspension S4M0084A (1) Front crossmember (17) Dust seal Tightening torque: N·m (kg-m, ft-lb) (2) Bolt ASSY (18) Strut mount 18 ± 5 (1.8 ± 0.5, 13.0 ± 3.6) (3) Housing (19) Spacer 20 ±...

  • Page 492: Rear Suspension

    COMPONENT PARTS [C200] 2. Rear Suspension 2. Rear Suspension S4M0085A (1) Stabilizer (15) Trailing link front bushing Tightening torque: N·m (kg-m, ft-lb) (2) Stabilizer bracket (16) Trailing link bracket 20 ± 6 (2.0 ± 0.6, 14.5 ± 4.3) (3) Stabilizer bushing (17) Cap (Protection) 25 ±...

  • Page 493: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. On-car Service 1. On-car Service A: WHEEL ALIGNMENT PROCEDURES Check, adjust and/or measure wheel alignment in accordance with procedures indicated in figure: B4M1088A...
  • Page 494 SERVICE PROCEDURE [W1B1] 1. On-car Service B: INSPECTION AND ADJUSTMENT 1. WHEEL ARCH HEIGHT (FRONT AND REAR) 1) Adjust tire pressure to specifications. 2) Set vehicle under “curb weight” conditions. (Empty luggage compartment, install spare tire, jack, service tools, and top up fuel tank.) 3) Set steering wheel in a wheel-forward position.
  • Page 495 SERVICE PROCEDURE [W1B2] 1. On-car Service ¼ Discard 2. CAMBER (FRONT AND REAR) loosened self-locking replace with a new one. ¼ Inspection 2) Turn camber adjusting bolt so that camber is 1) Place front wheel on turning radius gauge. set at the specification. Make sure ground contacting surfaces of front and NOTE: rear wheels are set at the same height.
  • Page 496 SERVICE PROCEDURE [W1B3] 1. On-car Service ¼ Adjustment 3. CASTER (FRONT) ¼ Inspection 1) Loosen the left and right side steering tie-rods lock nuts. 1) Place front wheel on turning radius gauge. 2) Turn the left and right tie rods equal amounts Make sure ground contacting surfaces of front and until the toe-in is at the specification.
  • Page 497 SERVICE PROCEDURE [W1B5] 1. On-car Service ¼ Adjustment 5. REAR WHEEL TOE-IN ¼ Inspection 1) Loosen self-locking nut on inner side of rear lateral link. 1) Using a toe-in gauge, measure rear wheel toe- CAUTION: ¼ When loosening or tightening adjusting bolt, Toe-in: hold bolt head and turn self-locking nut.
  • Page 498 SERVICE PROCEDURE [W1B6] 1. On-car Service 6. THRUST ANGLE 3) When left and right adjusting bolts are turned incrementally by one graduation in the same ¼ Inspection direction, the thrust angle of the AWD model will change approximately 10′ [“L” is almost equal to 1) Position vehicle on a level surface.
  • Page 499 SERVICE PROCEDURE [W1B7] 1. On-car Service Thrust angle: r = ( α − β )/2 7. STEERING ANGLE α: Right rear wheel toe angle ¼ Inspection β: Left rear wheel toe angle 1) Place vehicle on a turning radius gauge. 2) While depressing brake pedal, turn steering wheel fully to the left and right.

  • Page 500: Front Transverse Link

    SERVICE PROCEDURE [W2A0] 2. Front Transverse Link 2. Front Transverse Link A: REMOVAL S4M0089A (1) Front crossmember Tightening torque: N·m (kg-m, ft-lb) (2) Transverse link 29 ± 5 (3.0 ± 0.5, 21.7 ± 3.6) (3) Stabilizer link 44 ± 6 (4.5 ± 0.6, 32.5 ± 4.3) (4) Front stabilizer 98 ±...
  • Page 501 SERVICE PROCEDURE [W2E0] 2. Front Transverse Link 6) Remove bolt securing transverse link to cross- 4) If defective, replace with new one. member and extract transverse link from cross- D: ASSEMBLY member. 1. FRONT BUSHING To reassemble, reverse disassembly procedures. CAUTION: Install front bushing in correct direction, as shown in figure.

  • Page 502: Front Ball Joint

    SERVICE PROCEDURE [W3A0] 3. Front Ball Joint 4) Connect stabilizer link to transverse link, and 3. Front Ball Joint temporarily tighten bolts. A: REMOVAL CAUTION: Discard loosened self-locking nut and replace 1) Remove the wheel. with a new one. 2) Pull out the cotter pin from the ball stud, remove the castle nut, and extract the ball stud from the transverse link.
  • Page 503 SERVICE PROCEDURE [W3C0] 3. Front Ball Joint (3) Calculate plays from the following formula. C: INSTALLATION − 1) Install ball joint onto housing. (4) When plays are larger than the following value, replace with a new one. Torque (Bolt): 49 ± 10 N·m (5.0 ± 1.0 kg-m, 36 ± 7 ft-lb) FRONT BALL JOINT Specified play for replacement: CAUTION:...

  • Page 504: Front Strut

    SERVICE PROCEDURE [W4A0] 4. Front Strut 4. Front Strut A: REMOVAL B4M1085A (1) Dust seal (7) Helper Tightening torque: N·m (kg-m, ft-lb) (2) Strut mount (8) Coil spring 20 ± 6 (2.0 ± 0.6, 14.5 ± 4.3) (3) Spacer (9) Damper strut 54 ±...
  • Page 505 SERVICE PROCEDURE [W4C1] 4. Front Strut 7) Remove two bolts securing housing to strut. 2) Using ST, remove self-locking nut. ST 927760000 STRUT MOUNT SOCKET CAUTION: While holding head of adjusting bolt, loosen self-locking nut. 8) Remove the three nuts securing strut mount to body.
  • Page 506 SERVICE PROCEDURE [W4C2] 4. Front Strut 2. STRUT MOUNT 4) Using a coil spring compressor, compress the coil spring. Check rubber part wear, cracks NOTE: deterioration, and replace it with new one if defec- Make sure that the vertical installing direction of tive.
  • Page 507 SERVICE PROCEDURE [W4E0] 4. Front Strut 9) Using hexagon wrench to prevent strut rod from E: INSTALLATION turning, tighten self-locking nut with ST. 1) Install strut mount at upper side of strut to body ST 927760000 STRUT MOUNT SOCKET and tighten with nuts. Tightening torque: Tightening torque: 54 ±...

  • Page 508: Front Stabilizer

    SERVICE PROCEDURE [W5A0] 5. Front Stabilizer 5. Front Stabilizer A: REMOVAL S4M0098A (1) Front crossmember (6) Self-locking nut Tightening torque: N·m (kg-m, ft-lb) (2) Transverse link 25 ± 4 (2.5 ± 0.4, 18.1 ± 2.9) (3) Jack-up plate 29 ± 5 (3.0 ± 0.5, 21.7 ± 3.6) (4) Stabilizer link 18 ±...

  • Page 509: Front Crossmember

    SERVICE PROCEDURE [W6A0] 6. Front Crossmember B: INSPECTION 6. Front Crossmember 1) Check bushing for cracks, fatigue or damage. A: REMOVAL 2) Check stabilizer link for deformities, cracks, or 1) Disconnect ground cable from battery. damage, and bushing for protrusions from the hole 2) Loosen front wheel nuts.
  • Page 510 SERVICE PROCEDURE [W6B0] 6. Front Crossmember B: INSTALLATION 2) Purge air from power steering system. NOTE: 1) Installation is in the reverse order of removal Check wheel alignment and adjust if necessary. procedures. CAUTION: Always tighten rubber bushing when wheels are in full contact with the ground and vehicle is at curb weight condition.

  • Page 511: Rear Trailing Link

    SERVICE PROCEDURE [W7A0] 7. Rear Trailing Link 7. Rear Trailing Link A: REMOVAL S4M0183A (1) Trailing link (5) Housing Tightening torque: N·m (kg-m, ft-lb) (2) Front bushing (6) Self-locking nut 98 ± 20 (10.0 ± 2.0, 72 ± 14) (3) Rear bushing 113 ±...
  • Page 512 SERVICE PROCEDURE [W7B1] 7. Rear Trailing Link B: DISASSEMBLY 2) Using ST, press rear bushing out of place. ST 927730000 INSTALLER & REMOVER SET 1. FRONT BUSHING Using ST, press front bushing out of place. ST 927720000 INSTALLER & REMOVER SET G4M0525 C: INSPECTION G4M0524...
  • Page 513 SERVICE PROCEDURE [W7D2] 7. Rear Trailing Link D: ASSEMBLY 2. REAR BUSHING 1) Using ST, press bushing into trailing link. To assemble, reverse above disassembly proce- ST 927730000 INSTALLER & REMOVER SET dures. NOTE: 1. FRONT BUSHING If it is difficult to press bushing into trailing link, Using ST, press bushing into trailing link.
  • Page 514 SERVICE PROCEDURE [W7E0] 7. Rear Trailing Link 2) Press ST plunger until bushing flange protrudes E: INSTALLATION beyond trailing link. Installation is in the reverse order of removal. ST 927730000 INSTALLER & REMOVER SET CAUTION: Always tighten rubber bushing location when wheels are in full contact with the ground and vehicle is at curb weight condition.

  • Page 515: Lateral Link

    SERVICE PROCEDURE [W8A0] 8. Lateral Link 8. Lateral Link A: REMOVAL S4M0099A (1) Crossmember (8) Bushing (B) Tightening torque: N·m (kg-m, ft-lb) (2) Adjusting bolt (9) Washer 44 ± 6 (4.5 ± 0.6, 32.5 ± 4.3) (3) Stabilizer link (10) Cap (Protection) 98 ±...
  • Page 516 SERVICE PROCEDURE [W8B0] 8. Lateral Link 6) Remove DOJ from rear differential using ST. ST 28099PA100 DRIVE SHAFT REMOVER NOTE: The side spline shaft circlip comes out together with the shaft. G4M0994 CAUTION: Be careful not to damage side bearing retainer. Always use bolt as shown in figure, as support- ing point for ST during removal.
  • Page 517 SERVICE PROCEDURE [W8D0] 8. Lateral Link D: ASSEMBLY 2) Press ST plunger until bushing flange protrudes beyond lateral link. 1) Using ST, press bushing into place. NOTE: CAUTION: Use the same ST as that used during disassembly. Select ST according to the type of bushings used.
  • Page 518 SERVICE PROCEDURE [W8E0] 8. Lateral Link E: INSTALLATION To install, reverse removal procedures, reading the following instructions. ¼ Installation of DOJ to differential <Ref. to 4-2 [W3E2].> CAUTION: ¼ Do not allow DOJ splines to damage side oil seal. ¼ Always tighten rubber bushing when wheels are in full contact with the ground and vehicle is at curb weight condition.

  • Page 519: Rear Strut

    SERVICE PROCEDURE [W9A0] 9. Rear Strut 9. Rear Strut A: REMOVAL S4M0181A (1) Strut mount cap (7) Helper Tightening torque: N·m (kg-m, ft-lb) (2) Self-locking nut (8) Rubber seat lower 20 ± 6 (2.0 ± 0.6, 14.5 ± 4.3) (3) Strut mount (9) Damper strut 59 ±...
  • Page 520 SERVICE PROCEDURE [W9B0] 9. Rear Strut 8) Use a garage jack to support the rear housing. D: ASSEMBLY Refer to Front Strut as a guide for assembly pro- cedures. <Ref. to 4-1 [W4D0].> CAUTION: ¼ Install rear strut with “4WD” mark on strut mount facing outside of vehicle body.
  • Page 521 SERVICE PROCEDURE [W9E0] 9. Rear Strut 5) Insert brake hose clip between brake hose and Tightening torque: 88 ± 10 N·m (9 ± 1 kg-m, 65 ± 7 ft-lb) lower side of strut. CAUTION: 8) Install strut cap of rear quarter trim. ¼...

  • Page 522: Rear Crossmember

    SERVICE PROCEDURE [W10A0] 10. Rear Crossmember 10. Rear Crossmember A: REMOVAL S4M0107A (1) Crossmember (8) Washer Tightening torque: N·m (kg-m, ft-lb) (2) Floating bushing (9) Cap (Protection) 44 ± 6 (4.5 ± 0.6, 32.5 ± 4.3) (3) Adjusting bolt (10) Trailing link 98 ±...
  • Page 523 SERVICE PROCEDURE [W10C0] 10. Rear Crossmember 5) Remove bolts securing crossmember to vehicle C: INSTALLATION body, and remove crossmember. 1) Install in reverse order of removal. NOTE: One of the four crossmember installing bolts has a larger diameter than the others. Install it first. 2) Install rear differential.

  • Page 524: Rear Stabilizer

    SERVICE PROCEDURE [W11A0] 11. Rear Stabilizer 11. Rear Stabilizer A: REMOVAL S4M0182A (1) Rear stabilizer (5) Stabilizer link Tightening torque: N·m (kg-m, ft-lb) (2) Stabilizer bracket (6) Rear lateral link 25 ± 7 (2.5 ± 0.7, 18.1 ± 5.1) (3) Stabilizer bushing (7) Self-locking nut 44 ±...
  • Page 525 SERVICE PROCEDURE [W11C0] 11. Rear Stabilizer C: INSTALLATION 2) Always tighten rubber bushing location when wheels are in full contact with the ground and 1) To install, reverse the removal procedure. vehicle is curb weight. NOTE: Tightening torque: ¼ Install bushing while aligning it with paint mark Stabilizer link to rear lateral link: on stabilizer.

  • Page 526: Suspension

    DIAGNOSTICS [K1A0] 1. Suspension 1. Suspension A: 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 527: Wheels And Axles

    WHEELS AND AXLES Page SPECIFICATIONS AND SERVICE DATA............2 Tire and Wheel Size..................2 Tire Inflation Pressure .................2 Front Drive Shaft Assembly ................3 Rear Drive Shaft Assembly .................3 Application Table ..................4 Wheel Balance ....................4 COMPONENT PARTS ..................5 Front Axle ....................5 Rear Axle.....................6 SERVICE PROCEDURE ...................7 Front Axle ....................7 Rear Axle....................12...

  • Page 528: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Tire and Wheel Size 1. Tire and Wheel Size G4M0208 Tire size Rim size Rim offset P.C.D. mm (in) mm (in) 15 × 6JJ BASE, L P205/70R15 95S 48 (1.89) Front and Rear 100 (3.94) dia. 16 ×...

  • Page 529: Front Drive Shaft Assembly

    SPECIFICATIONS AND SERVICE DATA [S400] 4. Rear Drive Shaft Assembly 3. Front Drive Shaft Assembly SHAFT Model Type of drive shaft assembly Boot band identification color Shaft diameter All models BJ87L+SFJ82 26 mm (1.02 in) White S4M0230A 4. Rear Drive Shaft Assembly SHAFT Type of drive shaft assembly No.

  • Page 530: Application Table

    SPECIFICATIONS AND SERVICE DATA [S500] 5. Application Table 5. Application Table Model Power unit Front drive shaft Rear drive shaft 2500 cc BJ87L+SFJ82 79AC-RH, 79AC-LH 6. Wheel Balance Wheel balancing Standard Service limit Dynamic unbalance Less than 5 g (0.18 oz) Balance weight part number Weight g (oz) (For steel wheel)

  • Page 531: Component Parts

    COMPONENT PARTS [C100] 1. Front Axle 1. Front Axle S4M0301A (1) Baffle plate (SFJ) (10) Boot (BJ) (19) Hub bolt (2) Spring pin (11) BJ ASSY (20) Hub (3) Outer race (SFJ) (12) Baffle plate (21) Axle nut (4) Snap ring (13) Oil seal (IN) Tightening torque: N·m (kg-m, ft-lb) (5) Trunnion...

  • Page 532: Rear Axle

    COMPONENT PARTS [C200] 2. Rear Axle 2. Rear Axle B4M0704B (1) Baffle plate (DOJ) (10) Boot (BJ) (19) Hub bolt (2) Outer race (DOJ) (11) BJ ASSY (20) Hub (3) Snap ring (12) Oil seal (IN. No. 2) (21) Axle nut (4) Inner race (13) Oil seal (IN.
  • Page 533 SERVICE PROCEDURE [W1A0] 1. Front Axle 1. Front Axle 7) Remove front drive shaft assembly from hub. If it is hard to remove, use STs. A: REMOVAL ST1 926470000 AXLE SHAFT PULLER ST2 927140000 PLATE 1) Disconnect ground cable from battery. 2) Jack-up vehicle, support it with safety stands, CAUTION: ¼...
  • Page 534 SERVICE PROCEDURE [W1B0] 1. Front Axle 10) Using a puller, remove tie-rod ball joint from B: DISASSEMBLY knuckle arm. 1) Using ST1, support housing and hub securely. 2) Attach ST2 to housing and drive hub out. ST1 927080000 HUB STAND ST2 927060000 HUB REMOVER G4M0219 11) On ABS equipped models, remove ABS sen-...

  • Page 535: Service Procedure

    SERVICE PROCEDURE [W1D0] 1. Front Axle 3) Remove disc cover from housing. 9) Using ST and a hydraulic press, drive hub bolts out. ST 927080000 HUB STAND CAUTION: Be careful not to hammer hub bolts. This may deform hub. G4M0225 4) Using a standard screwdriver, remove outer and inner oil seals.
  • Page 536 SERVICE PROCEDURE [W1D0] 1. Front Axle CAUTION: 7) Using ST1 and ST2, press outer oil seal until it Be sure to press hub bolts until their seating contacts the bottom of housing. surfaces contact the hub. ST1 927410000 OIL SEAL INSTALLER ST2 927400000 HOUSING STAND NOTE: Use 12 mm (0.47 in) dia.
  • Page 537 SERVICE PROCEDURE [W1E0] 1. Front Axle 12) Attach hub to ST1 securely. 8) Install tie-rod end ball joint on housing knuckle arm. 13) Clean dust or foreign particles from the pol- ished surface of hub. Tightening torque: 14) Using ST2, press bearing into hub by driving 27.0 ±...

  • Page 538: Rear Axle

    SERVICE PROCEDURE [W2A1] 2. Rear Axle 2. Rear Axle 8) Disconnect parking brake cable end. A: REMOVAL 1. DISC BRAKE 1) Disconnect ground cable from battery. 2) Jack-up vehicle, and remove rear wheel cap and wheels. CAUTION: Be sure to loosen and retighten axle nut after removing wheel from vehicle.
  • Page 539 SERVICE PROCEDURE [W2A2] 2. Rear Axle 12) Disengage BJ from housing splines, and CAUTION: remove rear drive shaft assembly. If it is hard to Be sure to loosen and retighten axle nut after remove, use STs. removing wheel from vehicle. Failure to follow ST1 926470000 AXLE SHAFT PULLER this rule may damage wheel bearings.
  • Page 540 SERVICE PROCEDURE [W2A2] 2. Rear Axle 8) Using a flare-nut wrench, disconnect brake pipe 12) Remove bolts which secure lateral link assem- from wheel cylinder. bly to rear housing. CAUTION: CAUTION: Cover open end of wheel cylinder to prevent Discard old self-locking nut. Replace with a entry of foreign particles.
  • Page 541 SERVICE PROCEDURE [W2B0] 2. Rear Axle 15) Remove bolts which secure rear housing to 5) Using ST1 and ST2, remove bearing by press- strut, and separate the two. ing inner race. ST1 927430000 HOUSING STAND ST2 927440000 BEARING REMOVER CAUTION: ¼...
  • Page 542 SERVICE PROCEDURE [W2C0] 2. Rear Axle C: INSPECTION 2) Remove foreign particles (dust, rust, etc.) from mating surfaces of hub and tone wheel, and install Check the removed parts for wear and damage. If tone wheel to hub (only vehicle equipped with defective, replace with new ones.
  • Page 543 SERVICE PROCEDURE [W2D0] 2. Rear Axle 4) Install snap ring. 8) Using ST1 and ST2, press sub seal into place. ST1 927430000 HOUSING STAND CAUTION: ST2 927460000 OIL SEAL INSTALLER Ensure snap ring fits in groove properly. G4M0260 G4M0251 9) Apply sufficient grease to oil seal lip. 5) Using ST1 and ST2, press outer oil seal until it comes in contact with snap ring.
  • Page 544 SERVICE PROCEDURE [W2E1] 2. Rear Axle E: INSTALLATION Tightening torque: 44 ± 6 N·m (4.5 ± 0.6 kg-m, 32.5 ± 4.3 ft-lb) 1. DISC BRAKE 6) Connect parking brake cable to parking brake. 1) Connect rear housing assembly and strut 7) Install disc rotor on rear housing assembly.
  • Page 545 SERVICE PROCEDURE [W2E2] 2. Rear Axle 2. DRUM BRAKE 6) Connect parking brake cable to parking brake. 7) Clean brake pipe connection. Using a flare-nut 1) Connect rear housing assembly and strut wrench, connect brake pipe to wheel cylinder. assembly. 8) Connect rear ABS sensor to back plate (only vehicle equipped with ABS).

  • Page 546: Front And Rear Drive Shafts

    SERVICE PROCEDURE [W3A1] 3. Front and Rear Drive Shafts 3. Front and Rear Drive Shafts 2. REAR DRIVE SHAFT 1) Disconnect ground cable from battery. A: REMOVAL 2) Lift-up vehicle, and remove rear wheel cap and 1. FRONT DRIVE SHAFT wheels.
  • Page 547 SERVICE PROCEDURE [W3B1] 3. Front and Rear Drive Shafts CAUTION: 2) Remove SFJ boot band and boot. Be careful not to damage side bearing retainer. CAUTION: Always use bolt as shown in figure, as support- Be careful not to damage boot. ing point for ST during removal.
  • Page 548 SERVICE PROCEDURE [W3B2] 3. Front and Rear Drive Shafts 6) Place alignment mark on free ring and trunnion. 11) Place drive shaft in a vise between wooden blocks. CAUTION: Do not place drive shaft directly in the vise; use wooden block. 12) Raise boot band claws by means of screw- driver and hammer.
  • Page 549 SERVICE PROCEDURE [W3D1] 3. Front and Rear Drive Shafts 2) Loosen band by means of screwdriver or pliers 9) Remove snap ring, which fixes inner race to with care of not damaging boot. shaft, by using pliers. 10) Take out DOJ inner race. 11) Take off DOJ cage from shaft and remove DOJ boot.
  • Page 550 SERVICE PROCEDURE [W3D1] 3. Front and Rear Drive Shafts 4) Apply an even coat of specified grease [20 to Tightening torque: Large boot band 30 g (0.71 to 1.06 oz)] to the entire inner surface of boot. Also apply grease to shaft. 157 N·m (16.0 kg-m, 116 ft-lb) or more Small boot band NOTE:...
  • Page 551 SERVICE PROCEDURE [W3D2] 3. Front and Rear Drive Shafts 15) Align alignment marks on shaft and outer 22) Tap on the clip with the punch provided at the race, and install outer race. end of ST. ST 925091000 BAND TIGHTENING TOOL CAUTION: Tap to an extent that the boot underneath is not damaged.
  • Page 552 SERVICE PROCEDURE [W3D2] 3. Front and Rear Drive Shafts 3) Insert DOJ cage onto shaft. 6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into the interior of DOJ outer race. NOTE: 7) Apply a coat of specified grease to the cage Insert the cage with the cut-out portion facing the pocket and six balls.
  • Page 553 SERVICE PROCEDURE [W3E1] 3. Front and Rear Drive Shafts 14) Pinch the end of band with pliers. Hold the clip E: INSTALLATION and tighten securely. 1. FRONT DRIVE SHAFT NOTE: 1) Insert BJ into hub splines. When tightening boot, exercise care so that the air within the boot is appropriate.
  • Page 554 SERVICE PROCEDURE [W3E2] 3. Front and Rear Drive Shafts 7) While depressing brake pedal, tighten axle nut 5) Insert DOJ spline end into bore of side oil seal, to the specified torque. and remove ST. Tightening torque: CAUTION: 186 ± 20 N·m (19 ± 2 kg-m, 137 ± 14 ft-lb) Do not allow DOJ splines to damage side oil seal.

  • Page 555: Replacement Of Front Bj And Sfj Boots

    SERVICE PROCEDURE [W4B0] 4. Replacement of Front BJ and SFJ Boots 11) While depressing brake pedal, tighten axle nut 4. Replacement of Front BJ using a socket wrench. and SFJ Boots Tightening torque: 186 ± 20 N·m (19 ± 2 kg-m, 137 ± 14 ft-lb) A: REMOVAL CAUTION: 1) Disconnect ground cable from battery.

  • Page 556: Replacement Of Rear Doj And Bj Boots

    SERVICE PROCEDURE [W5A0] 5. Replacement of Rear DOJ and BJ Boots 5. Replacement of Rear DOJ B: INSTALLATION and BJ Boots 1) Install DOJ and BJ boots to drive shaft. <Ref. to 4-2 [W3D2].> A: REMOVAL 2) Using ST, install DOJ into differential. ST 28099PA090 SIDE OIL SEAL PROTEC- 1) Disconnect ground cable from battery.

  • Page 557: Steel Wheel And Tire

    SERVICE PROCEDURE [W6A1] 6. Steel Wheel and Tire CAUTION: 6. Steel Wheel and Tire Discard old self-locking nut. Replace with a A: INSPECTION new one. 6) Connect rear housing assembly to trailing link 1) Deformation or damage on the rim can cause assembly, and tighten self-locking nut.

  • Page 558: Aluminum Wheel

    SERVICE PROCEDURE [W7A0] 7. Aluminum Wheel 7. Aluminum Wheel A: INSPECTION Inspection for aluminum wheels is basically the same as the one for steel wheels. However, check the rim flange for cracks or damage, and replace (not repair) aluminum wheel if air leakage is found. B: PRECAUTIONS Aluminum wheels are easily scratched.

  • Page 559: Wheel Balancing

    Drive in the balance weight on both the bolts. (In the case of aluminum wheel, use top and rear sides of the rim. SUBARU genuine wheel nut for aluminum wheel.) 3) Some types of balancer can cause damage to 3) Manually tighten the nuts making sure the the wheel.

  • Page 560: Tire Rotation

    SERVICE PROCEDURE [W1000] 10. Tire Rotation 10. Tire Rotation If tires are maintained at the same positions for a long period of time, uneven wear results. Therefore, they should be periodically rotated. This lengthens service life of tires. CAUTION: When rotating tires, replace unevenly worn or damaged tires with new ones.

  • Page 561: Steering System

    STEERING SYSTEM Page SPECIFICATIONS AND SERVICE DATA............2 Steering System ..................2 COMPONENT PARTS ..................5 Steering Wheel and Column ...............5 Power Steering System................6 SERVICE PROCEDURE ...................8 Supplemental Restraint System “Airbag” .........8 Tilt Steering Column..................9 Steering Gearbox (Power Steering System) ...........13 Control Valve (Power Steering Gearbox) ..........23 Pipe Assembly (Power Steering System) ..........30 Oil Pump (Power Steering System) ............34 Power Steering Fluid.................38...

  • Page 562: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S1A0] 1. Steering System 1. Steering System A: SPECIFICATIONS Minimum turning radius m (ft) 5.4 (17.7) Steering angle (Inside-Outside) 34.4°±1.5° — 30.2°±1.5° Whole system Steering wheel diameter mm (in) 385 (15.16) Overall gear ratio (Turns, lock to lock) 19.0 (3.4) Type Rack and pinion, Integral...
  • Page 563 SPECIFICATIONS AND SERVICE DATA [S1C0] 1. Steering System C: RECOMMENDED POWER STEERING FLUID Recommended power steering fluid Manufacturer B.P. CALTEX CASTROL ATF DEXRON IIE or III MOBIL SHELL TEXACO...
  • Page 564 SPECIFICATIONS AND SERVICE DATA [S1C0] 1. Steering System MEMO:...

  • Page 565: Component Parts

    COMPONENT PARTS [C100] 1. Steering Wheel and Column 1. Steering Wheel and Column S4M0304A (1) Bushing (6) Steering wheel Tightening torque: N·m (kg-m, ft-lb) (2) Steering shaft (7) Flange nut 1.2 ± 0.2 (0.12 ± 0.02, 0.9 ± 0.1) (3) Knee protector (8) Airbag module 3.4 ±...

  • Page 566: Power Steering System

    COMPONENT PARTS [C200] 2. Power Steering System 2. Power Steering System S4M0175D...
  • Page 567 COMPONENT PARTS [C200] 2. Power Steering System (1) Eye bolt (28) Special bearing (55) Piston ring (2) Pipe C (29) Seal ring (56) Rack (3) Gasket (30) Pinion and valve ASSY (57) Rack bushing (4) Clip (31) Oil seal (58) Rack stopper (5) Pipe D (32) Back-up washer (59) Circlip...

  • Page 568: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Supplemental Restraint System “Airbag” 1. Supplemental Restraint System “Airbag” A: PRECAUTION Airbag system wiring harness is routed near the steering wheel, steering shaft and column. WARNING: ¼ All Airbag system wiring harness and con- nectors are colored yellow. Do not use electri- cal test equipment on these circuit.

  • Page 569: Tilt Steering Column

    SERVICE PROCEDURE [W2A0] 2. Tilt Steering Column 2. Tilt Steering Column A: REMOVAL S4M0136A Tightening torque: N·m (kg-m, ft-lb) 24 ± 3 (2.4 ± 0.3, 17.4 ± 2.2) 25 ± 5 (2.5 ± 0.5, 18.1 ± 3.6) 1) Disconnect battery minus terminal. 4) Remove steering wheel nut, then draw out 2) Lift-up vehicle.
  • Page 570 SERVICE PROCEDURE [W2B0] 2. Tilt Steering Column 5) Remove universal joint bolts and then remove 8) Disconnect connectors for ignition switch and universal joint. combination switch wiring harness under instru- ment panel. CAUTION: 9) Remove the two bolts under instrument panel Scribe alignment marks on universal joint so securing steering column.
  • Page 571 SERVICE PROCEDURE [W2D0] 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...
  • Page 572 SERVICE PROCEDURE [W2E0] 2. Tilt Steering Column E: INSTALLATION CAUTION: Ensure that front wheels are set in straight for- 1) Insert end of steering shaft into toeboard grom- ward direction. met. 8) Set steering wheel to neutral and install it onto 2) Tighten steering shaft mounting bolts under steering shaft.

  • Page 573: Steering Gearbox (Power Steering System)

    SERVICE PROCEDURE [W3A0] 3. Steering Gearbox (Power Steering System) 3. Steering Gearbox (Power Steering System) A: REMOVAL NOTE: For disassembly and assembly of gearbox unit, refer to section Control Valve (Power Steering Gearbox). <Ref. to 4-3 [W4B0].> and <Ref. to 4-3 [W4D0].> S4M0142B (1) Universal joint (19) Cotter pin...
  • Page 574 SERVICE PROCEDURE [W3A0] 3. Steering Gearbox (Power Steering System) 1) Disconnect battery minus terminal. 8) Remove lower side bolt of universal joint, then 2) Loosen front wheel nut. remove upper side bolt and lift the joint upward. 3) Lift vehicle and remove front wheels. NOTE: 4) Remove front exhaust pipe assembly.
  • Page 575 SERVICE PROCEDURE [W3B0] 3. Steering Gearbox (Power Steering System) B: DISASSEMBLY 6) Extend rack approximately 40 mm (1.57 in) out. Unlock lock wire at lock washer on each side of 1) Disconnect four pipes from gearbox. tie-rod end using a standard screwdriver. 2) Secure gearbox removed from vehicle in vice CAUTION: using ST.
  • Page 576 SERVICE PROCEDURE [W3C0] 3. Steering Gearbox (Power Steering System) 9) Using a wrench [32 mm (1.26 in) width across 10) Loosen adjusting screw and remove spring flats] or adjustable wrench, remove tie-rod. and sleeve. CAUTION: CAUTION: ¼ Check ball joint for free play, and tie-rod for Replace spring and/or sleeve if damaged.
  • Page 577 SERVICE PROCEDURE [W3C2] 3. Steering Gearbox (Power Steering System) 1. SERVICE LIMIT 2. RACK SHAFT PLAY IN RADIAL DIRECTION Make a measurement as follows. If it exceeds the specified service limit, adjust or replace. Right-turn steering: NOTE: Service limit When making a measurement, vise gearbox by 0.15 mm (0.0059 in) or less using ST.
  • Page 578 D: ASSEMBLY On condition P: 20 — 49 N (2 — 5 kg, 4 — 11 lb) CAUTION: Use only SUBARU genuine grease for gearbox. Grease: VALIANT GREASE M2 [Part No. 003608001, net 0.5 kg (1.1 lb)] 1) Clean all parts and tools before reassembling.
  • Page 579 SERVICE PROCEDURE [W3D0] 3. Steering Gearbox (Power Steering System) 5) Apply grease to sliding surface of sleeve and 8) Rack and pinion backlash adjustment spring seat, then insert sleeve into pinion housing. (1) Loosen adjusting screw. Fit spring into sleeve screw, pack grease inside of (2) Rotate input shaft so that rack is in the screw, then install the screw.
  • Page 580 SERVICE PROCEDURE [W3D0] 3. Steering Gearbox (Power Steering System) NOTE: 12) Fix boot end with clip (small). ¼ Hold adjusting screw with a wrench to prevent it CAUTION: from turning while tightening lock nut. After installing, check boot end is positioned ¼...
  • Page 581 SERVICE PROCEDURE [W3E0] 3. Steering Gearbox (Power Steering System) 15) Remove gearbox from ST. (4) Fasten the short yoke side with a spring ST 926200000 STAND washer and bolt, then fasten the long yoke side. 16) Install four pipes on gearbox. Tightening torque: (1) Connect pipes A and B to four pipe joints of 24 ±...
  • Page 582 SERVICE PROCEDURE [W3F0] 3. Steering Gearbox (Power Steering System) 14) Check fluid level in oil tank. 3) If steering wheel spokes are not horizontal when wheels are set in the straight ahead position, 15) After adjusting toe-in and steering angle, and error is more than 5°...

  • Page 583: Control Valve (Power Steering Gearbox)

    SERVICE PROCEDURE [W4A2] 4. Control Valve (Power Steering Gearbox) 4. Control Valve (Power Steering Gearbox) A: CHECKING OIL LEAKING POINTS S4M0153A (1) Power cylinder (3) Rack piston (5) Input shaft (2) Cylinder (4) Rack axle (6) Valve housing 1. OIL LEAKING POINTS be prepared.
  • Page 584 SERVICE PROCEDURE [W4B0] 4. Control Valve (Power Steering Gearbox) There are two possible causes. Take following 3) Slide dust cover out. step first. Remove the pipe assembly B from the valve housing, and close the circuit with ST. ST 926420000 PLUG Turn the steering wheel from lock to lock 30 to 40 times with the engine running, then make comparison of the leaked portion between...
  • Page 585 SERVICE PROCEDURE [W4C1] 4. Control Valve (Power Steering Gearbox) 2) Pull rack assembly from cylinder side, and draw 2) Apply a coat of specified power steering fluid to out rack bushing and rack stopper together with inner wall of valve housing. rack assembly.
  • Page 586 SERVICE PROCEDURE [W4C2] 4. Control Valve (Power Steering Gearbox) 4) Using ST and press, install special bearing in 2) Press out bearing together with backing washer valve housing. using pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555 ST 34099FA120 INSTALLER & REMOVER in) and press.
  • Page 587 SERVICE PROCEDURE [W4C3] 4. Control Valve (Power Steering Gearbox) 6) Secure valve assembly to ST1 and ST2. NOTE: 7) Put ST3 over pinion, and insert oil seal, then Rotate snap ring to check for proper installation. force-fit oil seal into housing using ST4. 3.
  • Page 588 ST and 1. RACK ASSEMBLY rack piston. CAUTION: ST 926390001 COVER AND REMOVER Use only SUBARU genuine grease for gearbox. Specified grease for gearbox: VALIANT GREASE M2 (Part No. 003608001) 1) Fixing rack housing Fix rack housing in vice using ST.
  • Page 589 5) Fit ST1 and ST2 over the end of rack, and 2. VALVE ASSEMBLY install rack bushing. CAUTION: ST1 926400000 GUIDE Use only SUBARU genuine grease for gearbox. ST2 927660000 GUIDE Specified grease for gearbox: CAUTION: VALIANT GREASE M2 (Part No.

  • Page 590: Pipe Assembly (Power Steering System)

    SERVICE PROCEDURE [W5A0] 5. Pipe Assembly (Power Steering System) 5) Tighten bolts alternately to secure valve assem- 5. Pipe Assembly (Power bly. Steering System) Tightening torque: 25 ± 5 N·m (2.5 ± 0.5 kg-m, 18.1 ± 3.6 ft-lb) A: REMOVAL CAUTION: 1) Disconnect battery minus terminal.
  • Page 591 SERVICE PROCEDURE [W5B0] 5. Pipe Assembly (Power Steering System) 4) Remove clamp E from pipes C and D. 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.
  • Page 592 SERVICE PROCEDURE [W5C0] 5. Pipe Assembly (Power Steering System) C: INSTALLATION 5) Temporarily connect pipes C and D to pipes (on the gearbox side). 1) Connect pipes C and D to steering gearbox. Tightening torque: Joint nut 15 ± 5 N·m (1.5 ± 0.5 kg-m, 10.8 ± 3.6 ft-lb) CAUTION: Visually check that hose between tank and pipe D is free from bending or twisting.
  • Page 593 SERVICE PROCEDURE [W5C0] 5. Pipe Assembly (Power Steering System) 9) Connect pipes A and B to four pipe joints of 10) Install jack-up plate. gearbox. Connect upper pipe B first, and lower 11) Connect battery minus terminal. pipe A second. 12) Feed the specified fluid and discharge air.

  • Page 594: Oil Pump (Power Steering System)

    SERVICE PROCEDURE [W6A0] 6. Oil Pump (Power Steering System) 6. Oil Pump (Power Steering 8) Remove three bolts from the front side of oil pump and detach the pump. 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.
  • Page 595 SERVICE PROCEDURE [W6B1] 6. Oil Pump (Power Steering System) B: CHECK ¼ In accordance with the following table, check all removed parts for wear and damage, and make repair or replacement if necessary. Parts Inspection Corrective action (1) Crack, damage or oil leakage Replace oil pump with a new one.
  • Page 596 SERVICE PROCEDURE [W6C0] 6. Oil Pump (Power Steering System) ¼ Play of pulley shaft ¼ Ditch deflection of pulley On condition: Service limit: P: 9.8 N (1.0 kg, 2.2 lb) 1.0 mm (0.039 in) or less Service limit: NOTE: Radial play (Direction Read the value for one surface of V ditch, and then 0.4 mm (0.016 in) or less the value for another off the dial.
  • Page 597 SERVICE PROCEDURE [W6C0] 6. Oil Pump (Power Steering System) CAUTION: 4) Place oil pump pulley and tighten pulley nut temporarily. Do not place oil pump directly in vise; use soft 5) Install pulley belt to oil pump. pads and hold oil pump lightly to protect it. 6) Tighten oil pump pulley nut to the specified Tightening torque: torque.

  • Page 598: Power Steering Fluid

    SERVICE PROCEDURE [W7A0] 7. Power Steering Fluid 7. Power Steering Fluid (3) Grinding noise is generated from oil pump. 10) Check the fluid leakage at flare nuts after turn- A: RECOMMENDED POWER ing steering wheel from lock to lock with engine STEERING FLUID AND AIR running.

  • Page 599: Power Steering

    DIAGNOSTICS [K1A0] 1. Power Steering 1. Power Steering A: STEERING CONDITION Trouble Possible cause Corrective action 1. Pulley belt ¼ Unequal length of pulley belts ¼ Adhesion of oil and grease ¼ Loose or damage of pulley belt Adjust or replace. ¼...
  • Page 600 DIAGNOSTICS [K1B0] 1. Power Steering B: MEASUREMENT OF HYDRAULIC 1B1 : MEASURE REGULAR PRESSURE. PRESSURE 1) Install STs to power steering pump. CAUTION: ¼ Be sure to complete all items aforemen- (1) Drain the power steering fluid about 0.35 (0.4 US qt, 0.3 Imp qt) from oil tank. tioned in “STEERING CONDITION”, prior to (2) Remove two bolts securing power steering measuring...
  • Page 601 DIAGNOSTICS [K1B3] 1. Power Steering 1B2 : MEASURE RELIEF PRESSURE. 1B3 : MEASURE WORKING PRESSURE. 1) Using STs, measure relief pressure. 1) Using STs, measure working pressure. ST1 925711000 PRESSURE GAUGE ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A ST3 34099AC010 ADAPTER HOSE A...
  • Page 602 DIAGNOSTICS [K1C0] 1. Power Steering C: MEASUREMENT OF STEERING EFFORT B4M1142A...
  • Page 603 DIAGNOSTICS [K1C0] 1. Power Steering 1) Measurement of steering effort is as shown in 2) Measurement of folding torque of universal joint the figures. is as shown in the figures. S4M0169 G4M0199 S4M0170 G4M0200 G4M0201 G4M0202...
  • Page 604 DIAGNOSTICS [K1C0] 1. Power Steering 3) Using ST, measure resistances of gearbox. ST 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 Sliding resistance: Right-turn steering;...
  • Page 605 DIAGNOSTICS [K1D0] 1. Power Steering D: 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 606 DIAGNOSTICS [K1E0] 1. Power Steering NOTE: E: NOISE AND VIBRATION Fluid level is specified at optimum position (range) CAUTION: for ordinary use. Accordingly, if the vehicle is used Don’t keep the relief valve operated over 5 sec- often under hard conditions such as on very rough onds at any time or inner parts of the oil pump roads or in mountainous areas, fluid may bleed out may be damaged due to rapid increase of fluid...
  • Page 607 DIAGNOSTICS [K1E0] 1. Power Steering Trouble Possible cause Corrective action Relief valve emits operating sound when steering wheel is completely turned in either direction. (Don’t keep this Normal Hiss noise (continuous) condition over 5 seconds.) While engine is running. Relief valve emits operating sound when steering wheel Defective is not turned.
  • Page 608 DIAGNOSTICS [K1F0] 1. Power Steering F: CLEARANCE TABLE CAUTION: This table lists various clearances that must be correctly adjusted to ensure normal vehicle driving without interfering noise, or any other faults. Location Minimum allowance mm (in) (1) Crossmember — Pipe 5 (0.20) (2) DOJ —...
  • Page 609 DIAGNOSTICS [K1G0] 1. Power Steering G: BREAKAGE OF HOSES the hoses and their service lives are shortening accordingly, it is necessary to perform careful CAUTION: inspection frequently when the vehicle is used Although surface layer materials of rubber in hot weather areas, cold weather area and/or hoses have excellent weathering resistance, a driving condition in which many steering heat resistance and resistance for low tem-...
  • Page 610 DIAGNOSTICS MEMO:...

  • Page 611: Brakes

    BRAKES Page SPECIFICATIONS AND SERVICE DATA............2 Brakes ......................2 COMPONENT PARTS ..................4 Front Disc Brake ..................4 Rear Disc Brake ..................5 Rear Drum Brake ..................6 Master Cylinder ...................7 Brake Booster....................8 ABS System ....................9 Parking Brake ....................11 SERVICE PROCEDURE .................12 Front Disc Brake ..................12 Rear Disc Brake ..................17 Rear Drum Brake ..................22 Parking Brake (Rear Disc Brake)..............27...

  • Page 612: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S1A0] 1. Brakes 1. Brakes A: SPECIFICATIONS Engine (cc) 2500 Driving system BASE Type Disc (Floating type, ventilated) Effective disc diameter mm (in) 228 (8.98) Disc thickness × Outer diam- 24 × 277 (0.94 × 10.91) mm (in) eter Front disc...
  • Page 613 SPECIFICATIONS AND SERVICE DATA [S1D0] 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 Disc thickness 24 mm (0.94 in) 22 mm (0.87 in) Disc runout —...

  • Page 614: Component Parts

    COMPONENT PARTS [C100] 1. Front Disc Brake 1. Front Disc Brake B4M1151C (1) Caliper body (9) Lock pin (Yellow) (17) Disc cover (2) Air bleeder screw (10) Support (3) Guide pin (Green) (11) Pad clip Tightening torque: N·m (kg-m, ft-lb) 8 ±...

  • Page 615: Rear Disc Brake

    COMPONENT PARTS [C200] 2. Rear Disc Brake 2. Rear Disc Brake S4M0111A (1) Caliper body (14) Shim (27) Primary shoe return spring (2) Air bleeder screw (15) Shoe hold-down pin (28) Adjusting spring (3) Guide pin (Green) (16) Cover (29) Adjuster (4) Pin boot (17) Back plate (30) Shoe hold-down cup...

  • Page 616: Rear Drum Brake

    COMPONENT PARTS [C300] 3. Rear Drum Brake 3. Rear Drum Brake B4M1120A (1) Air bleeder cap (11) Upper shoe return spring (21) Lower shoe return spring (2) Air bleeder screw (12) Retainer (22) Adjusting spring (3) Boot (13) Washer (23) Drum (4) Piston (14) Parking brake lever (24) Plug...

  • Page 617: Master Cylinder

    COMPONENT PARTS [C400] 4. Master Cylinder 4. Master Cylinder S4M0186A (1) Cap (6) Primary piston (11) Pin (2) Filter (7) Secondary piston Tightening torque: N·m (kg-m, ft-lb) (3) Reservoir tank (8) Cylinder body 14 ± 4 (1.4 ± 0.4, 10.1 ± 2.9) (4) Bracket (9) Cylinder pin (With ABS) (5) Piston retainer...

  • Page 618: Brake Booster

    COMPONENT PARTS [C500] 5. Brake Booster 5. Brake Booster B4M1121A (1) Push rod (5) Filter (9) Valve body (2) Return spring (6) Silencer (10) Plunger valve (3) Reaction disc (7) Operating rod (11) Diaphragm plate (4) Key (8) Poppet valve (12) Valve return spring...

  • Page 619: Abs System

    COMPONENT PARTS [C6A0] 6. ABS System 6. ABS System A: SENSOR S4M0293A (1) G sensor (5) Front ABS sensor LH Tightening torque: N·m (kg-m, ft-lb) (2) Rear ABS sensor RH (6) Front ABS sensor RH 7.4 ± 2.0 (0.75 ± 0.2, 5.4 ± 1.4) (3) ABS spacer 32 ±...
  • Page 620 COMPONENT PARTS [C6B0] 6. ABS System B: ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) B4M1220B (1) Stud bolt (6) Front-RH outlet Tightening torque: N·m (kg-m, ft-lb) (2) Damper (7) Primary inlet 18 ± 5 (1.8 ± 0.5, 13.0 ± 3.6) (3) ABS control module and hydrau- (8) Rear-LH outlet 29 ±...

  • Page 621: Parking Brake

    COMPONENT PARTS [C700] 7. Parking Brake 7. Parking Brake B4M0705B (1) Parking brake lever (7) Clamp Tightening torque: N·m (kg-m, ft-lb) (2) Parking brake switch (8) Parking brake cable RH 5.9 ± 1.5 (0.60 ± 0.15, 4.3 ± 1.1) (3) Lock nut (9) Cable guide 18 ±...
  • Page 622 SERVICE PROCEDURE [W1A1] 1. Front Disc Brake 1. Front Disc Brake 5) Apply thin coat of PBC GREASE (Part No. 003607000) to the frictional portion between pad A: ON-CAR SERVICE and pad clip. 1. PAD 1) Remove lock pin. 2) Raise caliper body. 3) Remove pad.
  • Page 623 SERVICE PROCEDURE [W1A2] 1. Front Disc Brake 3) Measure disc rotor thickness. G4M0365 NOTE: Make sure that micrometer is set 5 mm (0.20 in) inward of rotor outer perimeter. Standard Service limit Disc outer Disc rotor value dia. thickness A 24.0 22.0 mm (in)
  • Page 624 SERVICE PROCEDURE [W1B0] 1. Front Disc Brake B: REMOVAL B4M1151D (1) Caliper body (9) Lock pin (Yellow) (17) Disc cover (2) Air bleeder screw (10) Support Tightening torque: N·m (kg-m, ft-lb) (3) Guide pin (Green) (11) Pad clip 8 ± 1 (0.8 ± 0.1, 5.8 ± 0.7) (4) Pin boot (12) Outer shim 18 ±...

  • Page 625: Service Procedure

    SERVICE PROCEDURE [W1C0] 1. Front Disc Brake 1) Remove union bolt and disconnect brake hose 5) Remove disc rotor from hub. from caliper body assembly. NOTE: If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in holes B on the rotor.
  • Page 626 SERVICE PROCEDURE [W1D0] 1. Front Disc Brake 4) Gradually supply compressed air via caliper 4) Insert piston into cylinder. body brake hose to force piston out. CAUTION: CAUTION: Do not force piston into cylinder. Place a wooden block as shown in Figure to prevent damage to piston.

  • Page 627: Rear Disc Brake

    SERVICE PROCEDURE [W2A1] 2. Rear Disc Brake F: INSTALLATION 2. Rear Disc Brake 1) Install disc rotor on hub. A: ON-CAR SERVICE 2) Install support on housing. 1. PAD Tightening torque: 78 ± 10 N·m (8 ± 1 kg-m, 58 ± 7 ft-lb) 1) Remove lock pin.
  • Page 628 SERVICE PROCEDURE [W2A2] 2. Rear Disc Brake 4) Check pad thickness (including back metal). 2. DISC ROTOR Pad thickness: A 1) Install disc rotor by tightening the five wheel Standard value nuts. 15.0 mm (0.591 in) 2) Set a dial gauge on the disc rotor. Turn disc rotor to check runout.
  • Page 629 SERVICE PROCEDURE [W2B0] 2. Rear Disc Brake B: REMOVAL S4M0118A (1) Caliper body (8) Boot ring (15) Disc rotor (2) Air bleeder screw (9) Lock pin (Yellow) (3) Guide pin (Green) (10) Support Tightening torque: N·m (kg-m, ft-lb) 8 ± 1 (0.8 ± 0.1, 5.8 ± 0.7) (4) Pin boot (11) Pad clip 39 ±...
  • Page 630 SERVICE PROCEDURE [W2C0] 2. Rear Disc Brake C: DISASSEMBLY 4) Remove piston seal from caliper body cylinder. 1) Remove the boot ring. S4M0122A 5) Remove lock pin sleeve and boot from caliper S4M0120A body. 2) Remove the piston boot. 6) Remove guide pin boot. D: INSPECTION 1) Repair or replace faulty parts.
  • Page 631 SERVICE PROCEDURE [W2F0] 2. Rear Disc Brake 7) Apply a coat of specified grease to guide pin, F: INSTALLATION outer surface, sleeve outer surface, cylinder inner 1) Install disc rotor on hub. surface, and boot grooves. 2) Install support on back plate. Grease Tightening torque: NIGLUBE RX-2 (Part No.

  • Page 632: Rear Drum Brake

    SERVICE PROCEDURE [W3A0] 3. Rear Drum Brake 3. Rear Drum Brake A: REMOVAL B4M0075B (1) Air bleeder cap (11) Upper shoe return spring (21) Lower shoe return spring (2) Air bleeder screw (12) Retainer (22) Adjusting spring (3) Boot (13) Washer (23) Plug (4) Piston (14) Parking brake lever...
  • Page 633 SERVICE PROCEDURE [W3A2] 3. Rear Drum Brake NOTE: 7) Remove shoes one by one from back plate with If it is difficult to remove brake drum, remove adjuster. adjusting hole cover from back plate, and then, CAUTION: turn adjuster assembly pawls using a slot-type Be careful not to bend parking brake cable screwdriver until brake shoe separates from the excessively when removing brake shoes.
  • Page 634 SERVICE PROCEDURE [W3A3] 3. Rear Drum Brake 4) Unscrew the brake pipe flare nut and discon- B: DISASSEMBLY nect brake pipe. 1. WHEEL CYLINDER 1) Remove right and left dust boots from wheel cylinder. G4M0399 5) Remove hub. <Ref. to 4-2 [W2A2].> 6) Remove the bolts installing back plate, and B4M1126A then, remove brake assembly.
  • Page 635 SERVICE PROCEDURE [W3E2] 3. Rear Drum Brake D: ASSEMBLY 3) Apply rubber grease to the boot inside as shown in Figure. 1. WHEEL CYLINDER Grease: 1) Clean all parts in brake fluid. Check and replace NIGLUBE RX-2 (Part No. 003606000) faulty parts.
  • Page 636 SERVICE PROCEDURE [W3E3] 3. Rear Drum Brake 2) Apply grease to portions indicated by arrows in 6) Connect lower shoe return spring. Figure. 7) Fix shoes by connecting hold-down cup to hold- down pin. Brake grease: Dow Corning Molykote No. 7439 (Part No. 3.

  • Page 637: Parking Brake (Rear Disc Brake)

    SERVICE PROCEDURE [W4A0] 4. Parking Brake (Rear Disc Brake) 4. Parking Brake (Rear Disc Brake) A: REMOVAL B4M1127A (1) Back plate (8) Strut (15) Shoe hold down spring (2) Retainer (9) Shoe guide plate (16) Shoe hold down pin (3) Spring washer (10) Primary return spring (17) Adjusting hole cover (4) Lever...
  • Page 638 SERVICE PROCEDURE [W4B0] 4. Parking Brake (Rear Disc Brake) 10) Remove parking cable from parking lever. 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.

  • Page 639: Master Cylinder

    SERVICE PROCEDURE [W5B2] 5. Master Cylinder D: ADJUSTMENT 5. Master Cylinder 1. SHOE CLEARANCE A: REMOVAL 1) Remove adjusting hole cover from back plate. 1) Thoroughly drain brake fluid from reservoir 2) Turn adjusting screw using a slot-type screw- tank. driver until brake shoe is in close contact with disc 2) Disconnect fluid level indicator harness connec- rotor.
  • Page 640 SERVICE PROCEDURE [W5C0] 5. Master Cylinder CAUTION: 3) Press the pawl and install the piston retainer ¼ Do not disassemble the piston assembly; into the master cylinder. otherwise, the spring set value may be changed. ¼ Use brake fluid or methanol to wash inside wall of cylinder, pistons and piston cups.

  • Page 641: Brake Booster

    SERVICE PROCEDURE [W6C0] 6. Brake Booster 6. Brake Booster 4) Do not change the push rod length. If it has been changed, reset the projected length “L” to the A: REMOVAL standard length. Standard: 1) Remove or disconnect the following parts at L = 10 mm (0.39 in) engine compartment.
  • Page 642 SERVICE PROCEDURE [W6D0] 6. Brake Booster 3) Connect vacuum hose to brake booster. 10) Bleed air from brake system. Tightening torque (Air bleeder screw): 8 ± 1 N·m (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft-lb) 11) Conduct road tests to ensure brakes do not drag.
  • Page 643 SERVICE PROCEDURE [W6E3] 6. Brake Booster 3. OPERATION CHECK 2. AIR TIGHTNESS CHECK 1) With engine off, depress brake pedal several 1) Start engine and keep it running until a vacuum times applying the same pedal force and make of 66.7 kPa (500 mmHg, 19.69 inHg) = point A is sure that the pedal height does not vary with each indicated on vacuum gauge.

  • Page 644: Brake Hose

    SERVICE PROCEDURE [W6E4] 7. Brake Hose 4. LACK OF BOOSTING ACTION CHECK 7. Brake Hose Turn off engine, and set the vacuum gauge read- A: REMOVAL ing at “0”. Then, check the fluid pressure when brake pedal is depressed. The pressure must be 1) Separate brake pipe from brake hose.
  • Page 645 SERVICE PROCEDURE [W8A0] 8. Parking Brake Lever 7) While holding hexagonal part of brake hose fit- 8. Parking Brake Lever ting with a wrench, tighten flare nut to the specified A: REPLACEMENT torque. Tightening torque (Brake pipe flare nut): 1) Remove console box from front floor. +0.3 +2.2 N·m (1.5...
  • Page 646 SERVICE PROCEDURE [W8B1] 8. Parking Brake Lever B: PARKING BRAKE ADJUSTMENT 1. LEVER STROKE ADJUSTMENT 1) Remove console cover. 2) Forcibly pull parking brake lever 3 to 5 times. 3) Adjust parking brake lever by turning adjuster until parking brake lever stroke is set at 7 to 8 notches with operating force of 196 N (20 kg, 44 lb).

  • Page 647: Parking Brake Lever

    SERVICE PROCEDURE [W9A0] 9. Parking Brake Cable 9. Parking Brake Cable A: REPLACEMENT B4M0070B (1) Parking brake lever (7) Clamp Tightening torque: N·m (kg-m, ft-lb) (2) Parking brake switch (8) Parking brake cable RH 5.9 ± 1.5 (0.60 ± 0.15, 4.3 ± 1.1) (3) Lock nut (9) Cable guide 18 ±...

  • Page 648: Air Bleeding

    SERVICE PROCEDURE [W10A0] 10. Air Bleeding 8) Roll up floor mat and remove clamps. 10. Air Bleeding A: GENERAL RULES FOR EFFECTIVE BLEEDING 1) Start with the brakes (wheels) connecting to the secondary chamber of the master cylinder. 2) The time interval between two brake pedal operations (from the time when the pedal is released to the time when it is depressed another time) shall be approximately 3 seconds.
  • Page 649 SERVICE PROCEDURE [W10B0] 10. Air Bleeding 2) Fit one end of vinyl tube into the air bleeder and 7) Check the pedal stroke. While the engine is idling, depress the brake pedal put the other end into a brake fluid container. with a 490 N (50 kg, 110 lb) load and measure the distance between the brake pedal and steering wheel.

  • Page 650: Brake Fluid

    SERVICE PROCEDURE [W11A0] 11. Brake Fluid 11. Brake Fluid 5) Install one end of a vinyl tube onto the air bleeder of and insert the other end of the tube into A: REPLACEMENT a container to collect the brake fluid. CAUTION: ¼...

  • Page 651: Proportioning Valve

    SERVICE PROCEDURE [W12B0] 12. Proportioning Valve Tightening torque (Bleeder screw): 12. Proportioning Valve 8 ± 1 N·m (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft-lb) A: INSPECTION 10) Bleed air from each wheel cylinder using the same procedures as described in before. 1) Install the oil pressure gauges to measure the 11) Depress brake pedal with a force of approxi- master cylinder fluid pressure (front wheel brake...

  • Page 652: Abs Sensor

    SERVICE PROCEDURE [W12C0] 13. ABS Sensor CAUTION: 13. ABS Sensor Do not disassemble or adjust the proportioning A: REMOVAL valve. (The proportioning valve must be replaced as an assembly.) 1. FRONT ABS SENSOR C: INSTALLATION 1) Disconnect front ABS sensor connector located 1) Install proportioning valve to bracket.
  • Page 653 SERVICE PROCEDURE [W13B2] 13. ABS Sensor 6) Remove front drive shaft and housing and hub 2) Measure ABS sensor resistance. assembly. <Ref. to 4-2 [W1A0].> 7) Remove tone wheel while removing hub from housing and hub assembly. <Ref. to 4-2 [W1B0].> CAUTION: Be careful not to damage teeth faces of tone wheel during removal.
  • Page 654 SERVICE PROCEDURE [W13B3] 13. ABS Sensor 3. OUTPUT VOLTAGE 4) Install front ABS sensor on strut and wheel apron bracket. Output voltage can be checked by the following Tightening torque: method. Install resistor and condenser, then rotate 32 ± 10 N·m (3.3 ± 1.0 kg-m, 24 ± 7 ft-lb) wheel about 2.75 km/h (2 MPH) or equivalent.
  • Page 655 SERVICE PROCEDURE [W13C2] 13. ABS Sensor 4) Install rear sensor harness on rear trailing link. Tightening torque: 32 ± 10 N·m (3.3 ± 1.0 kg-m, 24 ± 7 ft-lb) S4M0299A 5) Place a thickness gauge between ABS sensor’s pole piece and tone wheel’s tooth face. After stan- dard clearance is obtained over the entire perimeter, tighten ABS sensor on back plate to specified torque.

  • Page 656: Abs Control Module And Hydraulic Control Unit (Abscm&H/U)

    SERVICE PROCEDURE [W14A0] 14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) 14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) A: REMOVAL B4M1220B (1) Stud bolt (6) Front-RH outlet Tightening torque: N·m (kg-m, ft-lb) (2) Damper (7) Primary inlet 18 ±...
  • Page 657 SERVICE PROCEDURE [W14C1] 14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) 7) Disconnect brake pipes from ABSCM&H/U. C: CHECKING THE HYDRAULIC UNIT ABS OPERATION CAUTION: Wrap brake pipes with vinyl bag to avoid spill- 1. CHECKING THE HYDRAULIC UNIT ABS ing brake fluid on vehicle body.
  • Page 658 SERVICE PROCEDURE [W14C2] 14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) 9) Remove air bleeder screws from the RL and RR 5) Perform ABS sequence control. <Ref. to 4-4 caliper bodies. [W14D1].> or <Ref. to 4-4 [W14D2].> 10) Connect the air bleeder screws to the FL and 6) Hydraulic unit begins to work;...
  • Page 659 SERVICE PROCEDURE [W14D3] 14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) 4) Within 0.5 seconds after the ABS warning light 3. CONDITIONS FOR COMPLETION OF goes out, depress the brake pedal and hold it ABS SEQUENCE CONTROL immediately after ignition switch is turned to ON. When the following conditions develop, the ABS CAUTION: sequence control stops and ABS operation is...
  • Page 660 SERVICE PROCEDURE [W14D4] 14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) 4. CONDITIONS FOR ABS SEQUENCE CONTROL B4M1001A NOTE: ¼ When select monitor is used, control operation starts at point A. The patterns from IGN key ON to the point A show that operation is started by diag- nosis connector.

  • Page 661: G Sensor

    SERVICE PROCEDURE [W15B1] 15. G Sensor E: INSTALLATION 15. G Sensor 1) Install ABSCM&H/U. A: REMOVAL AND INSTALLATION CAUTION: 1) Turn ignition switch to OFF. Confirm that specifications 2) Remove console cover. <Ref. to 5-4 [W1A0].> ABSCM&H/U conforms to the vehicle specifica- 3) Disconnect connector from G sensor.
  • Page 662 SERVICE PROCEDURE [W15B2] 15. G Sensor C: INSPECTION WITH SELECT 15B2 : CHECK G SENSOR. MONITOR Measure voltage between G sensor connector ter- 15C1 : CHECK G SENSOR. minals. Connector & terminal 1) Turn ignition switch to OFF. (P9) No. 2 (+) — No. 3 (−) 2) Connect select monitor connector to data link connector.

  • Page 663: Brake Pipe

    SERVICE PROCEDURE [W16B0] 16. Brake Pipe 16. Brake Pipe 15C3 : CHECK G SENSOR. A: SUPPLEMENTAL RESTRAINT Read the select monitor display. SYSTEM “AIRBAG” Airbag system wiring harness is routed near the center brake pipe. CAUTION: ¼ All Airbag system wiring harness and con- nectors are colored yellow.

  • Page 664: Entire Brake System

    DIAGNOSTICS [K100] 1. Entire Brake System 1. Entire Brake System Trouble and possible cause Corrective action 1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism Repair or replace (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose). (2) Entry of air into the hydraulic mechanism Bleed the air.
  • Page 665 DIAGNOSTICS [K100] 1. Entire Brake System Trouble and possible cause Corrective action 7. Brake noise (3) In the case of the disc brake: (click sound) (1) Excessively worn pad or the support Replace the pad or the support. In the case of the drum brake: (1) Excessively worn shoe ridge Replace the back plate.
  • Page 666 DIAGNOSTICS MEMO:...

  • Page 667: Pedal System And Control Cables

    PEDAL SYSTEM AND CONTROL CABLES Page SPECIFICATIONS AND SERVICE DATA............2 Pedal System ....................2 COMPONENT PARTS ..................3 Pedal ......................3 SERVICE PROCEDURE ...................5 Pedal ......................5 Accelerator Cable..................10 DIAGNOSTICS....................12 Pedal System and Control Cables............12...

  • Page 668: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Pedal System 1. Pedal System 1 — 3 mm (0.04 — 0.12 in) [Depress brake pedal pad Brake pedal Free play with a force of less than 10 N (1 kg, 2 lb).] Free play At clutch pedal pad 4 —...

  • Page 669: Component Parts

    COMPONENT PARTS [C1A0] 1. Pedal 1. Pedal A: MT MODEL S4M0302A (1) Holder (16) Brake pedal spring (31) Clutch switch (Starter interlock) (2) Accelerator bracket (17) Clutch pedal pad (32) Clutch switch (With cruise con- (3) Stopper (18) Clutch pedal trol) (4) Bushing (19) Bushing C...
  • Page 670 COMPONENT PARTS [C1B0] 1. Pedal B: AT MODEL B4M0738C (1) Accelerator pedal (11) Accelerator stopper (21) Brake pedal (2) Bushing (12) Clip (22) Clevis pin (3) Holder (13) Accelerator plate (23) Brake pedal spring (4) Accelerator bracket (14) Plug (5) Stopper (15) Pedal bracket Tightening torque: N·m (kg-m, ft-lb) 8 ±...
  • Page 671 SERVICE PROCEDURE [W1A2] 1. Pedal 1. Pedal 2. CLUTCH PEDAL 1) Push release fork until operating cylinder push A: ON-CAR SERVICE rod retracts. Check that clutch fluid level in reser- 1. BRAKE PEDAL voir tank increases. 1) Check position of pedal pad. Pedal height: L 148 mm (5.83 in) B4M1191A...
  • Page 672 SERVICE PROCEDURE [W1A3] 1. Pedal 3. ACCELERATOR PEDAL 4) Disconnect accelerator cable from accelerator pedal lever. Check pedal stroke and free play by operating accelerator pedal by hand. If it is not within specified value, adjust it by turn- ing nut connecting accelerator cable to throttle body.

  • Page 673: Service Procedure

    SERVICE PROCEDURE [W1C1] 1. Pedal 6) Remove bolts and nuts which secure brake and C: INSPECTION clutch pedals, and remove pedal assembly. 1. BRAKE AND CLUTCH PEDALS 3. BRAKE PEDAL Move brake and clutch pedal pads in the lateral 1) Disconnect ground cable from battery. direction with a force of approximately 10 N (1 kg, 2) Remove instrument panel lower cover from 2 lb) to ensure pedal deflection is in specified...
  • Page 674 SERVICE PROCEDURE [W1C2] 1. Pedal 2. ACCELERATOR PEDAL D: ASSEMBLY Lightly move pedal pad in lateral the direction to 1. BRAKE AND CLUTCH PEDAL ensure pedal deflection is in specified range. 1) Attach stop light switch, etc. to pedal bracket Deflection of accelerator pedal: temporarily.
  • Page 675 SERVICE PROCEDURE [W1F1] 1. Pedal E: INSTALLATION F: ADJUSTMENT 1) Installation is in the reverse order of removal 1. CLUTCH PEDAL procedures. 1) Turn cruise control clutch switch lock nuts until CAUTION: clutch pedal full stroke length is within specifica- ¼...

  • Page 676: Accelerator Cable

    SERVICE PROCEDURE [W2A0] 2. Accelerator Cable Specified clutch pedal full stroke: 6) Push release lever until operating cylinder push 130 — 135 mm (5.11 — 5.31 in) rod retracts. Ensure that clutch fluid level in reser- voir tank increases. If clutch fluid level increases, 5) Move clevis pin to the left and then to the right.
  • Page 677 SERVICE PROCEDURE [W2B0] 2. Accelerator Cable 3) Separate accelerator cable (1) from bracket, B: INSTALLATION then unlock inner cable. 1) Installation is in the reverse order of removal procedures. CAUTION: ¼ Be careful not to kink accelerator cable. ¼ Make sure that holder and casing cap are securely connected.

  • Page 678: Pedal System And Control Cables

    DIAGNOSTICS [K100] 1. Pedal System and Control Cables 1. Pedal System and Control Cables Trouble Corrective action Excessively worn brake pedal pad Replace. Failure of accelerator pedals to operate Connect cables correctly. Stop light switch does not light up. Adjust position of stop light switch. Stop light switch is not smooth and/or stroke is not correct.

  • Page 679: Heater And Ventilator

    HEATER AND VENTILATOR Page SPECIFICATIONS AND SERVICE DATA............2 Specifications ....................2 COMPONENT PARTS ..................3 Heater Unit ....................3 Intake Unit ....................4 Control Unit ....................5 SERVICE PROCEDURE ...................6 Precaution ....................6 Heater Unit ....................6 Blower Motor Assembly................7 Control Unit ....................7...

  • Page 680: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S1A0] 1. Specifications 1. Specifications A: HEATER SYSTEM Item Specifications Condition ¼ Mode selector switch Heating capacity 5.0 kW : HEAT (4,300 kcal/h, 17,062 BTU/h) ¼ Temperature control switch : FULL HOT or more ¼ Temperature difference : 65°C (149°F) between hot water and inlet air ¼...

  • Page 681: Component Parts

    COMPONENT PARTS [C100] 1. Heater Unit 1. Heater Unit H4M1045B (1) Vent door (7) Mix lever (13) Vent lever (2) DEF door (8) Foot door (14) Side link (3) DEF lever (9) Foot duct (4) Heater core (10) Heater case REAR Tightening torque: N·m (kg-m, ft-lb) 7.35 ±...

  • Page 682: Intake Unit

    COMPONENT PARTS [C200] 2. Intake Unit 2. Intake Unit S4M0082A (1) Intake unit case lower (6) Lever (A) Tightening torque: N·m (kg-m, ft-lb) (2) Lever (B) (7) Link 7.35 ± 1.96 (3) Intake unit case upper (8) Rod (0.750 ± 0.200, 5.421 ± 1.446) (4) Door (A) (9) Blower motor ASSY (5) Door (B)

  • Page 683: Control Unit

    COMPONENT PARTS [C300] 3. Control Unit 3. Control Unit S4M0083A (1) Temperature control cable (6) Bulb (11) Control lever knob (2) Recirc control cable (7) A/C switch ASSY (12) Plate (3) Clip (8) Mode control cable (13) Base unit (4) Blower switch ASSY (9) Control dial knob (5) Harness ASSY (10) A/C switch knob...

  • Page 684: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Precaution 1. Precaution 2. Heater Unit A: SUPPLEMENTAL RESTRAINT A: REMOVAL AND INSTALLATION SYSTEM “AIRBAG” 1) Disconnect GND cable from battery. 2) Remove heater hoses (inlet, outlet) in engine Airbag system wiring harness is routed near the compartment.

  • Page 685: Blower Motor Assembly

    SERVICE PROCEDURE [W4A0] 4. Control Unit 3. Blower Motor Assembly 4. Control Unit A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION 1) Disconnect GND cable from battery. 1) Disconnect GND cable from battery. 2) Remove glove box. 2) Set temperature control switch to “FULL HOT” and mode selector switch to “DEF”...
  • Page 686 SERVICE PROCEDURE [W4B1] 4. Control Unit 7) Remove control unit assembly from center con- 2. A/C SWITCH sole. Check A/C switch continuity between each termi- nal. S4M0034 8) Installation is in the reverse order of removal. H5M1281A NOTE: Before installing control unit, set temperature con- trol switch to “FULL HOT”...

  • Page 687: Air Conditioning System

    AIR CONDITIONING SYSTEM Page SPECIFICATIONS ....................2 Specifications ....................2 COMPONENT PARTS ..................3 Air Conditioning System................3 Intake Unit with Evaporator.................4 Compressor ....................5 SERVICE PROCEDURE ...................6 Safety Precautions ..................6 Basic Information..................7 Tools and Equipment...................8 O-ring Connections..................11 Refrigerant Service Procedure..............13 Discharge the System ................14 Evacuating and Charging................14 Leak Testing ....................18 Lubrication ....................20...

  • Page 688: Specifications

    SPECIFICATIONS [S100] 1. Specifications 1. Specifications Item Specifications Type of air conditioner Reheat air-mix type 5.23 kW Cooling capacity (4,500 kcal/h, 17,856 BTU/h) HFC-134a (CH Refrigerant [0.6±0.05 kg (1.3±0.11 lb)] Type 5-vane rotary, fix volume (CR-14) Compressor Discharge 144 cm (8.79 cu in)/rev Max.

  • Page 689: Component Parts

    COMPONENT PARTS [C100] 1. Air Conditioning System 1. Air Conditioning System S4M0035A (1) Condenser (5) Hose (Low-pressure) Tightening torque: N·m (kg-m, ft-lb) (2) Pipe (Condenser — Receiver (6) Compressor 7.4 ± 2.0 (0.75 ± 0.2, 5.4 ± 1.4) drier) (7) Hose (High-pressure) 18 ±...

  • Page 690: Intake Unit With Evaporator

    COMPONENT PARTS [C200] 2. Intake Unit with Evaporator 2. Intake Unit with Evaporator S4M0036A (1) Evaporator (6) Drain hose Tightening torque: N·m (kg-m, ft-lb) (2) Insulator (7) Intake unit case lower 4 ± 1 (0.4 ± 0.1, 2.9 ± 0.7) (3) Block expansion valve (8) Mount bracket 7.4 ±...

  • Page 691: Compressor

    COMPONENT PARTS [C300] 3. Compressor 3. Compressor S4M0052A (1) Alternator (7) Idler pulley ASSY Tightening torque: N·m (kg-m, ft-lb) (2) Alternator bracket nut (8) Compressor bracket upper 7.4 ± 2 (0.75 ± 0.2, 5.4 ± 1.4) (3) Compressor belt cover 23 ±...

  • Page 692: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Safety Precautions 1. Safety Precautions A: HFC-134a AIR CONDITIONING SYSTEM Component parts cooling system, refrigerant, compressor oil, and other parts are not the same for the HFC- 134a system and the older CFC-12 system. Do not interchange parts or liquid. Vehicles with HFC-134a air conditioning systems, use only HFC-134a parts that are indicated on a label attached to the vehicle.

  • Page 693: Basic Information

    SERVICE PROCEDURE [W200] 2. Basic Information D: HANDLING OF REFRIGERANT 2. Basic Information Because refrigerant boils at approx. −30°C (−22°F) 1) The combination of moisture and refrigerant at sea level, it is cold enough to give you severe forms acid, therefore, moisture should not be frostbite.

  • Page 694: Tools And Equipment

    SERVICE PROCEDURE [W300] 3. Tools and Equipment 3. Tools and Equipment pressor oil is mixed, poor lubrication will result and the compressor itself may be destroyed. In The following section provides information about order to help prevent mixing HFC-134a and the tools and equipment that will be necessary to CFC-12 parts and liquid, the tool and screw properly service the A/C system.
  • Page 695 SERVICE PROCEDURE [W300] 3. Tools and Equipment Tools and Equipment Description ¼ REFRIGERANT RECOVERY SYSTEM A REFRIGERANT RECOVERY SYSTEM is used for the recovery and reuse of A/C system refrigerant after contaminants and moisture have been removed from the refrigerant. G4M0574 ¼...
  • Page 696 SERVICE PROCEDURE [W300] 3. Tools and Equipment Tools and Equipment Description ¼ THERMOMETER Pocket THERMOMETERS are available from either industrial hard- ware store or commercial refrigeration supply houses. G4M0578 ¼ ELECTRONIC LEAK DETECTOR An ELECTRONIC LEAK DETECTOR can be obtained from either a specialty tool supply or an A/C equipment supplier.

  • Page 697: O-Ring Connections

    SERVICE PROCEDURE [W4C0] 4. O-ring Connections 4. O-ring Connections C: LUBRICATE THE COMPONENTS For lubrication of the components, use only refrig- A: GENERAL erant oil as described in the appropriate service The following points should be kept in mind when manual.
  • Page 698 SERVICE PROCEDURE [W4D0] 4. O-ring Connections D: TORQUE THE FITTING Using a back-up wrench in conjunction with a cali- brated torque wrench, torque the connection to the midrange of the specification. After completion of torquing, use a clean shop towel to remove any excess oil from the connection or any oil that may have dripped on the vehicle body or other parts.

  • Page 699: Refrigerant Service Procedure

    SERVICE PROCEDURE [W5A0] 5. Refrigerant Service Procedure 5. Refrigerant Service Procedure A: WORK FLOW H4M1261A...

  • Page 700: Discharge The System

    SERVICE PROCEDURE [W600] 6. Discharge the System 6. Discharge the System 7. Evacuating and Charging CAUTION: The following points should be kept in mind when The following points must be kept in mind evacuating and charging with a manifold gauge when discharging the system.
  • Page 701 SERVICE PROCEDURE [W7B0] 7. Evacuating and Charging 6) Slowly open the low-pressure manifold valve. 4) Note the low side gauge reading. G4M0597 G4M0600 7) When the low-pressure gauge reaches approxi- 5) After 5 minutes, re-check the low-pressure mately 66.43 kPa (498.3 mmHg, 19.62 inHg), gauge reading.
  • Page 702 SERVICE PROCEDURE [W7C0] 7. Evacuating and Charging C: PURGE THE CENTER HOSE E: CHECK THE GAUGE READINGS CAUTION: When both the high- and low-pressure gauge read- Be certain that goggle and glove are worn. ings are about equal, or the HFC-134a source is empty, or the system has been filled to 1) Verify that all three hose connections are tight specifications, close the high-pressure manifold...
  • Page 703 SERVICE PROCEDURE [W7J0] 7. Evacuating and Charging 5) Quickly turn the A/C switch on-off-on-off a few I: COMPLETE ALL SYSTEM times to prevent initial compressor damage due to CHECKS “load shock.” Finish this operation with the A/C 1) Evaluate the system performance. <Ref. to 4-7 switch in the ON position.

  • Page 704: Leak Testing

    SERVICE PROCEDURE [W8A0] 8. Leak Testing 8. Leak Testing 3. CALIBRATE LEAK DETECTOR Refer to the manufacturer’s instructions for the par- A: INSPECTION ticular type of detector used and calibrate the The following points should be kept in mind when instrument.
  • Page 705 SERVICE PROCEDURE [W8A7] 8. Leak Testing ¼ Check the area where the two parts of the fitting 2) Check the area. join each other. (1) Check the area where the fitting joins the tube. (2) Check the area where the two parts of the fitting join each other.

  • Page 706: Lubrication

    SERVICE PROCEDURE [W8A8] 9. Lubrication 3) With the ignition key in the “ACC” position, run 9. Lubrication the blower on high speed for 1 minute, then turn A: ADJUSTMENT the blower off. Place the probe in the center instru- ment panel vent, an turn the blower on low speed 1.

  • Page 707: Performance Test

    SERVICE PROCEDURE [W11A1] 11. Compressor 10. Performance Test 11. Compressor A: INSPECTION A: INSPECTION 1. VEHICLE SET UP 1. COMPRESSOR CLUTCH In order to obtain meaningful test results, the NOTE: ¼ Compressor is a 5-vane rotary type. When vehicle must be set up to meet the following con- ditions: trouble occurs, replace compressor as a single ¼...
  • Page 708 SERVICE PROCEDURE [W11B0] 11. Compressor B: REMOVAL 4) Compressor belt cover and generator belt cover: 1) Disconnect ground cable from battery. Remove bolts which secure belt covers. 2) Discharge refrigerant using refrigerant recovery system. <Ref. to 4-7 [W600].> (1) Fully close low-pressure valve of manifold gauge.
  • Page 709 SERVICE PROCEDURE [W11C0] 11. Compressor 8) Disconnect compressor harness: 4) Install compressor V-belt (Rear): After adjusting belt tension, tighten tension pulley Disconnect compressor harness from body har- lock bolt securely. ness. 9) Remove lower bracket: Remove bolts which secure lower compressor bracket.

  • Page 710: Condenser

    SERVICE PROCEDURE [W12A0] 12. Condenser B4M1098A 7) Install high-pressure hose (B) (Flexible hose 12. Condenser Pd) and low-pressure hose (A) (Flexible hose Ps): A: REMOVAL AND INSTALLATION Connect high-pressure hose (B) and low-pressure hose (A) with compressor. 1) Disconnect battery negative terminal. CAUTION: 2) Discharge refrigerant using refrigerant recovery Be sure to apply compressor oil to the periph-...

  • Page 711: Receiver Drier

    SERVICE PROCEDURE [W13A0] 13. Receiver Drier 6) Remove radiator brackets. 13. Receiver Drier 7) Remove the two bolts which secure condenser. A: REMOVAL AND INSTALLATION While lifting condenser, remove it through space between radiator and radiator panel. 1) Disconnect battery negative terminal. 2) Discharge refrigerant using refrigerant recovery system.

  • Page 712: Intake Unit With Evaporator

    SERVICE PROCEDURE [W14A0] 14. Intake Unit with Evaporator 14. Intake Unit with Evaporator B: DISASSEMBLY AND ASSEMBLY 1) Remove resistor assembly and remove thermo A: REMOVAL AND INSTALLATION control amplifier from intake unit case. 1) Disconnect battery negative terminal. 2) Discharge refrigerant using refrigerant recovery system.

  • Page 713: Condenser Fan Assembly

    SERVICE PROCEDURE [W15A0] 15. Condenser Fan Assembly 7) Before assembling intake unit, apply sealer to 15. Condenser Fan Assembly flange of intake unit case. A: REMOVAL AND INSTALLATION Sealer: THREE BOND 1215 or equivalent 1) Disconnect battery negative terminal. 2) Disconnect harness connector from fan motor. 3) Remove condenser fan bolt from radiator.

  • Page 714: Flexible Hose

    SERVICE PROCEDURE [W16A0] 16. Flexible Hose 16. Flexible Hose 17. Relay and Fuse A: REMOVAL AND INSTALLATION A: LOCATION CAUTION: Relays used with A/C system are located as shown With the following cautions, replace flexible in figure. ¼ A/C relay hoses with new ones if they are damaged or ¼...

  • Page 715: Pressure Switch (Dual Switch)

    SERVICE PROCEDURE [W18A0] 18. Pressure Switch (Dual Switch) B: INSPECTION 18. Pressure Switch (Dual Switch) Check conduction with a circuit tester (ohm range) according to the following table in figure. A: INSPECTION NOTE: Pressure switch is attached to receiver dryer. It has two built-in switches.

  • Page 716: Air Conditioning System Diagnosis

    DIAGNOSTICS [K100] 1. Air Conditioning System Diagnosis 1. Air Conditioning System Diagnosis H4M1265A...

  • Page 717: Performance Test Diagnosis

    DIAGNOSTICS [K200] 2. Performance Test Diagnosis 2. Performance Test Diagnosis Each shaded area on the following tables indicates a reading of the normal system when the tempera- If various conditions caused to other air condition- ture of outside air is 32.5°C (91°F). ing system, the characteristics revealed on mani- fold gauge reading are shown in the following.
  • Page 718 DIAGNOSTICS [K200] 2. Performance Test Diagnosis Condition Probable cause Corrective action Insufficient cooling. Expansion valve Check valve for opera- Sweated suction line. allows too much refrig- tion. If suction side No cooling. erant through evapora- does not show a pres- Sweating or frosted tor.
  • Page 719 DIAGNOSTICS [K200] 2. Performance Test Diagnosis Condition Probable cause Corrective action ¼ Check condenser FAULTY CONDENSER No cooling action. Condenser is often Engine may overheat. found not functioning cooling fan. ¼ Check condenser for Suction line is very well. hot. dirt accumulation.

  • Page 720: Blower Motor Diagnosis

    DIAGNOSTICS [K300] 3. Blower Motor Diagnosis 3. Blower Motor Diagnosis S4M0294A...

  • Page 721: Compressor Diagnosis

    DIAGNOSTICS [K400] 4. Compressor Diagnosis 4. Compressor Diagnosis H4M1267A...

  • Page 722: Compressor Clutch Diagnosis

    DIAGNOSTICS [K500] 5. Compressor Clutch Diagnosis 5. Compressor Clutch Diagnosis S4M0295A...
  • Page 723 DIAGNOSTICS [K500] 5. Compressor Clutch Diagnosis S4M0296A...

  • Page 724: Radiator Fan (Main Fan) Diagnosis

    DIAGNOSTICS [K600] 6. Radiator Fan (Main Fan) Diagnosis 6. Radiator Fan (Main Fan) Diagnosis S4M0297A...

  • Page 725: Condenser Fan (Sub Fan) Diagnosis

    DIAGNOSTICS [K700] 7. Condenser Fan (Sub Fan) Diagnosis 7. Condenser Fan (Sub Fan) Diagnosis S4M0298A...
  • Page 726 DIAGNOSTICS MEMO:...

  • Page 727: Body And Exterior

    BODY AND EXTERIOR Page SPECIFICATIONS AND SERVICE DATA............2 Precaution ....................2 Body Datum Points ..................2 Datum Dimensions ..................15 Datum Points and Dimensions Concerning On-Board Aiming Adjustment....................21 COMPONENT PARTS ..................22 Front Hood and Hood Lock...............22 Front Bumper ....................23 Rear Bumper .....................24 Side Protector....................25 Steering Support Beam................26 Guard Pipe ....................27 Sunroof ......................28...

  • Page 728: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S1A0] 1. Precaution 1. Precaution 2. Body Datum Points Various master repair locations are established as A: SUPPLEMENTAL RESTRAINT datum points used during body repairs. In addition, SYSTEM “AIRBAG” guide holes, locators and indents are provided to Airbag system wiring harness is routed on and facilitate panel replacement and achieve alignment along body panels.
  • Page 729 SPECIFICATIONS AND SERVICE DATA [S2A0] 2. Body Datum Points A: ENGINE COMPARTMENT AND ROOM S5M0073A (1) Radiator panel (UPR) repair bolt (10) Hood hinge attaching bolt hole (20) Center pillar gauge hole 12 mm hole M8 (Right) M8 (Symmetrical) (0.47 in) dia. (Symmetrical) (2) Radiator panel (UPR) repair bolt (11) Cowl panel mounting hole 6 mm (21) Belt anchor attaching bolt hole...
  • Page 730 SPECIFICATIONS AND SERVICE DATA [S2B0] 2. Body Datum Points B: LUGGAGE COMPARTMENT AND ROOM S5M0074A (27) Rear pillar (Inner) harness clip (43) Roof rail attaching square hole 9 (65) Seat belt anchor attaching bolt attaching hole 8 mm (0.31 in) mm (0.35 in) dia.
  • Page 731 SPECIFICATIONS AND SERVICE DATA [S2C0] 2. Body Datum Points C: UNDER BODY S5M0075A (50) Radiator panel (LWR) frame (53) Front suspension attaching bolt (56) Side frame gauge hole 15 mm gauge hole 15 mm (0.59 in) dia. hole M14 (0.59 in) dia. (Symmetrical) (Symmetrical) (54) Side frame gauge hole 20 mm (57) Rear differential attaching bolt...
  • Page 732 SPECIFICATIONS AND SERVICE DATA [S2D0] 2. Body Datum Points D: DATUM POINT LOCATION S5M0076A S5M0077A S5M0079A S5M0078A S5M0080A S5M0081A...
  • Page 733 SPECIFICATIONS AND SERVICE DATA [S2D0] 2. Body Datum Points S5M0083A S5M0082A S5M0085A S5M0084A S5M0087A S5M0086A S5M0089A S5M0088A...
  • Page 734 SPECIFICATIONS AND SERVICE DATA [S2D0] 2. Body Datum Points S5M0091A S5M0090A S5M0092A S5M0093A S5M0095A S5M0094A S5M0097A S5M0096A...
  • Page 735 SPECIFICATIONS AND SERVICE DATA [S2D0] 2. Body Datum Points S5M0098A S5M0099A S5M0100A S5M0101A S5M0102A S5M0103A S5M0104A S5M0105A...
  • Page 736 SPECIFICATIONS AND SERVICE DATA [S2D0] 2. Body Datum Points S5M0106A S5M0107A S5M0109A S5M0108A S5M0110A S5M0111A S5M0113A S5M0112A...
  • Page 737 SPECIFICATIONS AND SERVICE DATA [S2D0] 2. Body Datum Points S5M0114A S5M0115A S5M0116A S5M0117A S5M0118A S5M0119A S5M0120A S5M0121A...
  • Page 738 SPECIFICATIONS AND SERVICE DATA [S2D0] 2. Body Datum Points S5M0122A S5M0123A S5M0125A S5M0124A S5M0126A S5M0127A S5M0129A S5M0128A...
  • Page 739 SPECIFICATIONS AND SERVICE DATA [S2D0] 2. Body Datum Points S5M0130A S5M0131A S5M0132A S5M0133A S5M0134A S5M0135A S5M0136A...
  • Page 740 SPECIFICATIONS AND SERVICE DATA [S2D0] 2. Body Datum Points MEMO:...

  • Page 741: Datum Dimensions

    SPECIFICATIONS AND SERVICE DATA [S300] 3. Datum Dimensions 3. Datum Dimensions Use a tram tracking gauge to measure all dimen- sions. 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 742 SPECIFICATIONS AND SERVICE DATA [S3A0] 3. Datum Dimensions A: FRONT STRUCTURE S5M0137A Unit: mm (in) Point to point Dimension Point to point Dimension (11) R to (1) 851 (33.50) (10) R to (8) R 388 (15.28) (11) L to (1) 912 (35.91) (10) L to (8) L 388 (15.28)
  • Page 743 SPECIFICATIONS AND SERVICE DATA [S3B0] 3. Datum Dimensions B: CENTER STRUCTURE S5M0138A...
  • Page 744 SPECIFICATIONS AND SERVICE DATA [S3C0] 3. Datum Dimensions C: DOORS AND PASSENGER COMPARTMENT S5M0139A...
  • Page 745 SPECIFICATIONS AND SERVICE DATA [S3C0] 3. Datum Dimensions Unit: mm (in) Point to point Dimension Point to point Dimension (14) L to (18) L 1,454 (57.24) (16) L to (64) L 860 (33.86) (14) R to (18) R 1,454 (57.24) (16) R to (64) R 860 (33.86) (13) L to (64) L...
  • Page 746 SPECIFICATIONS AND SERVICE DATA [S3D0] 3. Datum Dimensions D: LUGGAGE COMPARTMENT S5M0140A Unit: mm (in) Point to point Dimension Point to point Dimension (45) to (48) L 913 (35.94) (41) to (65) R 1,105 (43.05) (45) to (48) R 913 (35.94) (41) to (65)L 1,105 (43.05) (45) to (47) L...

  • Page 747: Datum Points And Dimensions Concerning On-Board Aiming

    SPECIFICATIONS AND SERVICE DATA [S400] 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. NOTE: It is recommended to conduct On-board aiming adjustment with headlights turned OFF.

  • Page 748: Component Parts

    COMPONENT PARTS [C100] 1. Front Hood and Hood Lock 1. Front Hood and Hood Lock S5M0142A (1) Front hood (6) Hood lock ASSY Tightening torque: N·m (kg-m, ft-lb) (2) Hinge bracket (7) Striker 14 ± 1 (1.4 ± 0.1, 10.1 ± 0.7) (3) Lever ASSY (8) Seal (Front hood) 32 ±...

  • Page 749: Front Bumper

    COMPONENT PARTS [C200] 2. Front Bumper 2. Front Bumper S5M0143A (1) Bumper face (5) Beam upper Tightening torque: N·m (kg-m, ft-lb) (2) Spacer (6) Fog light cover 33 ± 1 (3.4 ± 0.1, 24.6 ± 0.7) (3) E/A form 70 ± 1 (7.1 ± 0.1, 51.4 ± 0.7) (4) Back beam...

  • Page 750: Rear Bumper

    COMPONENT PARTS [C300] 3. Rear Bumper 3. Rear Bumper S5M0144A (1) Bumper beam (4) Bumper face Tightening torque: N·m (kg-m, ft-lb) (2) E/A form (5) Bumper side plate 93 ± 25 (9.5 ± 2.5, 69 ± 18) (3) Side upper bracket (6) Rear arch cover...

  • Page 751: Side Protector

    COMPONENT PARTS [C400] 4. Side Protector 4. Side Protector S5M0145A (1) Side protector (Front fender) (3) Side protector (Rear door) (5) Side protector (Side sill) (2) Side protector (Front door) (4) Side protector (Rear quarter)

  • Page 752: Steering Support Beam

    COMPONENT PARTS [C500] 5. Steering Support Beam 5. Steering Support Beam S5M0146A (1) Bracket Tightening torque: N·m (kg-m, ft-lb) (2) Steering beam 18 ± 5 (1.8 ± 0.5, 13.0 ± 3.6)

  • Page 753: Guard Pipe

    COMPONENT PARTS [C600] 6. Guard Pipe 6. Guard Pipe S5M0147A (1) Guard pipe Tightening torque: N·m (kg-m, ft-lb) (2) Rear floor panel 32 ± 10 (3.3 ± 1.0, 23.9 ± 7.2)

  • Page 754: Sunroof

    COMPONENT PARTS [C700] 7. Sunroof 7. Sunroof S5M0290A (1) Glass lid (7) Harness (13) Shim (2) Rear drain ASSY (8) Sunshade Tightening torque: N·m (kg-m, ft-lb) (3) Frame ASSY (9) Garnish 7.4 ± 2.0 (0.75 ± 0.2, 5.4 ± 1.4) (4) Motor ASSY (10) Frame bracket (5) Drive unit...

  • Page 755: Service Procedure

    SERVICE PROCEDURE [W1B0] 1. Hood 1. Hood 2) Remove bolts which secure lock assembly to radiator panel, and remove lock assembly. A: REMOVAL AND INSTALLATION NOTE: The hood lock has a dual locking design which consists of a main lock and a safety lock mecha- nism.

  • Page 756: Fuel Flap

    SERVICE PROCEDURE [W1C0] 2. Fuel Flap 2. Fuel Flap 3) Check other levers and spring for rust formation and unsmooth movement. A: REMOVAL AND INSTALLATION 1) Remove bolts which hold hinge to car body, and detach fuel flap and hinge as a unit. G5M0140 C: ADJUSTMENT S5M0150...

  • Page 757: Front Bumper

    SERVICE PROCEDURE [W3A0] 3. Front Bumper 3. Front Bumper 8) Turn over the front mud guard of the front por- tion and then remove bolt. A: REMOVAL AND INSTALLATION 1) Disconnect the ground cable from the battery. 2) Remove front fog light. 3) Remove the front grille.

  • Page 758: Rear Bumper

    SERVICE PROCEDURE [W4A0] 4. Rear Bumper 4. Rear Bumper 8) Remove bolts from bumper stay. A: REMOVAL AND INSTALLATION 1) Disconnect the ground cable from the battery. 2) Open rear gate. 3) Remove five screws from upper side of bumper. G5M0161 9) Remove rear bumper beam.

  • Page 759: Coating Method For Pp Bumper

    SERVICE PROCEDURE [W5A0] 5. Coating Method for PP Bumper 5. Coating Method for PP Bumper A: PROCESS STEPS Process No. Process name Job contents Bumper mounting Set bumper on paint worktable if required. Use paint worktable con- forming to inner shape of bumper when possible.
  • Page 760 SERVICE PROCEDURE [W600] 6. Repair Instructions for Colored PP Bumper 6. 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 lus- tre of the base material or coating, can be almost fully restored.
  • Page 761 SERVICE PROCEDURE [W6C0] 6. Repair Instructions for Colored PP Bumper Process No. Process name Job contents Cutting If nature of damage is cracks or holes, cut a guide slit of 20 to 30 mm (0.79 to 1.18 in) in length along the crack or hole up to the bumper’s base surface.
  • Page 762 SERVICE PROCEDURE [W6C0] 6. Repair Instructions for Colored PP Bumper Process No. Process name Job contents Sanding (II) Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife, operate it at a rate lower than 1,500 rpm and grind the excess part little by little.
  • Page 763 SERVICE PROCEDURE [W6C0] 6. Repair Instructions for Colored PP Bumper Process No. Process name Job contents Top coat (II) Not required. Apply a clear coat three times at an interval of 3 to 5 minutes. ¼ Recommended paint: SC710 Overlay Clear No.

  • Page 764: Side Protector

    SERVICE PROCEDURE [W7A0] 7. Side Protector 7. Side Protector A: REMOVAL AND INSTALLATION S5M0164A...

  • Page 765: Front Fender

    SERVICE PROCEDURE [W9A0] 9. Mud Guard 8. Front Fender 9. Mud Guard A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION 1) Disconnect ground cable from battery. 1) Jack-up vehicle to remove tire. 2) Remove mud guard. 2) Remove screws and clips. Move mud guard 3) Remove parking light and headlight.

  • Page 766: Cowl Panel

    SERVICE PROCEDURE [W10A0] 10. Cowl Panel 10. Cowl Panel 11. Molding and Retainer A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION 1) Remove cowl panel side. 1) Remove weatherstrip. 2) Remove tapping screws. S5M0167 S5M0169 2) Open front hood. 3) Remove wiper arms. 3) Installation is in the reverse order of removal.

  • Page 767: Front Grill

    SERVICE PROCEDURE [W13A0] 13. Under Cover 12. Front Grill 13. Under Cover A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION 1) Remove four upper clips from body panel. To 1) Lift-up the vehicle. facilitate removal, press portion shown in figure 2) Remove bolts and clips then detach under using screwdriver while lightly pulling front grille.

  • Page 768: Roof Rail

    SERVICE PROCEDURE [W14A0] 14. Roof Rail 14. Roof Rail 2) Remove seven attaching bolts and then care- fully detach roof rail. A: REMOVAL AND INSTALLATION 1) Remove roof trim. S5M0171A 3) Installation is in the reverse order of removal. CAUTION: Be careful not to scratch body panels with roof rail stud bolts when removing and installing them.

  • Page 769: Sunroof

    SERVICE PROCEDURE [W15B1] 15. Sunroof 15. Sunroof NOTE: ¼ Make sure to connect harness connector. A: REMOVAL AND INSTALLATION ¼ When installing drain tube, insert it securely into drain pipe. 1. GLASS LID Length A: 1) Completely close glass lid and open sunshade. 15 mm (0.59 in) or more 2) Detach four covers (A) and then remove eight nuts.

  • Page 770: Crossbar

    SERVICE PROCEDURE [W15B2] 16. Crossbar 16. Crossbar 2. CHECKING FOR MOVEMENT OF SUNROOF PANEL ITSELF A: REMOVAL 1) Place a cloth on sunshade, and attach a spring scale to sunshade edge using the cloth. 1) Loosen and remove TORX bolt T30 from the top of each crossbar end support, and then remove inner clamp.
  • Page 771 SERVICE PROCEDURE [W16B2] 16. Crossbar 2) With the front direction arrow label on the top 2. REAR CROSSBAR right side of the crossbar pointing toward the front NOTE: of the vehicle, carefully place the crossbar across Rear crossbar does not have the “MAXIMUM the top of the vehicle so that the crossbar end LOAD ROOF RACK-150LBS.

  • Page 772: Sunroof

    DIAGNOSTICS [K100] 1. Sunroof 1. Sunroof (1) Check roof panel and sunroof glass lid for improper or poor sealing. Entry of water into compartment (2) Check drain tube for clogging. (3) Check sunroof frame seal and body for improper fit. (1) Check sunroof glass lid and roof panel for improper clear- Booming noise ance.

  • Page 773: Doors And Windows

    DOORS AND WINDOWS Page SPECIFICATIONS AND SERVICE DATA............2 Door Alignment....................2 COMPONENT PARTS ..................3 Front Door ....................3 Rear Door....................4 Fixed Glass ....................5 Front Door Glass..................6 Rear Door Glass ..................7 Rear Gate and Glass ..................8 Door Lock Assembly ...................9 Door Trim....................11 Weatherstrip ....................12 SERVICE PROCEDURE .................13 Door and Related Parts ................13 Door......................14...

  • Page 774: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Door Alignment 1. Door Alignment S5M0172A...

  • Page 775: Component Parts

    COMPONENT PARTS [C100] 1. Front Door 1. Front Door S5M0173A (1) Gusset (7) Checker Tightening torque: N·m (kg-m, ft-lb) (2) Weatherstrip (8) Sealing cover 7.4 ± 2.0 (0.75 ± 0.2, 5.4 ± 1.4) (3) Stabilizer (Outer) (9) Lower hinge 13 ± 3 (1.3 ± 0.3, 9.4 ± 2.2) (4) Stabilizer (Inner) (10) Upper hinge 25 ±...

  • Page 776: Rear Door

    COMPONENT PARTS [C200] 2. Rear Door 2. Rear Door S5M0174A (1) Weatherstrip (6) Seating cover Tightening torque: N·m (kg-m, ft-lb) (2) Stabilizer (Outer) (7) Checker 7.4 ± 2.0 (0.75 ± 0.2, 5.4 ± 1.4) (3) Stabilizer (Inner) (8) Lower hinge 25 ±...

  • Page 777: Fixed Glass

    COMPONENT PARTS [C300] 3. Fixed Glass 3. Fixed Glass S5M0175A (1) Windshield glass (4) Rearview mirror mount (7) Locate pin (2) Dam rubber (5) Side molding (8) Rear quarter garnish (3) Molding (6) Rear quarter glass...

  • Page 778: Front Door Glass

    COMPONENT PARTS [C400] 4. Front Door Glass 4. Front Door Glass S5M0176A (1) Door sash (Front) (5) Motor ASSY Tightening torque: N·m (kg-m, ft-lb) (2) Glass 7.4 ± 2.0 (0.75 ± 0.2, 5.4 ± 1.4) (3) Door sash (Rear) 14 ± 4 (1.4 ± 0.4, 10.1 ± 2.9) (4) Regulator ASSY...

  • Page 779: Rear Door Glass

    COMPONENT PARTS [C500] 5. Rear Door Glass 5. Rear Door Glass S5M0177A (1) Door sash (Front) (5) Motor ASSY Tightening torque: N·m (kg-m, ft-lb) (2) Glass 7.4 ± 2.0 (0.75 ± 0.2, 5.4 ± 1.4) (3) Door sash (Rear) 14 ± 4 (1.4 ± 0.4, 10.1 ± 2.9) (4) Regulator ASSY...

  • Page 780: Rear Gate And Glass

    COMPONENT PARTS [C600] 6. Rear Gate and Glass 6. Rear Gate and Glass S5M0178A (1) Locate pin (9) Clip Tightening torque: N·m (kg-m, ft-lb) (2) Dam rubber (10) Outer handle 7.4 ± 2.0 (0.75 ± 0.2, 5.4 ± 1.4) (3) Glass (11) Striker 14 ±...

  • Page 781: Door Lock Assembly

    COMPONENT PARTS [C7A0] 7. Door Lock Assembly 7. Door Lock Assembly A: FRONT DOOR S5M0179A (1) Inner remote ASSY (5) Door latch Tightening torque: N·m (kg-m, ft-lb) (2) Bell crank (6) Auto-door lock actuator 6.4 ± 2.0 (0.65 ± 0.2, 4.7 ± 1.4) (3) Door outer handle 7.4 ±...
  • Page 782 COMPONENT PARTS [C7B0] 7. Door Lock Assembly B: REAR DOOR S5M0180A (1) Door outer handle (5) Rod holder Tightening torque: N·m (kg-m, ft-lb) (2) Door latch (6) Inner remote ASSY 6.4 ± 2.0 (0.65 ± 0.2, 4.7 ± 1.4) (3) Auto-door lock actuator 7.4 ±...

  • Page 783: Door Trim

    COMPONENT PARTS [C800] 8. Door Trim 8. Door Trim S5M0181A (1) Gusset cover (4) Pull handle (7) Speaker grille (2) Weatherstrip (5) Inner remote cover (8) Handle (3) Trim panel (6) Pocket...

  • Page 784: Weatherstrip

    COMPONENT PARTS [C900] 9. Weatherstrip 9. Weatherstrip S5M0182A (1) Retainer and molding (3) Retainer (Center) (5) Weatherstrip (Rear door) (2) Upper and side weatherstrip (4) Weatherstrip (Front door)

  • Page 785: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Door and Related Parts 1. Door and Related Parts A: PROCEDURE CHART FOR REMOVING AND INSTALLING NOTE: This flowchart shows the main procedures for removing and installing the door and its related parts. For details, refer to the text. H5M0910A...

  • Page 786: Door

    SERVICE PROCEDURE [W2A1] 2. Door 2. Door 2. TRIM PANEL CAUTION: A: REMOVAL AND INSTALLATION Be careful not to break clip by applying undue 1. DOOR ASSEMBLY force. 1) Front door trim: 1) Remove lower trim and disconnect connectors (1) Remove gusset cover (A), power window from body harness.
  • Page 787 SERVICE PROCEDURE [W2A6] 2. Door 3) Remove sealer with a spatula. 5. INNER REMOTE CAUTION: 1) Remove trim panel. Be careful because cover may break if sealer is 2) Remove sealing cover. removed forcefully. 3) Disconnect joints of two rods. 4) Unlatch rod holder.
  • Page 788 SERVICE PROCEDURE [W2A7] 2. Door NOTE: 7) Remove bolts and nuts which secure gusset. ¼ Check operation of each part. Tightening torque: Bolt ¼ Check each sliding part for proper lubrication. 3 ± 3 N·m (1.3 ± 0.3 kg-m, 9.4 ± 2.2 ft-lb) CAUTION: Tightening torque: Nut After installation, be sure lock mechanism...
  • Page 789 SERVICE PROCEDURE [W2B3] 2. Door 2. INNER REMOTE 1) Lock the door. 2) Loosen bolt (A). 3) Lower bell crank (B) and then tighten bolt (A). S5M0191A 3. PROCEDURE CHART FOR ADJUSTING DOOR GLASS H5M0912A...
  • Page 790 SERVICE PROCEDURE [W2B4] 2. Door 4. FRONT DOOR GLASS S5M0196A ¼ 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 791 SERVICE PROCEDURE [W2B4] 2. Door 3) Lower door glass 10 to 15 mm (0.39 to 0.59 in) 3) If glass tilts to far rearward, loosen adjusting nut from fully closed position. While applying outward (C) and adjust glass to be parallel with center pillar, pressure (load) to upper edge of glass above mid- then after adjustment, tighten adjusting nut (C).
  • Page 792 SERVICE PROCEDURE [W2B4] 2. Door 2) Increase the upward travel of window glass up 1) Alternately adjust two rear sash adjusting bolts (A) until dimensions are obtained. to the position where upper edge just touches weatherstrip surface with door closed. CAUTION: Do not loosen two adjusting nuts (A) at the same time, as this moves sash fore and aft,...
  • Page 793 SERVICE PROCEDURE [W2B5] 2. Door 5. REAR DOOR GLASS 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.
  • Page 794 SERVICE PROCEDURE [W2C1] 2. Door ¼ Fore-aft adjustment ¼ Fit adjustment 1) Door glass alignment must be adjusted so that Increasing contact pressure causes rear door glass-to-center pillar fit is equal at all points. glass to be caught in center pillar upper and lower Always use dimensions as a guide during adjust- weatherstrip;...

  • Page 795: Rear Gate

    SERVICE PROCEDURE [W3A1] 3. Rear Gate 2. REAR DOOR GLASS 1) Close rear door and make sure of all clearances. S5M0204A 2) If any clearance is not correct, adjust affected 3. Rear Gate parts. Re-check that all clearances are correct. A: REMOVAL AND INSTALLATION CAUTION: ¼...
  • Page 796 SERVICE PROCEDURE [W3A2] 3. Rear Gate ¼ It is good practice to place a vinyl sack over 6) Gas stay: (1) Completely open rear gate. it before drilling the hole because oil may spurt out. Be careful to prevent vinyl cover from (2) Remove bolts which hold gas stay to rear becoming entangled on the drill.
  • Page 797 SERVICE PROCEDURE [W3A6] 3. Rear Gate 3. OUTER HANDLE 5. STRIKER 1) Remove rear skirt trim. 1) Remove trim panel. 2) Remove two bolts from striker (D) and detach 2) Remove latch (A). striker. 3) Remove two nuts used to hold outer handle (B) to the inside of rear gate, and detach outer handle.

  • Page 798: Procedure Chart For Removal And Installing Window Glass

    SERVICE PROCEDURE [W4A0] 4. Procedure Chart for Removal and Installing Window Glass 4. Procedure Chart for Removal and Installing Window Glass A: REMOVAL AND INSTALLATION H5M0914A...

  • Page 799: Windshield

    SERVICE PROCEDURE [W5A1] 5. Windshield 5. Windshield 1. MATERIALS REQUIRED FOR APPLICATION A: REMOVAL Description Remarks 1. USING WINDSHIELD KNIFE Repair adhesive set Sunstar No. 580 or Essex ¼ Cartridge of single-liquid Chemical Corp’s Urethane E The following procedure for the front windshield urethane adhesive Sunstar No.
  • Page 800 SERVICE PROCEDURE [W5A2] 5. Windshield NOTE: B: INSTALLATION A matching pin is cemented to corners of glass on 1) After cutting layer of adhesive, remove gum compartment side. Use a piano wire when cutting rubber remaining on body. each pin. 2) Finishing adhesion surface on body side: Using a cutter knife etc., cut layer of adhesive sticking firmly to body, and finish it to a smooth surface of...
  • Page 801 SERVICE PROCEDURE [W5B0] 5. Windshield 6) Application of primer: (2) Mount glass on body with matching pin (1) Using a sponge, apply primer to part of aligned. glass to be adhered. (2) Apply primer to part of body to be adhered. CAUTION: ¼...

  • Page 802: Rear Gate Glass

    SERVICE PROCEDURE [W6A0] 6. Rear Gate Glass 6. Rear Gate Glass CAUTION: ¼ Move vehicle very gently. ¼ Do not squirt strong hose stream on vehicle. A: REMOVAL 11) Spontaneous drying: 1) Remove rear wiper and rear gate trim. After completing all operations, leave vehicle alone 2) Disconnect connector from rear defogger termi- for 24 hours.
  • Page 803 SERVICE PROCEDURE [W6B0] 6. Rear Gate Glass 2) Install glass in same manner as windshield. 3) About one hour after installation, test for water leakage. Leave vehicle for 24 hours before using 4) Connect rear defogger connections. 5) Install rear gate trim and rear wiper. S5M0209A...

  • Page 804: Rear Quarter Glass

    SERVICE PROCEDURE [W7A0] 7. Rear Quarter Glass 7. Rear Quarter Glass A: REMOVAL 1) Remove rear quarter molding on corner. 2) Remove glass in same manner as in windshield. S5M0210A B: INSTALLATION 4) Application of primer: (1) Using a sponge, apply primer to surface of 1) Finish surface of adhesive layer on body: Using glass to be adhered.
  • Page 805 SERVICE PROCEDURE [W7B0] 7. Rear Quarter Glass (2) Open cartridge and put it into a gun with 7) Water leakage test: nozzle attached. After installing glass, test for water leakage after (3) Apply adhesive uniformly to all sides of about one hour. adhesion surface while operating gun along CAUTION: glass end face.

  • Page 806: Door Glass

    DIAGNOSTICS [K100] 1. Door Glass 1. Door Glass Condition Apparent cause/Correction ¼ Insufficient upward travel of glass Glass in fully 1) Glass runs out of weatherstrip lip when considerable hand closed 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 807 DIAGNOSTICS [K100] 1. Door Glass Condition Apparent cause/Correction ¼ Improper up-down and in-out glass Door in fully 1) Glass rides over weatherstrip lip when door is closed. closed/ open posi- alignments tion Adjust glass for up-down and in-out alignments (incl. rear sash, upper stop- per adjustment, etc.).
  • Page 808 DIAGNOSTICS [K100] 1. Door Glass Condition Apparent cause/Correction ¼ Improper fore-aft or in-out alignment Raise or lower 2) Center pillar weatherstrip is caught by rear window glass window glass when glass is raised. of window glass Lower regulator “B” channel to tilt win- dow glass back.

  • Page 809: Door Lock System

    DIAGNOSTICS [K300] 3. Power Window 2. Door Lock System Trouble Possible cause Remedy Door cannot be opened by Disconnect outer handle rod. Connect firmly. outer handle. (Door can be opened by inner handle.) Door cannot be opened by a. Joint of upper rod is disconnected. Connect firmly.
  • Page 810 DIAGNOSTICS MEMO:...
  • Page 811 SEAT, SEAT BELTS AND INTERIOR Page COMPONENT PARTS ..................2 Front Seat....................2 Rear Seat ....................3 Front Seat Belt ....................4 Rear Seat Belt.....................5 Inner Accessories ..................6 Inner Trim ....................7 SERVICE PROCEDURE ...................8 Front Seat....................8 Rear Seat ....................9 Front Seat Belt ..................10 Rear Seat Belt ...................11 Inner Trim Panel ..................11...
  • Page 812 COMPONENT PARTS [C100] 1. Front Seat 1. Front Seat S5M0221A (1) Front seat ASSY (4) Slide rail LH Tightening torque: N·m (kg-m, ft-lb) (2) Rail cover RH (5) Slide rail RH 52 ± 10 (5.3 ± 1.0, 38 ± 7) (3) Rail cover LH...

  • Page 813: Component Parts

    COMPONENT PARTS [C200] 2. Rear Seat 2. Rear Seat S5M0222A (1) Side pad (4) Side hinge Tightening torque: N·m (kg-m, ft-lb) (2) Backrest (5) Center hinge 25 ± 7 (2.5 ± 0.7, 18.1 ± 5.1) (3) Pillow (6) Cushion...

  • Page 814: Front Seat Belt

    COMPONENT PARTS [C300] 3. Front Seat Belt 3. Front Seat Belt S5M0223A (1) Adjuster anchor ASSY (5) Outer belt ASSY Tightening torque: N·m (kg-m, ft-lb) (2) Anchor cover 7.4 ± 2.0 (0.75 ± 0.2, 5.4 ± 1.4) (3) Webbing guide +2.0 +14.5 (3.0...

  • Page 815: Rear Seat Belt

    COMPONENT PARTS [C400] 4. Rear Seat Belt 4. Rear Seat Belt S5M0224A (1) Outer seat belt RH (5) Center seat belt Tightening torque: N·m (kg-m, ft-lb) (2) Outer seat belt LH 7.4 ± 2.0 (0.75 ± 0.2, 5.4 ± 1.4) (3) Inner seat belt LH +2.0 +14.5...

  • Page 816: Inner Accessories

    COMPONENT PARTS [C500] 5. Inner Accessories 5. Inner Accessories S5M0225A (1) Hook (4) Spring (7) Assist grip (retractable) (2) Sun visor (5) Rearview mirror (8) Assist grip (fixed) (3) Mount (6) Assist rail bracket...

  • Page 817: Inner Trim

    COMPONENT PARTS [C600] 6. Inner Trim 6. Inner Trim S5M0226A (1) Front pillar upper trim (6) Rear quarter lower trim (11) Center pillar lower trim (2) Center pillar upper trim (7) Rear skirt trim (12) Side sill rear lower cover (3) Rear quarter upper trim (8) Rear pillar lower trim (13) Side sill front upper cover...

  • Page 818: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. Front Seat 1. Front Seat B: INSTALLATION 1) While operating button (located on top of A: REMOVAL backrest), lift headrest out by placing your hand 1) While operating button (located on top of between backrest and headrest. backrest), lift headrest out with hand placed between backrest and headrest.

  • Page 819: Rear Seat

    SERVICE PROCEDURE [W2A3] 2. Rear Seat 2. Rear Seat 3. BACKREST 1) Remove cushion. A: REMOVAL AND INSTALLATION 2) Remove side pad. 1. CUSHION 3) Remove bolts and nuts. 4) Detach backrest. 1) Remove bolts securing hinges (located at front of cushion) to body.

  • Page 820: Front Seat Belt

    SERVICE PROCEDURE [W3A1] 3. Front Seat Belt 3. Front Seat Belt 6) Remove lap anchor bolt. 7) Remove belt retractor and outer belt. A: REMOVAL AND INSTALLATION 1. OUTER BELT 1) Remove anchor cover. 2) Remove shoulder anchor bolt. 3) Remove center pillar cover. S5M0232 8) Installation is in the reverse order of removal.

  • Page 821: Rear Seat Belt

    SERVICE PROCEDURE [W5A1] 5. Inner Trim Panel 4. Rear Seat Belt 5. Inner Trim Panel A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION 1. OUTER BELT 1. FRONT SECTION 1) Remove rear cushion and side pad. 1) Removal order of trim panel: 2) Remove rear backrest.
  • Page 822 SERVICE PROCEDURE [W5A2] 5. Inner Trim Panel 2. REAR SECTION (11) Roll mat, and take it out of opened rear door. 1) Removal order of trim panel: (1) Remove rear rail trim (I). (2) Remove strut cover (J). (3) Remove caps and screws then remove rear quarter upper trim (H).
  • Page 823 SERVICE PROCEDURE [W5A4] 5. Inner Trim Panel 4) Using ST, remove clips and then detach roof 5) Installation is in the reverse order of removal. trim. CAUTION: ST 925580000 PULLER When removing clip, use great care to prevent damaging the roof trim. S5M0242...
  • Page 824 SERVICE PROCEDURE MEMO:...

  • Page 825: Instrument Panel

    INSTRUMENT PANEL Page COMPONENT PARTS ..................2 Instrument Panel ..................2 SERVICE PROCEDURE ...................3 Instrument Panel ..............3...
  • Page 826 COMPONENT PARTS [C100] 1. Instrument Panel 1. Instrument Panel S5M0041A (1) Pad & frame (12) Pocket (23) Rear cup holder (2) Grille side (D) (13) Panel center (24) Console box (3) Front def. grille (14) Center pocket lid (25) Console pocket (4) Grille side (P) (15) Grille center (26) Rear console BRKT...
  • Page 827 SERVICE PROCEDURE [W1A0] 1. Instrument Panel 1. Instrument Panel 6) Disconnect data link connector (A) from lower cover. A: REMOVAL Airbag system wiring harness is routed on steering support beam. CAUTION: ¼ All Airbag system wiring harness and con- nectors are colored yellow. Do not use electri- cal test equipment on these circuits.
  • Page 828 SERVICE PROCEDURE [W1A0] 1. Instrument Panel 11) Remove two bolts and lower steering column. 13) Disconnect temperature control cable and mode control cable from heater unit then discon- nect recirc control cable from intake unit. NOTE: Do not move switch and link when installing. G5M0278 12) Set temperature control switch to “FULL HOT”, mode selector switch to “DEF”...
  • Page 829 SERVICE PROCEDURE [W1A0] 1. Instrument Panel 14) Disconnect harness connectors and then remove the installing bolts and nuts. CAUTION: Be sure to hold socket section and not harness when disconnecting. NOTE: Put matching mark, if necessary, for easy reassembly. S5M0050A...
  • Page 830 SERVICE PROCEDURE [W1B0] 1. Instrument Panel 15) Remove front defroster grille and two bolts. B: INSTALLATION Installation is in the reverse order of removal. CAUTION: ¼ Be careful not to snag the harness. ¼ Make sure to connect harness connectors. ¼...

  • Page 831: Supplemental Restraint System

    SUPPLEMENTAL RESTRAINT SYSTEM Page COMPONENT PARTS ..................2 SRS Airbag....................2 SERVICE PROCEDURE ...................3 General......................3 Inspection and Replacement Standards .............5 Airbag Module .....................8 Main Harness ....................11 Side Airbag Harness .................12 Airbag Control Module ................12 Side Airbag Sensor ...................13 Combination Switch...................14 Front Sub Sensor ..................15...

  • Page 832: Component Parts

    COMPONENT PARTS [C100] 1. SRS Airbag 1. SRS Airbag S5M0334A (1) Combination switch ASSY with (8) Side airbag module Tightening torque: N·m (kg-m, ft-lb) roll connector (9) Side airbag harness (RH) 4.4 ± 1.5 (0.45 ± 0.15, 3.3 ± 1.1) (2) TORX bolt T30 (10) Side airbag harness (LH) 7.4 ±...

  • Page 833: Service Procedure

    SERVICE PROCEDURE [W1A0] 1. General ¼ When checking the system, be sure to use a 1. General digital circuit tester. Use of an analog circuit tester A: PRECAUTION may cause the airbag to activate erroneously. Do not directly apply the tester probe to any connec- ¼...
  • Page 834 SERVICE PROCEDURE [W1A0] 1. General ¼ Do not drop the airbag modulator parts, subject ¼ Install the wire harness securely with the speci- it to high temperatures over 90°C (194°F), or apply fied clips so as to avoid interference or jamming with other parts.

  • Page 835: Inspection And Replacement Standards

    SERVICE PROCEDURE [W2F2] 2. Inspection and Replacement Standards ¼ Side airbag module determined as faulty during 2. Inspection and Replacement self-diagnosis. Standards D: MAIN HARNESS A: VEHICLES WHICH BECOME 1. INSPECTION STANDARD INVOLVED IN A COLLISION ¼ A vehicle damaged in a collision (regardless of If the vehicle equipped with an SRS airbag system whether or not airbag is deployed).
  • Page 836 SERVICE PROCEDURE [W2G1] 2. Inspection and Replacement Standards G: STEERING WHEEL H: STEERING COLUMN ASSEMBLY 1. INSPECTION STANDARD 1. INSPECTION STANDARD ¼ A vehicle damaged in a collision (regardless of ¼ A vehicle damaged in a collision (regardless of whether or not airbag is deployed). whether or not airbag is deployed).
  • Page 837 SERVICE PROCEDURE [W2J2] 2. Inspection and Replacement Standards I: FRONT SUB SENSOR J: SIDE AIRBAG SENSOR 1. INSPECTION STANDARD 1. INSPECTION STANDARD ¼ Check the front section (Refer to shaded area of ¼ Check the side section (Refer to shaded area of vehicle in figure) for damage, regardless of vehicle in figure) for damage, regardless of whether or not airbag is deployed.

  • Page 838: Airbag Module

    SERVICE PROCEDURE [W3A0] 3. Airbag Module ¼ Do not check airbag module (driver, passen- 3. Airbag Module ger and side) continuity with airbag removed A: REMOVAL AND INSTALLATION from the vehicle body. CAUTION: ¼ The airbag module (driver, passenger and side) must not be disassembled.
  • Page 839 SERVICE PROCEDURE [W3A0] 3. Airbag Module ¼ When storing a removed airbag module (driver and passenger), be sure to place it in parallel with floor with the pad facing up. Do not place it against a wall, or place anything on the pad;...
  • Page 840 SERVICE PROCEDURE [W3A1] 3. Airbag Module 1. DRIVER’S AIRBAG MODULE 4) Disconnect airbag connector. <Ref. to 5-5 [M2E2].> 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) Using TORX BIT T30, remove two TORX bolts.

  • Page 841: Main Harness

    SERVICE PROCEDURE [W4A0] 4. Main Harness 4. Main Harness 8) Disconnect front sub sensor connector (blue) from airbag main harness. A: REMOVAL AND INSTALLATION 9) Detach clips from steering support beam and remove main harness. 1) Turn ignition switch off. 2) Disconnect ground cable from battery and wait for at least 20 seconds before starting work.

  • Page 842: Side Airbag Harness

    SERVICE PROCEDURE [W5A0] 5. Side Airbag Harness 5. Side Airbag Harness 6. Airbag Control Module A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION 1) Turn ignition switch off. CAUTION: ¼ Do not disassemble the airbag control mod- 2) Disconnect ground cable from battery and wait for at least 20 seconds before starting work.

  • Page 843: Side Airbag Sensor

    SERVICE PROCEDURE [W7A0] 7. Side Airbag Sensor 7. Side Airbag Sensor 4) Disconnect airbag connector (AB3) and (AB8) below steering column. <Ref. to 5-5 [M2E2].> A: REMOVAL AND INSTALLATION CAUTION: Do not reconnect airbag connector at steering CAUTION: ¼ If the side of the vehicle body is damaged by column until airbag control module is securely re-installed.

  • Page 844: Combination Switch

    SERVICE PROCEDURE [W8A0] 8. Combination Switch 8. Combination Switch 7) Using steering puller, remove steering wheel. CAUTION: A: REMOVAL Do not allow connector to interfere when removing steering wheel. 1) Turn ignition switch off. 2) Disconnect ground cable from battery and wait for at least 20 seconds before starting work.

  • Page 845: Front Sub Sensor

    SERVICE PROCEDURE [W9A1] 9. Front Sub Sensor 9. Front Sub Sensor C: INSTALLATION CAUTION: A: REMOVAL AND INSTALLATION Failure to do this might damage roll connector. CAUTION: 1) Before installing combination switch, check to ¼ If the front end of the vehicle body is dam- ensure that combination switch is off and front aged by a collision, be sure to check the left wheels are set in the straight ahead position.
  • Page 846 SERVICE PROCEDURE [W9A2] 9. Front Sub Sensor 4) Disconnect airbag connector (AB3) and (AB8) 8) Remove wiring harness clips. below steering column. CAUTION: Do not reconnect airbag connector at steering column until front sub sensors are securely re- installed. G5M0315 9) Remove grommet and then detach front sub sensor harness.
  • Page 847 SERVICE PROCEDURE [W9A2] 9. Front Sub Sensor 5) Remove front sub sensor. S5M0336 6) Installation is in the reverse order of removal.
  • Page 848 SERVICE PROCEDURE MEMO:...

  • Page 849: Engine Electrical System

    ENGINE ELECTRICAL SYSTEM Page SPECIFICATIONS AND SERVICE DATA............2 Specifications ....................2 COMPONENT PARTS ..................3 Starter......................3 Generator ....................4 Ignition System....................5 SERVICE PROCEDURE ...................6 Starter......................6 Generator....................11 Spark Plug....................16 Ignition Coil and Ignitor Assembly.............21 Spark Plug Cord..................22 DIAGNOSTICS....................23 Starter......................23 Generator ....................24...

  • Page 850: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Specifications 1. Specifications Item Designation Type Reduction type Vehicle type MT vehicles AT vehicles Model M000T81681 M000T84481, M001T84481 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...

  • Page 851: Component Parts

    COMPONENT PARTS [C100] 1. Starter 1. Starter H6M0492B (1) Sleeve bearing (7) Internal gear ASSY (13) Armature (2) Front bracket (8) Shaft ASSY (14) Brush holder (3) Lever set (9) Gear ASSY (15) Brush (4) Magnet switch ASSY (10) Ball (16) Sleeve bearing (5) Stopper set (11) Packing...

  • Page 852: Generator

    COMPONENT PARTS [C200] 2. Generator 2. Generator H6M0493B (1) Pulley (5) Rotor (9) Brush (2) Front cover (6) Bearing (10) Rectifier (3) Ball bearing (7) Stator coil (11) Rear cover (4) Bearing retainer (8) IC regulator with brush (12) Terminal...

  • Page 853: Ignition System

    COMPONENT PARTS [C300] 3. Ignition System 3. Ignition System S6M0329A (1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kg-m, ft-lb) (2) Spark plug cord (#1, #3) 22 ± 2 (2.2 ± 0.2, 15.9 ± 1.4) (3) Ignition coil and ignitor ASSY...
  • Page 854 SERVICE PROCEDURE [W1A0] 1. Starter 1. Starter 4) Disconnect connector and terminal from starter. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S6M0002A Terminal Connector G6M0095 5) Remove starter from transmission. 2) Remove air intake chamber. <Ref. to 2-7 [W2A0].>...

  • Page 855: Service Procedure

    SERVICE PROCEDURE [W1B3] 1. Starter 2) Disconnect connector from terminal M, and 3. PERFORMANCE TEST connect positive terminal of battery and terminal M The starter should be submitted to performance using a lead wire and ground terminal to starter tests whenever it has been overhauled, to assure body.
  • Page 856 SERVICE PROCEDURE [W1C1] 1. Starter 3) Lock test 4) Remove armature and yoke. Ball used as a With starter stalled, or not rotating, measure the bearing will then be removed from the end of arma- torque developed and current draw when the volt- ture.
  • Page 857 SERVICE PROCEDURE [W1D1] 1. Starter 7) Remove overrunning clutch from shaft assem- 2) Run-out test bly as follows: Check the commutator run-out and replace if it (1) Remove stopper from ring by lightly tapping exceeds the limit. a fit tool placed on stopper. Commutator run-out: (2) Remove ring, stopper and clutch from shaft.
  • Page 858 SERVICE PROCEDURE [W1D2] 1. Starter 5) Armature ground test Measure brush spring force with a spring scale. If Using circuit tester, touch one probe to the com- it is less than the service limit, replace brush spring. mutator segment and the other to shaft. There should be no continuity.

  • Page 859: Generator

    SERVICE PROCEDURE [W2B0] 2. Generator 2. Generator 5) Remove bolts which install generator onto bracket. A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. S2M0942 6) Installation is in the reverse order of removal. G6M0095 CAUTION: Check and adjust V-belt tension. <Ref. to 1-5 2) Disconnect connector and terminal from gen- [G2A0].>...
  • Page 860 SERVICE PROCEDURE [W2C1] 2. Generator 2) Hold rotor with a vise and remove pulley nut. 4) Remove screws which secure IC regulator to rear cover, and unsolder connection between IC CAUTION: regulator and rectifier to remove IC regulator. When holding rotor with vise, insert aluminum plates or wood pieces on the contact surfaces of the vise to prevent rotor from damage.
  • Page 861 SERVICE PROCEDURE [W2C2] 2. Generator 1) Checking positive diode 3) Continuity test Check for continuity between the diode lead and Check resistance between slip rings using circuit the positive side heat sink. The positive diode is in tester. If the resistance is not within specification, good condition if continuity exists only in the direc- replace rotor assembly.
  • Page 862 SERVICE PROCEDURE [W2C3] 2. Generator 3. STATOR 2) Checking brush spring for proper pressure Using a spring pressure indicator, push the brush 1) Continuity test into the brush holder until its tip protrudes 2 mm Inspect stator coil for continuity between each end (0.08 in).
  • Page 863 SERVICE PROCEDURE [W2D0] 2. Generator 5. BEARING (FRONT SIDE) D: ASSEMBLY 1) Check front ball bearing. If resistance is felt To assemble, reverse order of disassembly. while rotating, or if abnormal noise is heard, 1) Pulling up brush replace the ball bearing. Before assembling, press the brush down into the 2) Replacing front bearing brush holder with your finger and secure in that...

  • Page 864: Spark Plug

    SERVICE PROCEDURE [W3A0] 3. Spark Plug 3. Spark Plug 6) Remove #1 spark plug cord by pulling boot, not cord itself. A: REMOVAL AND INSTALLATION CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: NGK: BKR5E-11 (Alternate)
  • Page 865 SERVICE PROCEDURE [W3A3] 3. Spark Plug 2. #2 SPARK PLUG 3. #3 SPARK PLUG 1) Disconnect battery ground cable. 1) Disconnect battery ground cable. G6M0095 G6M0095 2) Remove #2 spark plug cord by pulling boot, not 2) Disconnect mass air flow sensor connector. cord itself.
  • Page 866 SERVICE PROCEDURE [W3A4] 3. Spark Plug 6) Remove #3 spark plug cord by pulling boot, not 4. #4 SPARK PLUG cord itself. 1) Disconnect battery ground cable. B6M0928A G6M0095 7) Remove spark plug with the spark plug socket. 2) Disconnect washer motor connector. B6M0925 S2M0546 8) Installation is in the reverse order of removal.
  • Page 867 SERVICE PROCEDURE [W3B0] 3. Spark Plug 5) Remove #4 spark plug cord by pulling boot, not B: INSPECTION cord itself. Check electrodes and inner and outer porcelain of plugs, noting the type of deposits and the degree of electrode erosion. B6M0929A 6) Remove spark plug with the spark plug socket.
  • Page 868 SERVICE PROCEDURE [W3C0] 3. Spark Plug 3) Oil fouled C: CLEANING AND REGAPPING Wet black deposits show excessive oil entrance Clean spark plugs in a sand blast type cleaner. into combustion chamber through worn rings and Avoid excessive blasting. Clean and remove car- pistons or excessive clearance between valve bon or oxide deposits, but do not wear away por- guides and stems.

  • Page 869: Ignition Coil And Ignitor Assembly

    SERVICE PROCEDURE [W4B0] 4. Ignition Coil and Ignitor Assembly 4. Ignition Coil and Ignitor B: INSPECTION Assembly Using accurate tester, inspect the following items, and replace if defective. A: REMOVAL AND INSTALLATION 1) Primary resistance 2) Secondary coil resistance 1) Disconnect battery ground cable. CAUTION: If the resistance is extremely low, this indicates the presence of a short-circuit.

  • Page 870: Spark Plug Cord

    SERVICE PROCEDURE [W5A0] 5. Spark Plug Cord 5. Spark Plug Cord A: INSPECTION Check for: 1) Damage to cords, deformation, burning or rust formation of terminals 2) Resistance values of cords Resistance value: 5.24 — 12.23 k Ω S6M0337...

  • Page 871: Starter

    DIAGNOSTICS [K100] 1. Starter 1. Starter Trouble Probable cause Magnet switch poor contact or disconti- nuity of pull-in coil circuit Magnet switch does not operate. (no clicks are heard.) Improper sliding of magnet switch plunger Poor contact of magnet switch’s main contact point Starter does not start.

  • Page 872: Generator

    DIAGNOSTICS [K200] 2. Generator 2. Generator B6M0771...

  • Page 873: Body Electrical System

    BODY ELECTRICAL SYSTEM Page SPECIFICATIONS AND SERVICE DATA............2 Body Electrical.....................2 SERVICE PROCEDURE ...................3 Precautions....................3 Battery ......................3 Ignition Switch .....................5 Lighting ......................5 Front Wiper and Washer ................9 Rear Wiper and Washer ................12 Rear Window Defogger................14 Combination Meter ..................16 Radio, Speaker and Antenna ..............17 Front Fog Light..................17 Cruise Control ...................18 DIAGNOSTICS....................22...

  • Page 874: Specifications And Service Data

    SPECIFICATIONS AND SERVICE DATA [S100] 1. Body Electrical 1. Body Electrical Type MT model: 55D23L (MF) AT model: 75D23L (MF) Battery Reverse capacity MT model: 99 minutes AT model: 118 minutes Capacity Cold cranking ampere MT model: 356 amperes AT model: 520 amperes Speedometer Electric pulse type Temperature gauge...

  • Page 875: Service Procedure

    SERVICE PROCEDURE [W2B0] 2. Battery 1. Precautions 2. Battery ¼ Before disassembling or reassembling parts, A: REMOVAL AND INSTALLATION always disconnect battery ground cable. When 1) Disconnect the positive (+) terminal after dis- repairing radio, control modules, etc. which are connecting the negative (−) terminal of battery.
  • Page 876 SERVICE PROCEDURE [W2B1] 2. Battery ¼ Observe instructions when handling battery 1. BATTERY charger. 1) External parts: ¼ Before charging the battery on vehicle, dis- Check for the existence of dirt or cracks on the connect battery ground terminal. Failure to fol- battery case, top cover, vent plugs, and terminal low this rule may damage alternator’s diodes posts.

  • Page 877: Ignition Switch

    SERVICE PROCEDURE [W4A1] 4. Lighting 3. Ignition Switch 4. Lighting A: REMOVAL AND INSTALLATION A: ADJUSTMENT 1) Remove instrument panel lower cover. <Ref. to 1. HEADLIGHT AIMING 5-4 [W1A0].> CAUTION: 2) Remove screws, separate upper column cover Turn off the light before adjusting headlight and lower column cover.
  • Page 878 SERVICE PROCEDURE [W4B1] 4. Lighting 2) Turn the headlights on. Perform the aiming B: REMOVAL AND INSTALLATION adjustment for the other headlight as follows: 1. HEADLIGHT BULB CAUTION: 1) Disconnect the connector from inside of the Do not perform lateral headlight aiming adjust- engine compartment.
  • Page 879 SERVICE PROCEDURE [W4B4] 4. Lighting ¼ To keep water out, correctly engage the ¼ Remove all traces of adhesive tape from groove portion of the rubber cap. body before installation. ¼ Attach butyl rubber tape to back of rear com- 2.
  • Page 880 SERVICE PROCEDURE [W4C1] 4. Lighting C: INSPECTION 2. HEADLIGHT RELAY Check continuity between terminals when terminal 1. COMBINATION SWITCH (LIGHTING) No. 4 is connected to battery and terminal No. 3 is Move combination switch to respective positions grounded. and check continuity between terminals. When current Between terminals Continuity exists.

  • Page 881: Front Wiper And Washer

    SERVICE PROCEDURE [W5B3] 5. Front Wiper and Washer 5. Front Wiper and Washer 3. WIPER MOTOR AND LINK 1) Detach cowl panel. <Ref. to 5-1 [W10A0].> A: ADJUSTMENT NOTE: 1) Turn the wiper switch to OFF position. Apply silicone oil or soap water to both sides of 2) Adjust so that points “A”...
  • Page 882 SERVICE PROCEDURE [W5C1] 5. Front Wiper and Washer 6) Remove wiper link from service hole in front C: INSPECTION panel. 1. COMBINATION SWITCH (FRONT WIPER) Set wiper switch to each position and check conti- nuity between terminals. G6M0121 7) Installation is in the reverse order of removal. H6M0501B S6M0137...
  • Page 883 SERVICE PROCEDURE [W5C2] 5. Front Wiper and Washer 2. WIPER MOTOR 4) Reconnect battery and ensure that wiper motor stops at “AUTO STOP” after operating at low 1) Check wiper motor operation at low speed: speed. Connect battery to wiper motor. Check wiper motor for proper operation at low speed.

  • Page 884: Rear Wiper And Washer

    SERVICE PROCEDURE [W6A0] 6. Rear Wiper and Washer 6. Rear Wiper and Washer 2. WIPER ARM 1) Remove head cover. A: ADJUSTMENT 2) Remove nut and wiper arm. 1) Adjust wiper blade in original position as shown in figure by changing wiper arm installation. Original position: A: 30 ±...
  • Page 885 SERVICE PROCEDURE [W6C2] 6. Rear Wiper and Washer C: INSPECTION 2) Check wiper motor for proper stoppage: After operating wiper motor, disconnect battery 1. COMBINATION SWITCH (REAR WIPER) from wiper motor. Set rear wiper and washer switch to each position and check continuity between terminals.

  • Page 886: Rear Window Defogger

    SERVICE PROCEDURE [W6C3] 7. Rear Window Defogger 7. Rear Window Defogger 3. REAR WIPER RELAY 1) Connect battery to terminal No. 1 and ground A: INSPECTION terminal No. 2. 2) Check continuity between terminals. 1. HEAT WIRES 1) Start the engine so that battery is being Between terminals Continuity does charged.
  • Page 887 SERVICE PROCEDURE [W7B0] 7. Rear Window Defogger 4) When tester indicates 12 volts when its probe 5) Inspect the repaired wire for continuity. reaches point “A”, a broken circuit occurs between point “A” and the negative terminal. Slowly move tester probe toward the negative terminal while contacting it on heat wire to locate point where tester indication changes abruptly (0 volts).

  • Page 888: Combination Meter

    SERVICE PROCEDURE [W8A0] 8. Combination Meter 8. Combination Meter B: BULB REPLACEMENT A: REMOVAL AND INSTALLATION 1) Move steering wheel most down. 2) Remove screws which secure visor and remove visor. S6M0078A Tachometer Door open Turn RH Airbag HI-beam S6M0076A Turn LH 3) Remove screws which secure combination meter, and pull combination meter out.
  • Page 889 SERVICE PROCEDURE [W10A0] 10. Front Fog Light 9. Radio, Speaker and Antenna 10. Front Fog Light A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION 1. RADIO BODY 1) Disconnect ground cable from battery. 2) Remove the two screws, then draw out the front 1) Remove console box.

  • Page 890: Cruise Control

    SERVICE PROCEDURE [W11A0] 11. Cruise Control 11. Cruise Control A: ADJUSTMENT S6M0138A...
  • Page 891 SERVICE PROCEDURE [W11B1] 11. Cruise Control B: REMOVAL AND INSTALLATION 5) Disconnect cruise control vacuum hose from intake manifold. 1. ACTUATOR 1) Remove air intake chamber. S6M0089 6) Remove actuator attaching bolts. S6M0007 7) Disconnect connector from actuator, then remove the actuator. 2) Remove air intake chamber stay.
  • Page 892 SERVICE PROCEDURE [W11B2] 11. Cruise Control 2. CRUISE CONTROL MAIN SWITCH 4) Using TORX BIT T30 (Tamper resistant type), remove two TORX bolts which secure driver’s air- 1) Remove screws and clip from instrument panel bag module. lower cover. 2) Remove panel lower cover. S6M0094A 5) Disconnect airbag module connector on back of S6M0091...
  • Page 893 SERVICE PROCEDURE [W11B6] 11. Cruise Control 4. CRUISE CONTROL MODULE 5. STOP AND BRAKE SWITCH 1) Remove front pillar lower trim. Disconnect connector from switch, then remove the switch. <Ref. to 4-5 [C100].> 6. CLUTCH SWITCH Disconnect connector from switch, then remove the switch.

  • Page 894: At Shift Lock System

    DIAGNOSTICS [K1A0] 1. AT Shift Lock System 1. AT Shift Lock System A: WIRING DIAGRAM SU42-01...
  • Page 895 DIAGNOSTICS [K1B0] 1. AT Shift Lock System B: BASIC DIAGNOSTICS CHART H6M0504A...
  • Page 896 DIAGNOSTICS [K1C0] 1. AT Shift Lock System C: DIAGNOSTICS PROCEDURE NO. 1 H6M0505...
  • Page 897 DIAGNOSTICS [K1D0] 1. AT Shift Lock System D: DIAGNOSTICS PROCEDURE NO. 2 (SHIFT LOCK DOES NOT RELEASE.) H6M0506...
  • Page 898 DIAGNOSTICS [K1E0] 1. AT Shift Lock System E: DIAGNOSTICS PROCEDURE NO. 3 (KEY INTERLOCK DOES NOT OPERATE.) H6M0507...
  • Page 899 DIAGNOSTICS [K1F0] 1. AT Shift Lock System F: DIAGNOSTICS PROCEDURE NO. 4 (KEY INTERLOCK DOES NOT RELEASE.) H6M0508...

  • Page 900: Combination Meter

    DIAGNOSTICS [K2A0] 2. Combination Meter 2. Combination Meter 2A2 : CHECK GROUND CIRCUIT OF COM- BINATION METER. A: DIAGNOSTICS PROCEDURE If speedometer does not operate, or operates 1) Turn ignition switch to OFF. abnormally, check combination meter circuit. 2) Measure resistance of harness between com- bination meter connector and chassis ground.
  • Page 901 DIAGNOSTICS [K2A6] 2. Combination Meter 2A6 : CHECK HARNESS CONNECTOR 2A4 : CHECK HARNESS CONNECTOR BETWEEN COMBINATION METER BETWEEN VEHICLE SPEED SENSOR AND VEHICLE SPEED SENSOR 2. 2 AND ENGINE GROUND. 1) Disconnect connector from vehicle speed sen- 1) Turn ignition switch to OFF. sor 2.
  • Page 902 DIAGNOSTICS [K2A7] 2. Combination Meter 2A8 : CHECK VEHICLE SPEED SENSOR 2. 2A7 : CHECK VEHICLE SPEED SENSOR 2. NOTE: 1) Connect connector to vehicle speed sensor 2. ¼ If resistance between terminals of vehicle speed 2) Set the vehicle on free roller, or lift-up the sensor 2 is out of specification, the sensor may vehicle and support with safety stands.
  • Page 903 DIAGNOSTICS [K2A10] 2. Combination Meter 2A10 : CHECK AUTOMATIC TRANSMIS- 2A9 : CHECK HARNESS CONNECTOR BETWEEN COMBINATION METER SION CONTROL MODULE. AND AUTOMATIC TRANSMISSION CONTROL MODULE. 1) Connect connector to automatic transmission control module. 1) Disconnect connector from automatic transmis- 2) Set the vehicle on free roller, or lift-up the sion control module.
  • Page 904 DIAGNOSTICS MEMO:...
  • Page 905 AUTOMATIC TRANSMISSION AND DIFFERENTIAL BRAKES This portion of the service manual has been prepared SUPPLEMENTAL RESTRAINT to provide SUBARU service personnel with the neces- SYSTEM sary information and data for the correct maintenance and repair of SUBARU vehicles. BODY ELECTRICAL SYSTEM...
  • Page 906 All right reserved. This book may not be reproduced or copied, in whole or in part, without the written per- mission of FUJI HEAVY INDUSTRIES LTD., TOKYO JAPAN. SUBARU, are trademarks of FUJI HEAVY INDUSTRIES LTD. © Copyright 1998 FUJI HEAVY INDUSTRIES LTD.
  • Page 907 ¼ 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.
  • Page 908 FOREWORD DIAGNOSTICS [T200] 2. How to Use This Manual 2. 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...
  • Page 909 FOREWORD DIAGNOSTICS [T200] 2. How to Use This Manual 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. B0M0001...
  • Page 910 FOREWORD DIAGNOSTICS [T200] 2. How to Use This Manual ¼ In this manual, the following symbols are used. Character Description Circuit tester ¼ Voltage measurement B0M0002 Circuit tester ¼ Resistance measurement B0M0003 The arrow indicates that insertion of the probe or numbering of the connector pins is made from the side.
  • Page 911 FOREWORD DIAGNOSTICS [T3B0] 3. Basic Checks ¼ To disconnect a locking connector, first release 3. Basic Checks the lock, then pull the connector off. A: DISCONNECTING CONNECTORS <Unlock by pulling the locking tab.> ¼ Always hold the connector itself. CAUTION: Don’t pull the harness.
  • Page 912 FOREWORD DIAGNOSTICS [T3C1] 3. Basic Checks ¼ Connectors equipped with shock protectors C: CHECKING FOR POOR must be checked with a mini probe (thin), or it will CONTACT ON PLUG-IN be necessary to remove the shock protector. CONNECTORS 1. POOR CONTACT Poor contact is frequently caused by corroded terminals, dirt, foreign substances, weak contact points between male and female connectors, etc.
  • Page 913 FOREWORD DIAGNOSTICS [T4A2] 4. Diagnosis and Checking Procedure Using Instruments 4) Insert the male pin of the connector into the 4. Diagnosis and Checking female pin, then pull it out. Procedure Using Instruments NOTE: A: USING A CIRCUIT TESTER If one of the pins allows to pull out easily, it is a likely source of a malfunction.
  • Page 914 ¼ Before changing the measurement range the gauge must be reset to zero. B: USING A SUBARU SELECT MONITOR With this testing procedure the defective compo- nent can be determined by directly monitoring input/output signals of the ECM or the trouble codes.
  • Page 915 FOREWORD DIAGNOSTICS [T500] 5. Table of Contents 5. Table of Contents Engine Cooling System On-Board Diagnostics II System Automatic Transmission and Differential DIAGNOSTICS SECTION Brakes Supplemental Restraint System Body Electrical System (Cruise Control System)
  • Page 916 FOREWORD DIAGNOSTICS MEMO:...
  • Page 917 ENGINE COOLING SYSTEM Page DIAGNOSTICS ....................2 Wiring Diagram....................2 Radiator Main Fan..................3 Radiator Sub Fan (With A/C model only) ...........7...
  • Page 918 DIAGNOSTICS [T100] 1. Wiring Diagram 1. Wiring Diagram S2M1002...
  • Page 919 DIAGNOSTICS [T2A3] 2. Radiator Main Fan 2. Radiator Main Fan 2A2 : CHECK GROUND CIRCUIT OF MAIN FAN MOTOR. A: OPERATION DETECTING CONDITION: 1) Turn ignition switch to OFF. 2) Measure resistance between main fan motor Condition: ¼ Engine coolant temperature is above 95°C connector and chassis ground.
  • Page 920 DIAGNOSTICS [T2A4] 2. Radiator Main Fan 2A6 : CHECK POWER SUPPLY TO MAIN 2A4 : CHECK MAIN FAN MOTOR. FAN RELAY. Connect battery positive (+) terminal to terminal 1) Turn ignition switch to ON. No. 2, and negative (−) terminal to terminal No. 1 2) Measure voltage between main fan relay termi- of main fan motor connector.
  • Page 921 DIAGNOSTICS [T2A12] 2. Radiator Main Fan 2A11 : CHECK HARNESS CONNECTOR 2A8 : CHECK HARNESS CONNECTOR BETWEEN MAIN FUSE BOX AND A/C BETWEEN 20 A FUSE AND MAIN RELAY HOLDER 20 A FUSE. FAN RELAY IN A/C RELAY HOLDER. 1) Disconnect connector from main fuse box. Measure resistance of harness between 20 A fuse 2) Disconnect connectors (F25) and (F26) from and main fan relay terminal.
  • Page 922 DIAGNOSTICS [T2A13] 2. Radiator Main Fan 2A16 : CHECK MAIN FAN RELAY. 2A13 : CHECK HARNESS CONNECTOR BETWEEN IGNITION SWITCH AND JOINT BOX. 1) Turn ignition switch to OFF. 2) Check continuity between main fan relay termi- 1) Disconnect connector from ignition switch. nals.
  • Page 923 DIAGNOSTICS [T3A1] 3. Radiator Sub Fan (With A/C model only) 3. Radiator Sub Fan (With A/C 2A18 : CHECK HARNESS CONNECTOR BETWEEN MAIN FAN RELAY AND model only) MAIN FAN MOTOR. A: OPERATION Measure resistance of harness between main fan DETECTING CONDITION: motor connector and main fan relay terminal.
  • Page 924 DIAGNOSTICS [T3A2] 3. Radiator Sub Fan (With A/C model only) 3A4 : CHECK SUB FAN MOTOR. 3A2 : CHECK GROUND CIRCUIT OF SUB FAN MOTOR. Connect battery positive (+) terminal to terminal 1) Turn ignition switch to OFF. No. 2, and negative (−) terminal to terminal No. 1 2) Measure resistance between sub fan motor of sub fan motor connector.
  • Page 925 DIAGNOSTICS [T3A10] 3. Radiator Sub Fan (With A/C model only) 3A8 : CHECK HARNESS CONNECTOR 3A6 : CHECK POWER SUPPLY TO SUB FAN RELAY. BETWEEN MAIN FUSE BOX AND A/C RELAY HOLDER 20 A FUSE. 1) Turn ignition switch to ON. 1) Disconnect connector from main fuse box.
  • Page 926 DIAGNOSTICS [T3A11] 3. Radiator Sub Fan (With A/C model only) 3A13 : CHECK HARNESS CONNECTOR 3A11 : CHECK HARNESS CONNECTOR BETWEEN 20 A FUSE AND SUB BETWEEN IGNITION SWITCH AND FAN RELAY IN A/C RELAY HOLDER. JOINT BOX. Measure resistance of harness between 20 A fuse 1) Disconnect connector from ignition switch.
  • Page 927 DIAGNOSTICS [T3A20] 3. Radiator Sub Fan (With A/C model only) 3A18 : CHECK HARNESS CONNECTOR 3A16 : CHECK SUB FAN RELAY. BETWEEN SUB FAN RELAY AND SUB FAN MOTOR. 1) Turn ignition switch to OFF. 2) Check continuity between sub fan relay termi- Measure resistance of harness between sub fan nals.
  • Page 928 DIAGNOSTICS MEMO:...
  • Page 929 ON-BOARD DIAGNOSTICS II SYSTEM Page DIAGNOSTICS ....................2 General......................2 Electrical Components Location..............3 Diagnosis System..................16 Cautions ................32 Specified Data ...................36 Basic Diagnostic Procedure ..............43 Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) ..46 Diagnostics for Engine Starting Failure ............59 General Diagnostic Table ................89 Diagnostics Chart with Trouble Code ............92...

  • Page 930: General

    (OBD-II general scan tool) formed by ISO 9141 CARB. ¼ The OBD-II diagnostics procedure is different from the usual diagnostics procedure. When troubleshooting OBD-II vehicles, connect Subaru select monitor or the OBD-II general scan tool to the vehicle. B: ENGINE 1.

  • Page 931: Electrical Components Location

    DIAGNOSTICS [T2A1] 2. Electrical Components Location 2. Electrical Components Location A: ENGINE 1. MODULE S2M0226A (1) Engine control module (ECM) (3) Data link connector (2) CHECK ENGINE malfunction (4) Test mode connector indicator lamp (MIL) B2M2237C S2M0257A S2M0258A S2M0259A...
  • Page 932 DIAGNOSTICS [T2A2] 2. Electrical Components Location 2. SENSOR S2M0887A (1) Pressure sensor (4) Throttle position sensor (2) Mass air flow sensor (5) Knock sensor (3) Engine coolant temperature sen- (6) Camshaft position sensor (7) Crankshaft position sensor...
  • Page 933 DIAGNOSTICS [T2A2] 2. Electrical Components Location S2M0260A B2M2239A S2M1175A B2M2240A B2M2241A B2M2242A B2M0213I...
  • Page 934 DIAGNOSTICS [T2A2] 2. Electrical Components Location S2M1035A (1) Front oxygen sensor (3) Rear catalytic converter (2) Rear oxygen sensor (4) Front catalytic converter S2M0264A OBD0019K S2M0266B S2M1036A...
  • Page 935 DIAGNOSTICS [T2A2] 2. Electrical Components Location S2M0866A (1) Fuel level sensor (Main) (3) Fuel tank pressure sensor (2) Fuel temperature sensor (4) Fuel level sensor (Sub) H2M3207A B2M1807A S2M0270A...
  • Page 936 DIAGNOSTICS [T2A3] 2. Electrical Components Location 3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS S2M0887B (1) Pressure sources switching sole- (2) Idle air control solenoid valve (4) Ignition coil & Ignitor ASSY noid valve (3) Purge control solenoid valve...
  • Page 937 DIAGNOSTICS [T2A3] 2. Electrical Components Location B2M0777B B2M2243A B2M2254B B2M2245A...
  • Page 938 DIAGNOSTICS [T2A3] 2. Electrical Components Location S2M0866B (1) Pressure control solenoid valve (3) Drain valve (2) Canister (4) Air filter H2M2443A S2M0949B H2M2444A...
  • Page 939 DIAGNOSTICS [T2A3] 2. Electrical Components Location MEMO:...
  • Page 940 DIAGNOSTICS [T2A3] 2. Electrical Components Location S2M0226C (1) Inhibitor switch (4) Fuel pump relay (7) Starter (2) Fuel pump (5) Radiator cooling main fan relay (3) Main relay (6) Radiator cooling sub fan relay B2M2246A S2M1184A S2M0278A S2M0279A...
  • Page 941 DIAGNOSTICS [T2B1] 2. Electrical Components Location B2M2247B B: TRANSMISSION 1. MODULE S2M0226D (1) AT diagnostic indicator light (for (2) Transmission Control Module AT vehicles) (TCM) (for AT vehicles) S2M0217A B3M0443N...
  • Page 942 DIAGNOSTICS [T2B2] 2. Electrical Components Location 2. SENSOR B2M2258A B2M2259A B2M2260A B2M2261A OBD0653B (1) Vehicle speed sensor 1 (for AT AWD vehicles) (2) Vehicle speed sensor 2 (for MT vehicles) (3) Vehicle speed sensor 2 (for AT AWD vehicles) (4) Torque converter turbine speed sensor (5) ATF temperature sensor (for AT vehicles) (6) Brake light switch...
  • Page 943 DIAGNOSTICS [T2B3] 2. Electrical Components Location 3. SOLENOID VALVE AND RELAY ¼ For AT vehicles B2M2262A B2M2246B B2M2263A B2M2264A (1) Dropping resistor (2) Inhibitor switch (3) Shift solenoid valve 1 (4) Shift solenoid valve 2 (5) Duty solenoid valve A (6) Duty solenoid valve B (7) Duty solenoid valve C (8) Duty solenoid valve D...

  • Page 944: Diagnosis System

    DIAGNOSTICS [T3A1] 3. Diagnosis System 3. Diagnosis System 4) When ignition switch is turned to ON (engine off) or to “START” with the test mode connector A: CHECK ENGINE MALFUNCTION connected, the MIL blinks at a cycle of 3 Hz. INDICATOR LAMP (MIL) 1.
  • Page 945 1) This connector is used both for OBD-II general scan tools and the Subaru Select Monitor. 2) Terminal No. 4 to No. 6 of the data link connec- tor is used for the Subaru Select Monitor signal. CAUTION: Do not connect any scan tools other than the...
  • Page 946 DIAGNOSTICS [T3B3] 3. Diagnosis System 3. CURRENT POWERTRAIN DIAGNOSTIC DATA (MODE $01) Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the powertrain system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. Data Unit of measure Number of emission-related powertrain trouble codes and MIL status...
  • Page 947 NOTE: Refer to OBD-II general scan tool manufacturer’s instruction manual to access oxygen sensor monitoring test results (MODE $05). C: SUBARU SELECT MONITOR 2) Connect diagnosis cable to Subaru select monitor. 1. HOW TO USE SUBARU SELECT 3) Insert cartridge into Subaru select monitor.
  • Page 948 DIAGNOSTICS [T3C2] 3. Diagnosis System 4) Connect Subaru select monitor to data link con- 6) Using Subaru select monitor, call up diagnostic nector. trouble code(s) and various data, then record (1) Open the cover data link connector located them. in the lower portion of the instrument panel (on 2.
  • Page 949 DIAGNOSTICS [T3C4] 3. Diagnosis System 4. READ CURRENT DATA SHOWN ON DISPLAY FOR ENGINE. (NORMAL MODE) 1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key.
  • Page 950 Idle switch signal Idle Switch Signal ON or OFF Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF Camshaft position sensor signal Camshaft Position Sig. ON or OFF NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
  • Page 951 Rear oxygen sensor output signal Oxygen Sensor #12 Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 On-board diagnostic system OBD System — NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
  • Page 952 Vehicle Speed km/h or MPH NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. 7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA SHOWN ON DISPLAY FOR ENGINE. (OBD MODE) 1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key.
  • Page 953 Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF entered. When camshaft position sensor signal is Camshaft position sensor signal Camshaft Position Sig. ON or OFF entered. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
  • Page 954 ON or OFF Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF Automatic transmission diagnosis indicator lamp AT Diagnosis Lamp ON or OFF NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
  • Page 955 WARNING: 5) When the ‘Done’ and ‘Turn Ignition Switch OFF’ ¼ Before raising the vehicle, ensure parking are shown on the display screen, turn the Subaru brakes are applied. Select Monitor and ignition switch to OFF. ¼ Do not use a pantograph jack in place of a NOTE: safety stand.
  • Page 956 DIAGNOSTICS [T3E2] 3. Diagnosis System 2. SUBARU SELECT MONITOR 5) Connect Subaru Select Monitor to data link connector. After performing diagnostics and clearing the (1) Open the cover and connect Subaru Select memory, check for any remaining unresolved Monitor to data link connector located in the trouble data.
  • Page 957 1. SUBARU SELECT MONITOR CAUTION: Do not connect the scan tools except for 1) Prepare Subaru Select Monitor kit. Subaru Select Monitor and OBD-II general scan tool. S2M0285 2) Connect diagnosis cable to Subaru Select S2M0258B Monitor.
  • Page 958 12) Select the desired compulsory actuator on the Actuator ON/OFF Operation display screen and S2M0259B press the [YES] key. 5) Connect Subaru Select Monitor to data link 13) Pressing the [NO] key completes the compul- connector. sory operation check mode. The display will then...
  • Page 959 ¼ Because ASV solenoid valve, FICD solenoid valve and air injection system diagnosis solenoid valve are not installed, ASV Solenoid Valve, FICD Solenoid Valve and Pressure Switching Sol.2 will be displayed but non-functional. ¼ For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

  • Page 960: Cautions

    1. SUBARU SELECT MONITOR SYSTEM “AIRBAG” 1) Turn ignition switch to OFF. Airbag system wiring harness is routed near the 2) Turn Subaru Select Monitor switch to OFF. engine control module (ECM), main relay and fuel pump relay. CAUTION: ¼ All Airbag system wiring harness and con- nectors are colored yellow.
  • Page 961 DIAGNOSTICS [T4C1] 4. Cautions ¼ The antenna feeder must be placed as far 7) Use ECM mounting stud bolts at the body head grounding point when measuring voltage and apart as possible from the ECM and MFI har- resistance inside the passenger compartment. ness.
  • Page 962 DIAGNOSTICS [T4C2] 4. Cautions 2. ENGINE GROUNDING Make sure the engine grounding terminal is prop- erly connected to the engine. B2M2266B...
  • Page 963 DIAGNOSTICS [T4C2] 4. Cautions MEMO:...

  • Page 964: Specified Data

    DIAGNOSTICS [T5A0] 5. Specified Data 5. Specified Data A: ENGINE CONTROL MODULE (ECM) I/O SIGNAL B2M2267A Signal (V) Connec- Terminal Content Note Ignition SW ON tor No. Engine ON (Idling) (Engine OFF) Signal (+) B135 −7 — +7 Sensor output waveform Crankshaft position Signal (−)
  • Page 965 DIAGNOSTICS [T5A0] 5. Specified Data Signal (V) Connec- Terminal Content Note Ignition SW ON tor No. Engine ON (Idling) (Engine OFF) Engine Signal B136 1.0 — 1.4 1.0 — 1.4 After warm-up the engine. coolant tempera- GND (sen- ture sen- B136 After warm-up the engine.
  • Page 966 DIAGNOSTICS [T5A0] 5. Specified Data Signal (V) Connec- Terminal Content Note Ignition SW ON tor No. Engine ON (Idling) (Engine OFF) Torque control 1 signal B135 — Torque control 2 signal B135 — Torque control cut sig- B134 — Mass air flow signal for B136 0.8 —...
  • Page 967 DIAGNOSTICS [T5B0] 5. Specified Data B: ENGINE CONDITION DATA Content Specified data 1.7 — 3.3 (g/sec): Idling Mass air flow 7.1 — 14.2 (g/sec): 2,500 rpm racing 1.6 — 2.9 (%): Idling Engine load 6.4 — 12.8 (%): 2,500 rpm racing Measuring condition: ¼...
  • Page 968 DIAGNOSTICS [T5C0] 5. Specified Data C: TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL B2M2269A NOTE: Check with ignition switch ON. Connector Terminal Content Measuring conditions Voltage (V) Back-up power supply Ignition switch OFF 10 — 16 Ignition power supply Ignition switch ON (with engine OFF) 10 —...
  • Page 969 DIAGNOSTICS [T5C0] 5. Specified Data Resistance to Connector Terminal Content Measuring conditions Voltage (V) body (ohms) Throttle fully closed. 0.3 — 0.7 Throttle position — sensor Throttle fully open. 4.3 — 4.9 Throttle position Ignition switch ON (with sensor power 4.8 —...
  • Page 970 Less than 1 FWD indicator — Fuse removed from FWD lamp More than 9 switch. Data link signal — — (Subaru Select — — — Monitor) AT diagnosis Less than 1 ←→ More than 4 Ignition switch ON — signal...
  • Page 971 OBD-II general scan tool to data link connector. 6) Line pressure test <Ref. to 3-2 [W9A0].> 3) Turn ignition switch to ON and the Subaru 7) Transfer clutch pressure test <Ref. to 3-2 Select Monitor or OBD-II general scan tool switch [W10A0].>...
  • Page 972 DIAGNOSTICS [T6C1] 6. Basic Diagnostic Procedure C: CHECK LIST FOR INTERVIEW 1. CHECK LIST NO. 1 Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer’s name Engine no. Date of sale Fuel brand Date of repair Odometer reading...
  • Page 973 DIAGNOSTICS [T6C2] 6. Basic Diagnostic Procedure 2. CHECK LIST NO. 2 NOTE: Use copies of this page for interviewing customers. Check the following items about the vehicle’s state when MIL turns on. a) Other warning lights or indicators turn on. „ Yes/„ No „...

  • Page 974: Diagnostics For Check Engine Malfunction Indicator Lamp (Mil)

    DIAGNOSTICS [T7A0] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) A: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON. ¼ DIAGNOSIS: ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. ¼...
  • Page 975 DIAGNOSTICS [T7A5] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7A4 : CHECK HARNESS BETWEEN COM- 7A1 : CHECK OUTPUT SIGNAL FROM ECM. BINATION METER AND ECM CON- NECTOR. 1) Turn ignition switch to ON. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM connector and 2) Remove combination meter.
  • Page 976 DIAGNOSTICS [T7A6] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7A7 : CHECK POOR CONTACT. 7A6 : CHECK HARNESS BETWEEN COM- BINATION METER AND IGNITION SWITCH CONNECTOR. Check poor contact in combination meter connec- tor. 1) Turn ignition switch to ON. <Ref.
  • Page 977 DIAGNOSTICS [T7A7] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) MEMO:...
  • Page 978 ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted. ¼ TROUBLE SYMPTOM: ¼ Although MIL comes on when engine runs, trouble code is not shown on Subaru Select Monitor or OBD-II general scan tool display. ¼ WIRING DIAGRAM:...
  • Page 979 DIAGNOSTICS [T7B1] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7B1 : CHECK HARNESS BETWEEN COM- BINATION METER AND ECM CON- NECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Turn ignition switch to ON. S2M0217B : Does the MIL come on? : Repair ground short circuit in harness...
  • Page 980 DIAGNOSTICS [T7C0] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 Hz. ¼ DIAGNOSIS: ¼ The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. ¼...
  • Page 981 DIAGNOSTICS [T7C4] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7C3 : CHECK HARNESS BETWEEN ECM 7C1 : CHECK OPERATION OF CHECK ENGINE MALFUNCTION INDICATOR AND TEST MODE CONNECTOR. LAMP (MIL). 1) Turn ignition switch to OFF. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM.
  • Page 982 DIAGNOSTICS [T7C5] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7C5 : CHECK GROUND CIRCUIT. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between test mode connector and chassis ground. Connector & terminal (B76) No. 1 — Chassis ground: B2M0514A : Is resistance less than 5 Ω...
  • Page 983 DIAGNOSTICS [T7C5] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) MEMO:...
  • Page 984 DIAGNOSTICS [T7D0] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) D: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 Hz. ¼ DIAGNOSIS: ¼ Test mode connector circuit is shorted. ¼ TROUBLE SYMPTOM: ¼ Even though test mode connector is disconnected, MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
  • Page 985 DIAGNOSTICS [T7D1] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) 7D1 : CHECK HARNESS BETWEEN ECM CONNECTOR AND ENGINE GROUNDING TERMINAL. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM connector and chassis ground.
  • Page 986 DIAGNOSTICS [T7D1] 7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) MEMO:...

  • Page 987: Diagnostics For Engine Starting Failure

    ↓ 7. Inspection of camshaft position sensor circuit. <Ref. to 2-7 [T8H0].> ↓ 8. Inspection using Subaru Select Monitor or OBD-II general scan tool <Ref. to 2-7 [T1000].>, or inspection using “9. Gen- eral Diagnostics Table”. <Ref. to 2-7 [T900].>...
  • Page 988 DIAGNOSTICS [T8B0] 8. Diagnostics for Engine Starting Failure B: STARTER MOTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref. to 2-7 [T3E0].>. ¼ WIRING DIAGRAM: S2M0985 2) Disconnect connector from starter motor. 8B1 : CHECK VEHICLE TYPE.
  • Page 989 DIAGNOSTICS [T8B6] 8. Diagnostics for Engine Starting Failure 4) Measure power supply voltage between starter 8B4 : CHECK HARNESS BETWEEN BAT- motor connector terminal and engine ground. TERY AND IGNITION SWITCH CON- NECTOR. Connector & terminal (B14) No. 1 (+) — Engine ground (−): 1) Turn ignition switch to OFF.
  • Page 990 DIAGNOSTICS [T8B7] 8. Diagnostics for Engine Starting Failure 8B9 : CHECK TRANSMISSION HARNESS. 8B7 : CHECK INHIBITOR SWITCH CIRCUIT. 1) Turn ignition switch to OFF. Measure resistance of harness between transmis- 2) Place the selector lever in the “P” or “N” posi- sion harness and inhibitor switch connector.
  • Page 991 DIAGNOSTICS [T8B12] 8. Diagnostics for Engine Starting Failure 8B12 : CHECK STARTER INTERLOCK CIR- 8B11 : CHECK STARTER INTERLOCK CIR- CUIT. CUIT. 1) Turn ignition switch to “ST”. 1) Turn ignition switch to OFF. 2) Measure voltage between clutch switch con- 2) Measure resistance between clutch switch con- nector and chassis ground.
  • Page 992 DIAGNOSTICS [T8C0] 8. Diagnostics for Engine Starting Failure C: CONTROL MODULE POWER SUPPLY AND GROUND LINE CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref. to 2-7 [T3E0].>. ¼ WIRING DIAGRAM: S2M1183 4) Measure resistance between main relay termi- 8C1 :...
  • Page 993 DIAGNOSTICS [T8C5] 8. Diagnostics for Engine Starting Failure 8C4 : CHECK GROUND CIRCUIT OF ECM. 8C2 : CHECK MAIN RELAY. Measure resistance between main relay terminals. Measure resistance of harness between ECM and chassis ground. Terminals No. 4 — No. 6: Connector &...
  • Page 994 DIAGNOSTICS [T8C6] 8. Diagnostics for Engine Starting Failure 8C8 : CHECK GROUND CIRCUIT OF ECM. 8C6 : CHECK GROUND CIRCUIT OF ECM. Measure resistance of harness between ECM and Measure resistance of harness between ECM and chassis ground. chassis ground. Connector &...
  • Page 995 DIAGNOSTICS [T8C13] 8. Diagnostics for Engine Starting Failure 8C12 : CHECK HARNESS BETWEEN ECM 8C10 : CHECK INPUT VOLTAGE OF ECM. AND MAIN RELAY CONNECTOR. 1) Disconnect connector from ECM. 1) Ignition switch to OFF. 2) Measure voltage between ECM connector and 2) Measure voltage between ECM and chassis chassis ground.
  • Page 996 DIAGNOSTICS [T8C14] 8. Diagnostics for Engine Starting Failure 8C16 : CHECK INPUT VOLTAGE OF MAIN 8C14 : CHECK INPUT VOLTAGE OF MAIN RELAY. RELAY. Check voltage between main relay connector and Measure voltage between main relay connector chassis ground. and chassis ground. Connector &...
  • Page 997 DIAGNOSTICS [T8C21] 8. Diagnostics for Engine Starting Failure 8C20 : CHECK INPUT VOLTAGE OF ECM. 8C18 : CHECK INPUT VOLTAGE OF ECM. 1) Connect main relay connector. Measure voltage between ECM connector and 2) Ignition switch to ON. chassis ground. 3) Measure voltage between ECM connector and Connector &...
  • Page 998 DIAGNOSTICS [T8C22] 8. Diagnostics for Engine Starting Failure 8C22 : CHECK GROUND CIRCUIT OF ECM. Measure resistance of harness between ECM and chassis ground. Connector & terminal (B135) No. 25 — Chassis ground: B2M2424A : Is the resistance less than 5 Ω ? : Check ignition control system.
  • Page 999 DIAGNOSTICS [T8C22] 8. Diagnostics for Engine Starting Failure MEMO:...
  • Page 1000 DIAGNOSTICS [T8D0] 8. Diagnostics for Engine Starting Failure D: IGNITION CONTROL SYSTEM CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].> and INSPECTION MODE <Ref. to 2-7 [T3E0].>. ¼ WIRING DIAGRAM: S2M1043...

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